2005 CHRYSLER CARAVAN torque

(2) Remove the appropriate seat from the vehicle
and place it on a clean work surface, (Refer to 23 -
BODY/SEATS/SEAT - REMOVAL).
(3) Remove the Memory Seat/Mirror Module
(MSMM) mounting fasteners (if equipped).
(4) Disconnect the MSMM electrical harness con-
nectors and remove the MSMM from the power seat
track (if equipped).
(5) Remove the front seat track rear cover, (Refer
to 23 - BODY/SEATS/SEAT TRACK REAR COVER -
REMOVAL).
(6) Remove the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION SIDE COVERS - REMOVAL).
(7) Disconnect all electrical connectors connecting
the power seat track to the seat assembly.
(8) Pull the seat back trim cover up slightly to
access and remove the two seat back frame mounting
bolts and also remove two seat back recliner bolts.
(9) Remove four seat track mounting bolts from
the seat cushion pan.
(10) Remove the power seat track from the seat.INSTALLATION
(1) Position the seat cushion on the seat track.
(2) Install the four seat track retaining bolts in the
seat cushion pan. Torque the bolts to 28.5 N´m (21 ft-
lbs.).
(3) Position the seat back and install the two seat
back frame mounting bolts and the two seat back
recliner bolts. Torque the bolts to 55 N´m (40.5
ft-lbs.).
(4) Route and connect the electrical connectors
between the power seat track and the seat assembly.
(5) Install the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION SIDE COVERS - INSTALLATION).
(6) Install the front seat track rear cover, (Refer to
23 - BODY/SEATS/SEAT TRACK REAR COVER -
INSTALLATION).
(7) Position the Memory Seat/Mirror Module
(MSMM) and connect the MSMM electrical connec-
tors (if equipped).
(8) Install the MSMM mounting fasteners (if
equipped).
(9) Install the seat assembly in the vehicle (Refer
to 23 - BODY/SEATS/SEAT - INSTALLATION).
(10) Connect the battery negative cable.
RSPOWER SEAT SYSTEM8N-39
POWER SEAT TRACK (Continued)

(5) Partially close the door and pull the latch
assembly out of the side door inner panel, (Fig. 5).
(6) Disconnect all electrical connectors leading to
the latch assembly.
(7) Disconnect the inside and outside handle cables
from the latch assembly.
(8) Disconnect the hold open latch cable from the
latch assembly.
(9) Disconnect lock actuator link rod from the
latch assembly.
(10) Remove the latch assembly from the vehicle.
INSTALLATION
(1) Position the latch assembly in the vehicle. Be
certain all latch mounted components are installed
on the replacement latch assembly. If not, transfer
components from the old latch to the new latch
assembly, (Fig. 6).
(2) Connect the lock actuator link rod on the latch
assembly.
(3) Connect the hold open latch cable on the latch
assembly.
(4) Connect the inside and outside handle cables
on the latch assembly.
(5) Connect all electrical connectors leading to the
latch assembly.
(6) With assistance from another person, position
the side door and install the door latch retaining
bolts, (Fig. 7). Torque to 10 - 12 N´m (100 in. lbs.).
(7) Install the weathershield if necessary.(8) Install the appropriate side door trim panel,
(Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - INSTALLATION) for detailed instructions.
(9) Connect the negative battery cable.
Fig. 5 POWER LATCH POSITION & ORIENTATION
1 - POWER LATCH ASSEMBLY
Fig. 6 POWER LATCH POSITION & ORIENTATION
1 - POWER LATCH ASSEMBLY
Fig. 7 REMOVING LATCH RETAINING BOLTS
1 - LATCH RETAINING BOLTS
2 - SIDE DOOR
8N - 50 POWER SLIDING DOOR SYSTEMRS
LATCH (Continued)

SLIDING DOOR MOTOR
DESCRIPTION
The door motor is located in the center of the
power sliding door (Fig. 8) and is comprised of three
parts. The three parts of the door motor assembly are
the motor, gear reduction and clutch assembly. The
door motor assembly provides the power and torque
to move the sliding door from the open/closed posi-
tion to full closed/open position, after the power
latching mechanism has released.
The door motor is replaced as a complete assembly,
which includes the DC motor, gear reduction and
clutch assemblies.
OPERATION
With the push of a power sliding door command
switch, the power sliding door control module will
signal the latch assembly to release the door from its
primary locked position. The door motor will then
take over to provide the power to open the door to its
full open or closed position. The gear reduction por-
tion of the motor assembly reduces the speed of the
motor from 5800 to 260 rpm and also increases the
torque to the lower drive unit. The clutch portion of
the motor assembly engages the motor to drive thedoor under power and disengages it so the door can
be moved easily under manual operation.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the door trim panel from the appropri-
ate door, (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - REMOVAL).
(3) Remove the water shield as necessary to gain
access to motor assembly.
(4) Remove retaining clip holding flex drive assem-
bly to the motor (Fig. 9). Pull flex drive cable straight
out of the motor assembly.
(5) Disconnect door motor electrical connector.
(6) Using a trim stick (special tool #C-4755) or
equivalent, gently pry out push-pin fasteners retain-
ing the door motor.
(7) Remove the door motor assembly from the
vehicle.
INSTALLATION
(1) Position the door motor assembly on the door
inner panel.
(2) Install the push-pin fasteners retaining the
motor assembly to the power sliding door.
Fig. 8 POWER SLIDING DOOR COMPONENTS
1 - POWER SLIDING DOOR CONTROL MODULE
2 - MODULE RETAINING SCREW
3 - MODULE ELECTRICAL CONNECTORS
4 - DOOR MOTOR ASSEMBLY
5 - FLEX DRIVE ASSEMBLY
6 - DOOR MOTOR RETAINING FASTENERS
7 - DOOR MOTOR ELECTRICAL CONNECTOR
Fig. 9 FLEX DRIVE RETAINING CLIP
1 - FLEX DRIVE CABLE RETAINING CLIP
2 - FLEX DRIVE CABLE
3 - DOOR MOTOR ASSEMBLY
RSPOWER SLIDING DOOR SYSTEM8N-51

INSTALLATION
(1) Position the lower drive unit near the lower
hinge.
(2) Connect the flex drive assembly on the lower
drive unit. Push the flex drive collar straight on until
the it snaps in place (Fig. 14).It may be necessary
to rotate the drive unit slightly until the flex
drive seats in place.
(3) Install the lower drive unit retaining fasteners
(Fig. 15). Torque the larger allen headed center stud
to 9 N´m (80 in. lbs.). Torque the smaller screw to 3
N´m (28 in. lbs.).
(4) Install the lower drive unit cover and retaining
screws (Fig. 16).
(5) Connect the battery negative cable.
Fig. 14 LOWER DRIVE UNIT
1 - LOWER DRIVE UNIT
2 - FLEX DRIVE ASSEMBLY
Fig. 15 LOWER DRIVE UNIT RETAINING
FASTENERS
1 - LOWER DRIVE UNIT RETAINING SCREW
2 - DO NOT REMOVE
3 - LOWER DRIVE UNIT RETAINING BOLT
Fig. 16 SLIDING DOOR LOWER HINGE ASSEMBLY
1 - LOWER DRIVE UNIT COVER
2 - LOWER DRIVE UNIT COVER RETAINING SCREWS
3 - SLIDING DOOR
4 - LOWER HINGE ARM BRACKET
8N - 54 POWER SLIDING DOOR SYSTEMRS
LOWER DRIVE UNIT (Continued)

FLEX DRIVE
DESCRIPTION
The flex drive assembly is located in the lower por-
tion of the power sliding door (Fig. 17) and is used to
connect the door motor to the lower drive unit. An
E-clip is used to secure the flex drive to the motor
assembly, while the flex drive collar is used to secure
the drive to the lower drive unit. The flex drive
assembly is basically a flexible drive shaft for the
power sliding door system. The flex drive assembly is
a replaceable component.
OPERATION
With one end of the flex drive attached to the door
motor and the other attached to the lower drive unit,the flex drive transfers the power and torque from
the motor to the drive unit. A square shaped drive
cable, inside the flex drive assembly engages the
motor drive and rotates to move the door accordingly.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the appropriate sliding door trim
panel, (Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - REMOVAL).
(3) Position the weathershield aside to gain access
to the flex drive assembly.
(4) Remove the E-clip from the flex drive assembly
(Fig. 18).
(5) Pull the flex drive straight out of the motor
assembly.
Fig. 17 POWER SLIDING DOOR COMPONENTS
1 - POWER SLIDING DOOR CONTROL MODULE
2 - MODULE RETAINING SCREW
3 - MODULE ELECTRICAL CONNECTORS
4 - DOOR MOTOR ASSEMBLY
5 - FLEX DRIVE ASSEMBLY
6 - DOOR MOTOR RETAINING FASTENERS
7 - DOOR MOTOR ELECTRICAL CONNECTOR
Fig. 18 FLEX DRIVE E-CLIP
1 - FLEX DRIVE CABLE RETAINING CLIP
2 - FLEX DRIVE CABLE
3 - DOOR MOTOR ASSEMBLY
RSPOWER SLIDING DOOR SYSTEM8N-55

(7) Pull back the sealing patches and remove the
lower track retaining nuts (Fig. 24).
(8) Carefully remove the lower sliding door track
from the vehicle.
INSTALLATION
(1) Carefully position the lower sliding door track
in the vehicle.
(2) Install the lower track retaining nuts and
install the sealing patches, (Fig. 25). Torque the nuts
to 8 N´m (70 in. lbs).
(3) Install the lower hinge assembly on the door,
(Refer to 23 - BODY/DOORS - SLIDING/LOWER
ROLLER ARM - INSTALLATION).NOTE: Take care to locate the lower hinge assem-
bly on the door in its original position (ie. match
screw washer with rings left on hinge). Adjust door
fit if required, (Refer to 23 - BODY/DOORS - SLID-
ING/SLIDING DOOR - ADJUSTMENTS).
(4) Remove the floor jack.
(5) Install the hold-open striker, (Refer to 23 -
BODY/DOORS - SLIDING/HOLD OPEN LATCH
STRIKER - INSTALLATION).
(6) Install the side door sill plate, (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION).
(7) Connect the battery negative cable.
Fig. 24 Lower Track Retaining Nuts
1 - Lower Track Retaining Nuts
2 - Lower Door Track
Fig. 25 Lower Track Retaining Nuts
1 - Lower Track Retaining Nuts
2 - Lower Door Track
8N - 58 POWER SLIDING DOOR SYSTEMRS
LOWER DRIVE UNIT TRACK & RACK (Continued)

(12) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(13) Connect the 4±way harness connector to the
speed control/horn harness to the clockspring.
(14) Connect the 2±way connector to the remote
radio control harness.
(15) Install the driver airbag (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION). Torque the two screws to 10 N´m (90 in.
lbs.).
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING). Personal injury or
death may result if the system test is not performed
properly.
REMOVAL
(1) Position steering wheel and front wheels
straight ahead.
(2) Release hood latch and open hood.
(3) Disconnect and isolate the battery negative
cable.
(4)
WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to
do so may result in accidental airbag deployment,
personal injury or death.
(5) Remove driver airbag from steering wheel
(Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER
AIRBAG - REMOVAL).
(6) Disconnect wire connectors from back of driver
airbag.
(7) Disconnect the 2±way connector from remote
radio control harness.
(8) Disconnect the 4±way harness connector from
the speed control/horn harness to the clockspring.
(9) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(10) Remove steering column shrouds and discon-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - REMOVAL).
(11) Disconnect 4-way and 6-way connectors
between the clockspring and the instrument panel
wiring harness.
(12) Remove clockspring from column assembly by
removing the two retaining screws that attach the
clock spring to the column.
INSTALLATION
(1) Install the clockspring on the column.
(2) Connect the 4-way and 6-way connectors
between the clockspring and the instrument panel
wiring harness.
(3) Install the steering column shrouds and con-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - INSTALLATION).
(4) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(5) Connect the 4±way harness connector to the
speed control/horn harness to the clockspring.
(6) Connect the 2±way connector to the remote
radio control harness (if equipped).
(7) Install the driver airbag (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION). Torque the two screws to 10 N´m (90 in.
lbs.).
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
CURTAIN AIRBAG
DESCRIPTION
Curtain Airbags (Fig. 11) are available when it is
also equipped with dual front airbags. These airbags
are passive and inflatable, Supplemental Restraint
System (SRS) components, and vehicles with this
equipment can be readily identified by a molded
identification trim button with the ªSRS - AIRBAGº
logo (Fig. 12) located on the B-pillar and C-pillar
upper trim panels. This system is designed to reduce
injuries to the vehicle occupants in the event of a
side impact collision.
Curtain airbags have two individually controlled
curtain airbag units. These airbag units are con-
cealed and mounted above the headliner where they
are each secured to one of the roof side rails (Fig.
13). Each airbag cushion is contained within a fabric
wrap that extends along the roof rail from the A-pil-
lar at the front of the vehicle to just behind the
D-pillar at the rear of the vehicle. One tether extends
down the A-pillar from the front of the airbag cush-
ion, and a second tether extends to the roof rail at
the D-pillar. The end of the A-pillar tether is secured
to a slot in the sheet metal with a metal hook
retained by a bolt. The D-pillar tether is attached to
the d-pillar.
8O - 12 RESTRAINTSRS
CLOCKSPRING (Continued)

INSTALLATION
DEPLOYED AIRBAG
(1) Perform clean up procedure (Refer to 8 - ELEC-
TRICAL/RESTRAINTS - STANDARD PROCEDURE
- SERVICE AFTER AN AIRBAG DEPLOYMENT).
(2) Install a new steering column assembly and
lower steering column coupler (Refer to 19 - STEER-
ING/COLUMN - INSTALLATION).
(3) Install the new clockspring.
(4) Connect the 4-way and 6-way connectors
between the clockspring and the instrument panel
wiring harness.
(5) Install the steering column shrouds and con-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - INSTALLATION).
(6) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(7) Connect the 4±way harness connector to the
speed control/horn harness to the clockspring.
(8) Connect the 2±way connector to the remote
radio control harness.
(9) Install the driver airbag and the two screws
retaining the airbag. Tighten screws to 10 N´m (90
in. lbs.)
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
UNDEPLOYED AIRBAG
(1) Connect the harness connector on the driver
airbag trim cover (horn, speed controls) to the clock-
spring.
(2) Connect the squib connectors to the driver air-
bag.
(3) Position the driver airbag into the steering
wheel.
(4) Install the two screws retaining the airbag.
Tighten screws to 10 N´m (90 in. lbs.)
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
IMPACT SENSOR
DESCRIPTION
FRONT IMPACT SENSORS
There are two front impact sensors (Fig. 21), one
on the left, and one on the right front sides of the
vehicle. These sensors are mounted remotely from
the impact sensor that is internal to the Occupant
Restraint Controller (ORC). The right and left front
and side impact sensors are identical in construction
and calibration and each front impact sensor is
secured with two screws. The front impact sensors
are secured with two screws to the outboard sides of
the right and left front rail tips.
The impact sensor housing has an integral connec-
tor and two mounting ears, each with a metal sleeve
to provide crush protection. A cavity in the center of
the molded black plastic impact sensor housing con-
tains the electronic circuitry of the sensor which
includes an electronic communication chip and an
electronic impact sensor. Potting material fills the
cavity to seal and protect the internal electronic cir-
cuitry and components. The front impact sensors are
each connected to the vehicle electrical system
through the headlamp to dash wire harness.
The front impact sensors cannot be repaired or
adjusted and, if damaged or faulty, they must be
replaced. If a front impact sensor is faulty, only the
sensor needs to be replaced. If the sensor is damaged
or faulty, or if proper tightening torque of the screws
that secure the sensor to the bracket cannot be
achieved, the sensor and bracket must be replaced.
Refer to the proper body diagnostic information for
diagnosis and testing.
Fig. 21 FRONT IMPACT SENSOR
8O - 18 RESTRAINTSRS
DRIVER AIRBAG (Continued)