Contents Section: Procedures All sections

Maintenance Information Dodge Grand Caravan III

Procedures 6 illustrations ~1317 words

VIN LOCATION

The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the code characters.

VIN CODE ID EXPLANATION

Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN example below.

VIN Code ID Explanation. Scheme 1

Scheme 1: VIN Code ID Explanation

SEVERE & NORMAL SERVICE DEFINITIONS

Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on the following primary operating conditions

Normal Service

  1. Driven More Than 10 Miles Daily
  2. No Severe Service Operating Conditions

Note. Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or more) of these conditions

Severe Service

  1. Sustained High Speed Driving In Hot Weather
  2. Stop-And-Go Driving In Dusty Conditions
  3. Extensive Idling
  4. Frequent Short Trips
  5. Trailer Towing Or Commercial Use

CAMSHAFT TIMING BELT

Inspect the camshaft timing belt only on the 3.0L at 60,000 miles and every 30,000 miles after inspection. Replace if necessary at intervals.

CAUTIONFailure to replace a faulty camshaft timing belt may result in serious engine damage.

The condition of camshaft drive belts should always be checked on vehicles which have more than 50,000 miles. Although some manufacturers do not recommend belt replacement at a specified mileage, others require it at 60,000-100,000 miles. A camshaft drive belt failure may cause extensive damage to internal engine components on most engines, although some designs do not allow piston-to-valve contact. These designs are often called "Free Wheeling".

Many manufacturers changed their maintenance and warranty schedules in the mid-1980's to reflect timing belt inspection and/or replacement at 50,000-60,000 miles. Most service interval schedules in this manual reflect these changes.

Belts or components should be inspected and replaced if any of the following conditions exist

  1. Cracks Or Tears In Belt Surface
  2. Missing, Damaged, Cracked Or Rounded Teeth
  3. Oil Contamination
  4. Damaged Or Faulty Tensioners
  5. Incorrect Tension Adjustment

Scheme 2

Scheme 2: SERVICE POINT LOCATIONS

Scheme 3

Scheme 3

Scheme 4

Scheme 4

TIRE REPLACEMENT

The tires on your new vehicle provide a balance of many characteristics. They should be inspected regularly for wear and correct inflation pressure. Chrysler strongly recommends that you use tires equivalent to the originals in quality and performance when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety, handling and ride of your vehicle. We recommend that you contact your original equipment tire dealer on any questions you may have on tire specifications or capability.

TIRE INFLATION

Tire pressure is listed on a certification label attached to vehicle's left front door.

WHEEL TIGHTENING

Tighten all wheel lug nuts to 100 ft.lbs. (135 N.m).

BATTERY SPECIFICATIONS

Vehicle is factory equipped with a maintenance free battery. The top of the batter is permanently sealed, and water never has to be added, and periodic maintenance is not required either. But, periodically check the battery terminals and battery hold-down bracket for corrosion. Replace with a battery of the same group number as shown on original battery's label.

CAUTIONWhen battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section.

SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)

Note. See the AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT Section.

Modifications or improper maintenance, including incorrect removal and installation of the Supplemental Restraint System (SRS), can adversely affect system performance. DO NOT cover, obstruct or change the steering wheel horn pad in any way, as such action could cause improper function of the system. Use only plain water when cleaning the horn pad. Solvents or cleaners could adversely affect the air bag cover and cause improper deployment of the system.

WARNINGTo avoid injury from accidental air bag deployment, read and carefully follow all warnings and service precautions. See appropriate AIR BAGS article in ACCESSORIES/SAFETY EQUIPMENT.
WARNINGAny maintenance performed on or near the components of the SRS must be performed only by an authorized dealer. Do not permit anyone else to service, inspect maintain, or service any SRS components or wiring. Similarly, no part of the SRS should ever be handled or disposed of by anyone except an authorized dealer. Improper work on the SRS components or wiring could result in inadvertent deployment of the air bags or could render the SRS system inoperative. Either situation could result in serious injury
WARNINGIf the car has had any front-end damage, have the SRS system inspected by an authorized dealer to ensure it is working properly.
WARNINGIf any of the following conditions occur, the SRS is not working properly. Immediately have it inspected by an authorized dealer: The SRS warning light does not illuminate when you start the car. The SRS warning light does not go off after about 7 seconds. The SRS warning light illuminates while driving.
CAUTIONDisconnect negative battery cable before servicing any air bag system, steering column or passenger side dash component. After any repair, turn ignition key to the ON position from passenger's side of vehicle in case of accidental air bag inflation

AIR CONDITIONING SERVICING

WARNINGAvoid breathing R-134a refrigerant and PAG lubricant vapors, exposure may irritate eyes, nose and throat. To remove R-134a from system use R-134a recycling equipment that meets SAE J2210 specifications. If accidental system discharge occurs, ventilate work area before resuming service.
WARNINGR-134a service equipment or vehicle A/C systems SHOULD NOT be pressure tested or leak tested with compressed air. Some mixtures of air/R134a have shown to be combustible at elevated pressures. These mixtures are dangerous and may cause fire and/or explosions. See AIR CONDITIONING SERVICE article in GENERAL INFORMATION section.

AIR CONDITIONING MAINTENANCE

WARNINGNEVER add A/C refrigerant to correct a non-cooling problem unless pressure gauges are connected to the system by a certified technician. Lack of cooling may be caused by a restriction, therefore adding refrigerant can cause a dangerous pressure rise.

ANTI-LOCK BRAKE SYSTEM

CAUTIONThe anti-lock brake system contains electronic equipment that can be susceptible to interference caused by improperly installed or high output radio transmitting equipment. Since this interference could cause the possible loss of the antilock braking capability, such equipment should be installed by qualified professionals.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions

  1. DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK BRAKE SYSTEM article in the BRAKES Section.
  2. DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
  3. Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.

BATTERY WARNING

WARNINGWhen battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure.
WARNINGBatteries produce flammable hydrogen gas. Keep flames and sparks away from the battery or and explosion may occur. Never smoke when working in the vicinity of the battery.
WARNINGWhen checking or servicing the battery, disconnect the negative cable. Be careful not to cause a short circuit by allowing metal objects to contact the battery posts and the vehicle at the same time.

REPLACING BLOWN FUSES

CAUTIONBefore replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system overload.

BRAKE PAD WEAR INDICATOR

Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.

BRAKE HOSES

WARNINGWorn brake hoses can burst and cause brake failure. If any sign of cracking, scuffing, or worn spots are found, replace the brake hoses immediately.

BRAKE FLUID

WARNINGThe use of incorrect fluid in the brake system may cause damage to components. DO NOT use any fluid other than DOT-3 brake fluid. DO NOT use reclaimed fluid or fluid that has been stored in old or open containers. It is essential that foreign particles and other liquids are kept out of the brake fluid reservoir.

CATALYTIC CONVERTER

CAUTIONTo prevent catalytic converter overheating, DO NOT allow engine to idle for more than 20 minutes.

COOLANT

CAUTIONTo avoid possible damage to vehicle use only ethylene-glycol based coolants with a mixture ratio from 50-70% anti-freeze. DO NOT use 100% anti-freeze as it will cause the formation of cooling system deposits.

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

WARNINGMany solid state electrical components can be damaged by static electricity (ESD). Some will display a warning label, but many will not. Discharge personal static electricity by touching a metal ground point on the vehicle prior to servicing any ESD sensitive component.

ENGINE AIR CLEANER

WARNINGThe air cleaner can provide a measure of protection in case of engine backfire. Do not remove the air cleaner unless such removal is necessary for repair or maintenance. Make sure that no one is near the engine compartment before stating the vehicle with the air cleaner removed. Failure to do so could result in serious personal injury

ENGINE OIL

WARNINGThe engine oil may be high enough to burn your fingers when the drain plug is loosened. Wait until the drain plug is cool enough to touch with you bare hands.
WARNINGContinuous contact with used engine oil has been found to cause skin cancer in laboratory animals. Brief contact with used engine oil may irritate skin. To minimize your exposure to used oil, wear a long sleeve shirt and moisture-proof gloves when changing oil. If oil contacts your skin, wash thoroughly with soap and water.
CAUTIONOverfilling the crankcase will cause oil aeration and loss of oil pressure. This could damage your engine.
CAUTIONNever use non-detergent or straight mineral oil.

FUEL SYSTEM SERVICE

WARNINGRelieve fuel system pressure prior to servicing any fuel system component (fuel injection models).

HALOGEN BULBS

WARNINGHalogen bulbs contain pressurized gas which may explode if overheated. DO NOT touch glass portion of bulb with bare hands. Eye protection should be worn when handling or working around halogen bulbs.

METHANOL GASOLINE

CAUTIONDo NOT use gasoline containing methanol. This type of alcohol can cause vehicle performance problems and could damage critical fuel system components.

RADIATOR CAP

CAUTIONAlways disconnect the fan motor when working near the radiator fan. The fan is temperature controlled and could start at any time even when the ignition key is in the OFF position. DO NOT loosen or remove radiator cap when cooling system is hot.

RADIATOR FAN

WARNINGKeep hands away from radiator fan. Fan is controlled by a thermostatic switch which may come on or run for up to 15 minutes even after engine is turned off.

SPARK PLUGS

CAUTIONWhen replacing plugs, do not overtighten. You could damage them and cause them to leak.

POWER STEERING

WARNINGFluid level should be checked with the engine off to prevent injury from moving parts. Do not overfill. Do not use automatic transmission fluid. Use only Power Steering Fluid.

STEERING GEAR

CAUTIONDo not check for free play in the steering wheel when the engine is running.

TIRE WARNINGS

WARNINGImproperly inflated tires are dangerous and can cause accidents.
WARNINGUnder Inflation increases tire flexing and can result in tire failure.
WARNINGOver Inflation reduces a tires ability to cushion shock Objects on the road and chuck hole can cause damage to tires.
WARNINGUnequal tire pressures can cause steering problems. Always drive with each tire inflated to the recommended pressure.

WARRANTY INFORMATION

CAUTIONDue to the different warranties offered in various regions and the variety of after-market extended warranties available, please refer to the warranty package that came with the vehicle to verify all warranty options.

FUSES & CIRCUIT BREAKERS

The fuse block is located on the bottom left side of the instrument panel near the parking brake pedal. Pull the cover straight away from the instrument panel for access to fuses. A Power Distribution center, for circuits that operate only under the hood, is located in the engine compartment. An identification label is located on the underside of the cover.

Scheme 5

Scheme 5: UNDERHOOD POWER DISTRIBUTION CENTER IDENTIFICATION
WARNINGAlways disconnect battery ground cable before servicing "high-current fuses. It is recommended that "high-current" fuses be replaced by a qualified technician.

Fuse & Circuit Breaker Identification

  1. 1 - 10 Amp Mini (Red) Airbag
  2. 2 - 10 Amp Mini (Red) Airbag
  3. 3 - Not Used
  4. 4 - 10 Amp Mini (Red) Headlight High - Left
  5. 5 - 10 Amp Mini (Red) Headlight High - Right
  6. 6 - 15 Amp Mini (Blue) Headlight Low - Left, Fog Light - Left
  7. 7 - 15 Amp Mini (Blue) Headlight Low - Right, Fog Light - Right
  8. 8 - 20 Amp Mini (Yellow) Cigarette Lighter, Accessory, Front Wiper De-Ice
  9. 9 - 20 Amp Mini (Yellow) Horns
  10. 10 - 20 Amp Mini (Yellow) Hazard Warning Flashers, Turn Signals
  11. 11 - 15 Amp Mini (Blue) A/C Clutch
  12. 12 - 25 Amp Mini (Natural) ABS System
  13. 13 - 20 Amp Mini (Yellow) Stop Lights, Center High Mounted Stop Light
  14. 14 - Not Used
  15. 15 - 20 Amp Mini (Yellow) Automatic Transmission Controller, Transmission Solenoids
  16. 16 - 20 Amp Mini (Yellow) Fuel Pump, Engine Controller
  17. 17 - 20 Amp Mini (Yellow) Engine, Generator
  18. 18 - 15 Amp Mini (Blue) Interior Lights
  19. 19 - 30 Amp Green Wipers - Front
  20. 20 - Not Used
  21. 21 - 40 Amp Orange Blower Motor - Front
  22. 22 - 40 Amp Orange Park Lights, License Light, Feeds Fuses #1, #4, & #6 In Fuse Box
  23. 23 - 40 Amp Orange Ignition Switch, Starter Solenoid, Engine, Front & Rear Washers, Left & Right Rear Window Vents, Power Windows, Feeds Fuses #2, #3, & #8 In Fuse Block
  24. 24 - 40 Amp Orange Radiator Fan
  25. 25 - 40 Amp Orange ABS Pump
  26. 26 - 40 Amp Orange Power Door Lock, Power Seats, Feeds Fuses #10, #11, & #12 In Fuse Block
  27. 27 - 40 Amp Orange Rear Window Defroster, Heated Mirrors, Feeds Fuse #7 In Fuse Block
  28. 28 - 10 Amp (Red) Ignition Off Draw (I.O.D.), Instrument Cluster, Radio, Body Controller, Keyless Entry

Relay Identification

  1. A - Cigarette & Accessory Relay
  2. B - Front Wiper Hi/Lo Relay
  3. C - Front Wiper On Relay
  4. D - High Beam Relay
  5. E - Low Beam Relay
  6. F - Not Used
  7. G - Horn Relay
  8. H - A/C Clutch Relay
  9. J - Not Used
  10. K - Blower Motor Relay
  11. L - Starter Relay
  12. M - Park Lights Relay
  13. N - Automatic Transmission Controller Shutdown Relay
  14. P - Fuel Pump Relay
  15. Q - Auto Shutdown Relay

Scheme 6

Scheme 6: FUSE BLOCK PANEL IDENTIFICATION
  1. 1 - 10 Amp (Red) Instrument Panel Illumination
  2. 2 - 10 Amp (Red) Gauge
  3. 3 - 20 Amp (Yellow) Rear Wiper, Instrument Panel Warning Lights
  4. 4 - 15 Amp (Lt. Blue) Right Parking Light, Instrument Panel Illumination
  5. 5 - Not Used
  6. 6 - 15 Amp (Lt. Blue) Left Parking Light, License Light
  7. 7 - 10 Amp (Red) Heated Mirrors
  8. 8 - 10 Amp (Red) Radio
  9. 9 - Not Used
  10. 10 - 10 Amp (Red) ABS
  11. 11 - 20 Amp (Yellow) Rear Blower Motor
  12. 12 - 10 Amp (Red) Back Up Lights, Automatic Dimming Mirror, Turn Signal Flasher
  13. 13 - Spare Fuse 10 Amp (Red)
  14. 14 - Spare Fuse 15 Amp (Lt. Blue)
  15. 15 - Spare Fuse 20 Amp (Yellow)
  16. 16 - Spare Fuse