2005 CHRYSLER CARAVAN belt

MODE DOOR ACTUATOR - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 C135 20DB/GY (ATC) MODE DOOR DRIVER (B)
1 C34 20DB/LB (MTC) COMMON DOOR DRIVER (B)
2 C35 20LB/OR MODE DOOR DRIVER (A)
MULTI-FUNCTION SWITCH - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 W52 22BR/YL FRONT WIPER SWITCH MUX
2 G902 22VT/LB MULTI-FUNCTION SWITCH MUX RETURN
3 L305 20WT/LB TURN SIGNAL SWITCH MUX
4 G194 22VT/LG HIGH BEAM/FRONT WASHER SWITCH MUX
NATURAL VACUUM LEAK DETECTION ASSEMBLY (EXCEPT EXPORT) - LT. GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 Z166 18BK/WT GROUND
2 K107 20VT/WT NVLD SWITCH SIGNAL
3 K106 20VT/LB NVLD SOL CONTROL
OCCUPANT CLASSIFICATION MODULE - BLACK 18 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3- -
4 D105 20LG/LB BELT TENSION SENSOR SIGNAL
5 Z104 20BK/LG GROUND
6 R741 20LG/VT PASSENGER BLADDER PRESSURE SENSOR SIGNAL
7 R740 20LG/OR PASSENGER BLADDER PRESSURE SENSOR POWER
8 D25 20WT/VT PCI BUS
9 F201 20PK/OR ORC RUN-START DRIVER
10 - -
11 - -
12 - -
13 - -
14 R986 20LG/BR BELT TENSION SENSOR GROUND
15 R941 20LG/DG PASSENGER BLADDER PRESSURE SENSOR GROUND
16 R86 20LG/LB BELT TENSION SENSOR FEED
17 - -
18 - -
8W - 80 - 102 8W-80 CONNECTOR PIN-OUTSRS

OCCUPANT RESTRAINT CONTROLLER C1 - YELLOW 32 WAY
CAV CIRCUIT FUNCTION
1 R53 20LG/YL DRIVER SEAT BELT TENSIONER LINE 2
2 R55 20LG/DG DRIVER SEAT BELT TENSIONER LINE 1
3 R56 20LB/DG (EXCEPT OCCUPANT
SENSING)PASSENGER SEAT BELT TENSIONER LINE 1
4 R54 20LB/YL (EXCEPT OCCUPANT
SENSING)PASSENGER SEAT BELT TENSIONER LINE 2
5- -
6- -
7 R4 20OR/LB (SIDE AIRBAG/OCCUPANT
SENSING)RIGHT CURTAIN SQUIB 1 LINE 1
8 R2 20WT/LB (SIDE AIRBAG/OCCUPANT
SENSING)RIGHT CURTAIN SQUIB 1 LINE 2
9 R57 20LG/GY DRIVER SEAT BELT SWITCH SENSE
10 R58 20LB/GY (OCCUPANT SENSING) PASSENGER SEAT BELT SWITCH SENSE
11 R59 20LG/TN DRIVER SEAT BELT SWITCH GROUND
12 R60 20LG/TN (OCCUPANT SENSING) PASSENGER SEAT BELT SWITCH GROUND
13 - -
14 - -
15 R13 20LB (SIDE AIRBAG) LEFT SIDE IMPACT SENSOR 1 SIGNAL
16 R16 20BR/LG (SIDE AIRBAG) RIGHT SIDE IMPACT SENSOR 1 GROUND
17 - -
18 - -
19 R15 20DB (EXCEPT RHD LWB/SIDE
AIRBAG)LEFT SIDE IMPACT SENSOR 1 GROUND
19 R15 20LB (RHD LWB/SIDE AIRBAG) LEFT SIDE IMPACT SENSOR 1 GROUND
20 R19 20LG/WT (SIDE AIRBAG) LEFT SIDE IMPACT SENSOR 2 GROUND
21 R20 20WT/LG (SIDE AIRBAG) RIGHT SIDE IMPACT SENSOR 2 GROUND
22 R17 20LG (SIDE AIRBAG) LEFT SIDE IMPACT SENSOR 2 SIGNAL
23 R18 20LB (SIDE AIRBAG) RIGHT SIDE IMPACT SENSOR 2 SIGNAL
24 R14 20TN/LG (SIDE AIRBAG) RIGHT SIDE IMPACT SENSOR 1 SIGNAL
25 R1 20LB/WT (SIDE AIRBAG) LEFT CURTAIN SQUIB 1 LINE 2
26 R3 20LB/OR (SIDE AIRBAG) LEFT CURTAIN SQUIB 1 LINE 1
27 R4 20OR/LB (SIDE AIRBAG/EXCEPT
OCCUPANT SENSING)RIGHT CURTAIN SQUIB 1 LINE 1
28 R2 20WT/LB (SIDE AIRBAG/EXCEPT
OCCUPANT SENSING)RIGHT CURTAIN SQUIB 1 LINE 2
29 - -
30 - -
31 R56 20LB/DG (OCCUPANT SENSING) PASSENGER SEAT BELT TENSIONER LINE 1
32 R54 20LB/YL (OCCUPANT SENSING) PASSENGER SEAT BELT TENSIONER LINE 2
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 103

PASSENGER SEAT BELT SWITCH (OCCUPANT SENSING) - YELLOW 2 WAY
CAV CIRCUIT FUNCTION
1 R58 16LB/GY PASSENGER SEAT BELT SWITCH SENSE
2 R60 16LB/TN PASSENGER SEAT BELT SWITCH GROUND
PASSENGER SEAT BELT TENSIONER-2WAY
CAV CIRCUIT FUNCTION
1 R56 18LB/DG (EXCEPT EXPORT) PASSENGER SEAT BELT TENSIONER LINE 1
1 R54 18LB/YL (EXPORT) PASSENGER SEAT BELT TENSIONER LINE 2
2 R54 18LB/YL (EXCEPT EXPORT) PASSENGER SEAT BELT TENSIONER LINE 2
2 R56 18LB/DG (EXPORT) PASSENGER SEAT BELT TENSIONER LINE 1
PASSENGER SEAT WEIGHT SENSOR - BLACK 3 WAY
CAV CIRCUIT FUNCTION
A R941 20LG/DG PASSENGER BLADDER PRESSURE SENSOR GROUND
B R741 20LG/VT PASSENGER BLADDER PRESSURE SENSOR SIGNAL
C R740 20LG/OR PASSENGER BLADDER PRESSURE SENSOR POWER
8W - 80 - 112 8W-80 CONNECTOR PIN-OUTSRS

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Driver Blend Door Actuator GY On HVAC N/S
Driver Door Courtesy Lamp GY At Lamp 43
Driver Door Lock Switch BK At Switch 43
Driver Heated Seat Back LTGN At Seat N/S
Driver Heated Seat Cushion BK At Seat N/S
Driver Heated Seat Module C1 GY Driver Heated Seat N/S
Driver Heated Seat Module C2 GY Driver Heated Seat Back N/S
Driver Heated Seat Module C3 GN At Seat N/S
Driver Knee Blocker Airbag Squib YL Below Steering Column 20
Driver Power Seat Front Riser
MotorRD At Seat N/S
Driver Power Seat Front Riser
Position SensorBK At Seat N/S
Driver Power Seat Horizontal
MotorBK At Seat N/S
Driver Power Seat Horizontal
Position SensorBK At Seat N/S
Driver Power Seat Rear Riser
MotorRD At Seat N/S
Driver Power Seat Rear Riser
Position SensorBK At Seat N/S
Driver Power Seat Recliner Motor GN At Seat N/S
Driver Power Seat Recliner
Position SensorBK At Seat N/S
Driver Power Seat Switch GN At Switch N/S
Driver Power Window Motor RD At Motor 43
Driver Power Window Switch
(LHD Low Line)LTGY At Switch 43
Driver Power Window Switch
(LHD Except Low Line)LTGN At Switch N/S
Driver Power Window Switch
(RHD)NAT At Switch N/S
Driver Seat Belt Switch WT At Switch on Seat Harness N/S
Driver Seat Belt Tensioner YL On Seat Harness N/S
DVD Screen BK Headliner 50
DVD/CD Changer C1 BK Below Radio N/S
DVD/CD Changer C2 Below Radio N/S
EGR Solenoid (Diesel) LTGY Above Transmission
Right Side of Engine15
EGR Solenoid (3.3L) BK Above A/C Compressor Right Side
of Engine18
Engine Control Module C1
(Diesel)BK Right Side of Engine N/S
Engine Control Module C2
(Diesel)BK Right Side of Engine N/S
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Passenger Door Courtesy Lamp GY At Lamp 44
Passenger Door Lock Switch BK At Switch 44
Passenger Folding Mirror Relay
(Export)BL Left Kick Panel 7
Passenger Heated Seat Back GN At Seat N/S
Passenger Heated Seat Cushion BK At Seat N/S
Passenger Heated Seat Module GY At Heated Seat N/S
Passenger Power Seat Front
Riser MotorRD Under Seat N/S
Passenger Power Seat Horizontal
MotorBK Under Seat N/S
Passenger Power Seat Rear
Riser MotorRD Under Seat N/S
Passenger Power Seat Recliner
MotorGN Under Seat N/S
Passenger Power Seat Switch GN At Switch N/S
Passenger Power Window Motor RD At Motor 44
Passenger Power Window Switch BK At Switch 44
Passenger Seat Belt Switch
(Occupant Sensing)YL On Seat Harness N/S
Passenger Seat Belt Tensioner On Seat Harness N/S
Passenger Seat Weight Sensor BK Passenger Seat N/S
Power Folding Mirror Switch
(Export)BK Near Steering Column 31
Power Liftgate Module C1 BK Left Quarter 46, 47
Power Liftgate Module C2 Left Quarter 46, 47
Power Liftgate Motor BK Left Quarter 47
Power Mirror Switch BK Rear of Switch 30
Power Outlet (Except Lowline) BK Instrument Panel 20, 23, 25
Power Seat Circuit Breaker GY Under Seat N/S
Powertrain Control Module C1 BK Left Front Engine Compartment 11
Powertrain Control Module C2 OR Left Front Engine Compartment 11
Powertrain Control Module C3 NAT Left Front Engine Compartment 11
Powertrain Control Module C4 GN Left Front Engine Compartment 11
Power Window Circuit Breaker GY Left Side Kick Panel 41 42
Radiator Fan No.1 (Gas) BK Left Side At Motor 1
Radiator Fan No.1 (Diesel) GY Left Side At Motor 1
Radiator Fan No.2 (Gas) BK Right Side At Motor 1, 2
Radiator Fan No.2 (Diesel) GY Right Side At Motor 1, 2
Radiator Fan Relay (Gas) Top of Left Front Frame Rail 1
Radiator Fan Relay No. 1
(Diesel)BL Left Front Engine Compartment 2
Radiator Fan Relay No. 2
(Diesel)BL Left Front Engine Compartment 2
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

INSTALLATION
INSTALLATION - CYLINDER HEAD ON.....33
INSTALLATION - CYLINDER HEAD OFF....33
HYDRAULIC LASH ADJUSTERS
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER NOISE DIAGNOSIS......34
REMOVAL.............................35
INSTALLATION.........................35
ROCKER ARMS
REMOVAL.............................35
INSPECTION..........................35
INSTALLATION.........................35
ENGINE BLOCK
DESCRIPTION.........................36
STANDARD PROCEDURE - CYLINDER BORE
HONING............................36
CLEANING............................37
INSPECTION..........................37
CRANKSHAFT
STANDARD PROCEDURE - CRANKSHAFT
ENDPLAY ...........................37
REMOVAL - CRANKSHAFT................37
INSPECTION..........................38
INSTALLATION - CRANKSHAFT............39
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................41
INSTALLATION.........................42
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................42
INSTALLATION.........................42
PISTON & CONNECTING ROD
DESCRIPTION.........................44
STANDARD PROCEDURE - PISTON TO
CYLINDER BORE FITTING..............44
REMOVAL.............................44
INSTALLATION.........................45
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING...........46
PISTON RINGS
STANDARD PROCEDURE
PISTON RING - FITTING................47
REMOVAL.............................47
INSTALLATION.........................47
VIBRATION DAMPER
REMOVAL.............................48
INSTALLATION.........................49
STRUCTURAL COLLAR
REMOVAL.............................49
INSTALLATION.........................49
ENGINE MOUNTING
DESCRIPTION.........................50
FRONT MOUNT
REMOVAL.............................50
INSTALLATION.........................50
LEFT MOUNT
REMOVAL.............................50INSTALLATION.........................50
REAR MOUNT
REMOVAL.............................51
INSTALLATION.........................52
RIGHT MOUNT
REMOVAL.............................52
INSTALLATION.........................52
LUBRICATION
DESCRIPTION.........................53
OPERATION...........................53
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE................53
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK.............54
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE..................54
OIL FILTER
DESCRIPTION.........................54
REMOVAL.............................54
INSTALLATION.........................54
OIL PAN
REMOVAL.............................55
INSTALLATION.........................55
OIL PRESSURE SWITCH
REMOVAL.............................56
INSTALLATION.........................56
OIL PUMP
REMOVAL.............................56
DISASSEMBLY.........................57
CLEANING............................57
INSPECTION..........................58
ASSEMBLY............................58
INSTALLATION.........................59
INTAKE MANIFOLD
DESCRIPTION.........................60
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS.....................60
INTAKE MANIFOLD - UPPER
REMOVAL.............................60
INSPECTION..........................61
INSTALLATION.........................61
INTAKE MANIFOLD - LOWER
REMOVAL.............................62
INSPECTION..........................62
INSTALLATION.........................62
EXHAUST MANIFOLD
REMOVAL.............................63
CLEANING............................63
INSPECTION..........................63
INSTALLATION.........................63
TIMING BELT COVER(S)
REMOVAL.............................63
INSTALLATION.........................64
TIMING BELT AND SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT...............65
9 - 2 ENGINE 2.4LRS

REMOVAL - CAMSHAFT SPROCKETS.....66
REMOVAL - CRANKSHAFT SPROCKET....66
CLEANING............................67
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET . 67
INSTALLATION - CAMSHAFT SPROCKETS . . 67
INSTALLATION - TIMING BELT...........67
TIMING BELT TENSIONER & PULLEY
REMOVAL.............................69INSTALLATION.........................70
BALANCE SHAFTS AND CARRIER ASSEMBLY
DESCRIPTION.........................71
OPERATION...........................71
REMOVAL.............................71
INSTALLATION.........................73
ENGINE 2.4L
DESCRIPTION
The 2.4 Liter (148 cu. in.) in-line four cylinder
engine is a double over head camshaft with hydraulic
lash adjusters and four valve per cylinder design.
The engine is free-wheeling; meaning it has provi-
sions for piston-to-valve clearance. However valve-to-
valve interference can occur, if camshafts are rotated
independently.
The cylinders are numbered from front of the
engine to the rear. The firing order is 1±3±4±2.
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).
For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
²Hydraulic Lash Adjuster Noise Diagnosis
²Engine Oil Leak Inspection
Fig. 1 Engine Identification
1 - ENGINE IDENTIFICATION LOCATION
RSENGINE 2.4L9-3

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
9 - 4 ENGINE 2.4LRS
ENGINE 2.4L (Continued)