Top 10 2006 Dodge Grand Caravan Questions & Answers

I replaced the EGR Valve ($80 after tax), problem solved, vanruns great now. Now my problem is that I can't get the light to turn off.

Hi, here is the step by step guide you requested. its a easy read and it will help you with this replacement procedure.

Step1 Park the Caravan on a flat, level paved or concrete surface. Release the hood latch and apply the parking brake. Step2 Open the hood and **** out half of the brake fluid from the master cylinder reservoir using the turkey baster. Discard the fluid appropriately. Do not reuse it. Replace the cap on the master cylinder. Step3 Break the lug nuts loose on the left wheel first using the breaking bar and a socket. Do not remove the lug nuts or loosen them too much. Step4 Lift the Caravan using the floor jack and place the lift point under the transmission bushing. Place a jack stand under the inside of the rocker panel in the left front where the frame is boxed. Do not place the jack stand on the rocker panel as it will most likely collapse. You can leave the floor jack in place as an added safety support, but make sure to use a jack stand. Step5 Remove the lug nuts and wheel. Step6 Remove the caliper bolts with the ratchet and a socket. Gently pry the caliper off of the rotor using the screwdriver. The pads are clipped to the caliper. Step7 Remove the outboard pad first by prying it off the caliper housing with the screwdriver. Remove the inboard pad by pulling it out of the caliper piston bore. Support the caliper to the coil spring using the bungee cord. Step8 Compress the piston in using the C-clamp. Squeeze slowly and steadily to avoid damaging the caliper piston. Step9 Install the new pads starting with the inboard pad. Since the inboard and outboard pads are identifiably different, there's only one way they will fit properly. There is a slight difference in the molding of the backing plates of the pads. Refer to the old pads you removed to make sure you're applying the pads for the left side. Step10 Apply a liberal coat of silicone brake lubricant on the caliper anchor where the backing plate of the pads sit against. Step11 Reinstall the caliper over the rotor. Step12 Apply a light coat of silicone brake lubricant to the smooth area of the caliper bolts. Insert it into the caliper to lock it to the caliper anchor. Tighten the bolts properly. Step13 Replace the wheel and lug nuts, tightening the lug nuts as tight as you can using the ratchet and a socket. Lower the Caravan and retighten the lug nuts in an alternate fashion using the torque wrench set at 100 foot pounds and a socket. Step14 Repeat the procedure for the right side. Step15 Pump the foot brake pedal when you're finished with the right side until the hydraulic pressure is restored to the caliper pistons and the brake pedal feels normal. Release the parking brake. Step16 Check and adjust the brake fluid level in the master cylinder reservoir. Only add new DOT-approved brake fluid for your Caravan. Step17 Remove the wheel chock and test drive.


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The cooling fan control relay is located behing the grill in a crossmember (see the pic). It works in conjuction with the Integrated Control Module.

1. Grill
2. Fan control relay
3. Rivet
4. A/C condenser

Hope this helps.

actually there are 4 sensors. one on each exhaust manifold and then as you said one prior and aft the catalytic convertor. this is saying it is reading too rich a reading. check the condition of your spark plugs. you need to pin point the reason. chances are it is not the o2 sensor. happy holidays

You should be able to use any brand, any kind.Most brake fluids are made to standards ok for all cars. Some expensive cars might take a special fluid, race cars do. I use walmart special, never noticed a difference. Hope this helps.

Removal & Installation 2.4L Engine To Remove:

1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature sensor and remove the air cleaner assembly.
3. Remove the EVAP purge solenoid and move it out of the way.
4. Disconnect the wiring from the alternator.
5. Remove the accessory drive belt from the alternator.
6. Remove the alternator.

1. Install the alternator.
2. Install the accessory drive belt
3. Connect the wiring to the alternator.
4. Install the EVAP purge solenoid in the bracket.
5. Install the air cleaner and duct, then connect the intake air temperature sensor.
6. Connect the negative battery cable.

1. Disconnect the negative battery cable.
2. Disconnect the wiring from the alternator.
3. Raise and safely support the vehicle.
4. Remove the right front tire and lower splash shield.
5. Remove accessory drive belt.
6. Remove the lower engine oil dipstick tube bolt, then remove the wiring harness from the dipstick tube.
7. Remove the 3 mounting bolts.
8. Lower the vehicle.
9. Remove engine oil dipstick tube.
10. Roll and carefully remove the alternator from vehicle.

1. Place the alternator into position on the engine.
2. Install upper mounting bolts to hold the alternator in place.
3. Lubricate the o-ring with engine oil and install the dipstick tube.
4. Install the upper dipstick tube bolt.
5. Connect the wiring to the alternator.
6. Raise and safely support the vehicle.
7. Install the alternator lower mounting bolt and tighten.
8. Install the lower oil dip stick tube bolt.
9. Install the accessory drive belt.
10. Install the right front splash shield and tire.
11. Lower vehicle.
12. Install the wiring harness at the dipstick tube
13. Connect the negative battery cable.

You will need a new thermostat(make sure you have the gasket), ratchet, extension, sockets, screwdriver, scraper, coolant, and maybe gasket sealant. drain down the coolant below the top hose. follow the hose to the engine( this connects to the thermostat housing cover, or cap), disconnect the hose from the cap, and remove. you will see 2 bolts holding down the cap, and remove those( save them for later). now gently pry up the cap( the cap is made of cheap metal, and bends or cracks easily). you will see the old thermostat and remove. now you need to scrape the cap and housing clean of any old gasket material, and gasket sealant( if present, this way you have no leaks). now that you have just metal, now you take the gasket and soak a minute in clean water( to swell the gasket) and put the new thermostat in, and set the gasket down( if you don't want to do that, apply gasket sealant around the housing, set gasket in place, and apply sealant around the cap). now that the gasket is in place, place the cap on top. using those bolts you saved. re-bolt the the engine(CAUTION do not over tighten, just tight, the cap WILL break or crack). reconnect the hose, and add fluid. start the vehicle, and let warm up, when the thermostat opens, check for leaks. Now finish topping off the radiator, and you are done. Job takes about 30 to 45 minutes for a beginner. Hope this helps. please rate this if its helpful or not

The most likely reason your display is reading gas cap is that you have an unsolved evaporation code. Most of the time simply replacing the gas cap will fix the problem, but since you have already done that there is a whole list of other things you could check. I would start with your hose that runs to your tank from your fill spout. It is possible that it has a small crack in it. Or it is even possible that one of your injector O rings has gotten bad. The bottom line is that evaporation codes are very hard to pin point and usually do not cause any problems at all. So if you decide to do nothing and not spend any money on the problem you will probably be just as well off. Well that is other then being annoyed by your gas cap light. I hope this helps you out, and if you have any other questions please feel free to ask.

disable door lock...Close all of the doors of the Caravan and insert the key into the ignition.

Move the key to the "ON" position, and then back to the "OFF" position. Repeat this step four times.

Press the driver's side door lock to the "LOCK" position within 10 seconds of turning the ignition to the "OFF" position. If done properly, a single chime will emit from the Caravan to indicate that you have disabled the auto-lock feature.

also a good video on how to remove door lock on Caravan....youtube.
hope this helps a little

This fairly easy but requires a little strength. There is a keeper on the top of the sliding door that stops it from going too far.loosen this keeper or remove it. Slide it all the way to pen then stick your hand in under the cover near the end there will be a slot or opening an inch or two long. Take the roller wheel and put it in the opening. Push up and you will be able to feel it seat into the track like a closer door, It may take a . pretty good push .Then replace the keeper on the top of the door. Sliding the door half closed will keep you from pushing it back off before your replace the clip. I worked at the plant that built your van.