2005 CHRYSLER CARAVAN battery

REMOVAL
REMOVAL - 2.4L
The electronic ignition coil pack attaches directly
to the valve cover.
(1) Diconnect the negative battery cable.
(2) Disconnect electrical connector from coil pack.
(3) Remove coil pack mounting bolts.(4) Remove coil pack and heat shield (Fig. 9).
REMOVAL - 3.3/3.8L
(1) Disconnect the negative battery cable.
(2) Remove the throttle and speed control cables
from clip.
(3) Remove 2 bolts from the Power steering reser-
voir to intake manifold.
(4) Loosen the lower nut for the power steering
reservoir from stud on ignition coil bracket.
(5) Reposition the Power steering reservoir (Fig.
11).
(6) Remove the ignition cables from the ignition
coil.
(7) Disconnect the electrical connector from the
ignition coil.
(8) Remove 2 nuts from the ignition coil studs.
INSTALLATION
INSTALLATION - 2.4L
(1) Install ignition coil and heat shield to valve
cover and tighten bolts.
(2) Connect the electrical connector to the ignition
coil.
(3) Transfer spark plug cables to new coil pack.
The coil pack towers are numbered with the cylinder
identification. Be sure the ignition cables are fully
seated onto the towers.
(4) Connect the negative battery cable.
Fig. 9 IGNITION COIL - 2.4L
Fig. 10 IGNITION COIL - 3.3/3.8L
1 -Ignition Coil
Fig. 11 IGNITION COIL BRACKET 3.3/3.8L
RSIGNITION CONTROL8I-7
IGNITION COIL (Continued)

INSTALLATION - 3.3/3.8L
(1) Install coil over studs on bracket.
(2) Install 2 nuts to the ignition coil studs. Tighten
nuts and bolts.
(3) Connect the electrical connector to the ignition
coil.
(4) Install the ignition cables to the ignition coil.
(5) Reposition the Power steering reservoir. Slide
bracket over the mounting stud (Fig. 11).
(6) Install 2 bolts to the Power steering reservoir
to intake manifold.
(7) Tighten the lower nut to stud on ignition coil
bracket.
(8) Install the throttle and speed control cables to
clip.
(9) Connect the negative battery cable.
KNOCK SENSOR
DESCRIPTION
The knock sensor threads into the cylinder block.
The knock sensor is designed to detect engine vibra-
tion that is caused by detonation.
OPERATION
When the knock sensor detects a knock in one of
the cylinders, it sends an input signal to the PCM. In
response, the PCM retards ignition timing for all cyl-
inders by a scheduled amount.
Knock sensors contain a piezoelectric material
which constantly vibrates and sends an input voltage
(signal) to the PCM while the engine operates. As the
intensity of the crystal's vibration increases, the
knock sensor output voltage also increases.
The voltage signal produced by the knock sensor
increases with the amplitude of vibration. The PCM
receives as an input the knock sensor voltage signal.
If the signal rises above a predetermined level, the
PCM will store that value in memory and retard
ignition timing to reduce engine knock. If the knock
sensor voltage exceeds a preset value, the PCM
retards ignition timing for all cylinders. It is not a
selective cylinder retard.
The PCM ignores knock sensor input during engine
idle conditions. Once the engine speed exceeds a
specified value, knock retard is allowed.
Knock retard uses its own short term and long
term memory program.
Long term memory stores previous detonation
information in its battery-backed RAM. The maxi-
mum authority that long term memory has over tim-
ing retard can be calibrated.
Short term memory is allowed to retard timing up
to a preset amount under all operating conditions (as
long as rpm is above the minimum rpm) except WOT.The PCM, using short term memory, can respond
quickly to retard timing when engine knock is
detected. Short term memory is lost any time the
ignition key is turned off.
NOTE: Over or under tightening affects knock sen-
sor performance, possibly causing improper spark
control.
REMOVAL
REMOVAL - 2.4L
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 12).
(1) Disconnect electrical connector from knock sen-
sor.
(2) Use a crow foot socket to remove the knock
sensors.
REMOVAL - 3.8L
The knock sensor threads into the side of the cyl-
inder block in the rear.
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) On All Wheel Drive vehicles remove the PTU
(Power Transfer Unit), refer to the Transmission sec-
tion for more information.
(4) Disconnect electrical connector from knock sen-
sor.
(5) Use a crow foot socket to remove the knock
sensor.
INSTALLATION
INSTALLATION - 2.4L
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 12).
(1) Install knock sensor. Tighten knock sensor to
10 N´m (7 ft. lbs.) torque.Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach electrical connector to knock sensor.
INSTALLATION - 3.8L
The knock sensor threads into the side of the cyl-
inder block in the rear.
(1) Install knock sensor. Tighten knock sensor to
10 N´m (7 ft. lbs.) torque.Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach electrical connector to knock sensor.
(3) On All Wheel Drive vehicles install the PTU
(Power Transfer Unit) for the rear wheels, refer to
the Transmission section for more information.
8I - 8 IGNITION CONTROLRS
IGNITION COIL (Continued)

INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - SELF-
DIAGNOSTICS.........................2
DIAGNOSIS AND TESTING - CLUSTER
DIAGNOSIS...........................3REMOVAL.............................11
INSTALLATION.........................11
CLUSTER LENS
REMOVAL.............................11
INSTALLATION.........................11
INSTRUMENT CLUSTER
DESCRIPTION
The instrumentation gauges are contained in a
subdial assembly within the instrument cluster. The
individual gauges are not serviceable. If one of the
cluster gauges becomes faulty, the entire cluster
would require replacement.
The Mechanical Instrument Cluster (MIC) with a
tachometer is equipped with a electronic vacuum flu-
orescent transmission range indicator (PRND3L),
odometer, and trip odometer display.
The MIC without a tachometer is equipped with a
Light Emitting Diode (LED) transmission range indi-
cator (PRND3L) and a vacuum fluorescent odometer
display.
The MIC is equipped with the following warning
lamps.
²Lift Gate Ajar
²Low Fuel Level
²Low Windshield Washer Fluid Level
²Cruise
²Battery Voltage
²Fasten Seat Belt
²Door Ajar
²Coolant Temperature
²Anti-Lock Brake
²Brake
²Oil Pressure
²MIL (Malfunction Indicator Lamp)
²VTSS/SKIS Indicator
²Airbag
²Traction Control
²Autostick
Export Only- uses a message center that displays
the following telltales:
²Turns Signals
²High Beam
²Tire Pressure Monitoring (TPM)²Glow Plug (Export Only)
²Supplemental Cabin Heater (Export Only)WATER IN FUEL LAMP - EXPORT
The Water In Fuel Lamp is located in the message
center. When moisture is found within the fuel sys-
tem, the sensor sends a message via the PCI data
bus to the instrument cluster. The MIC illuminates
the bulb in the message center, The sensor is located
underneath the vehicle, directly above the rear axle.
The sensor is housed within the fuel filter/water sep-
arator assembly cover. The sensor is not serviced sep-
arately. If found defective, the entire assembly cover
must be replaced.
OPERATION
Refer to the vehicle Owner's Manual for operation
instructions and conditions for the Instrument Clus-
ter Gauges.
WATER IN FUEL LAMP/SENSOR - EXPORT
The Water In Fuel Sensor is a resistive type
switch. It is calibrated to sense the different resis-
tance between diesel fuel and water. When water
enters the fuel system, it is caught in the bottom of
the fuel filter/water separator assembly, where the
sensor is located. Water has less resistance than die-
sel fuel. The sensor then sends a PCI data bus mes-
sage to the instrument cluster to illuminate the
lamp.
If the lamp is inoperative, perform the self diag-
nostic test on the instrument cluster to check the
lamp operation before continuing diagnosis.
RSINSTRUMENT CLUSTER8J-1

CONDITION POSSIBLE CAUSES CORRECTION
ALL SEGMENTS ARE
ON.1. NO PCI BUS
MESSAGE FROM THE
TCM.1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED)
PASSES TEST GO TO STEP 1.B. IF PRND3L
(PRND1234 IF AUTOSTICK EQUIPPED) FAILS TEST,
REPLACE CLUSTER ASSEMBLY.
1.B. CHECK THE TCM USING A DRB IIITSCAN
TOOL. REFER TO THE PROPER TRANSMISSION
DIAGNOSTIC PROCEDURES MANUAL TO
PROPERLY DIAGNOSE AND REPAIR.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove Over Steering Column Bezel by lifting
it straight up with a firm pull.
(3) Remove the four cluster bezel attaching screws.
(4) Tilt the steering column in the full down posi-
tion.
(5) Pull rearward on the cluster bezel and remove.
(6) Remove the four screws holding instrument
cluster to instrument panel.
(7) Rotate top of cluster outward.
(8) Disconnect the cluster harness connector.
(9) Remove instrument cluster from instrument
panel.
INSTALLATION
(1) Connect the instrument cluster wire connector.
(2) Rotate top of cluster inward as placing into
instrument panel opening.
(3) Install the four screws holding instrument clus-
ter to instrument panel.
(4) Position cluster bezel into place.
(5) Install the four bezel attaching screws.(6) Install the Over Steering Column Bezel by
firmly snapping into place.
(7) Connect the battery negative cable.
CLUSTER LENS
REMOVAL
(1) Remove the instrument cluster. Refer to Elec-
trical, Instrument Cluster, Removal.
(2) Remove the screws holding the lens to the
instrument cluster.
(3) Press down on the snap features of the lens
and remove the lens from the cluster.
INSTALLATION
(1) Insert the lens snap features into the cluster.
(2) Install the screws holding the lens to the
instrument cluster.
(3) Install the instrument cluster. Refer to Electri-
cal, Instrument Cluster, Installation.
RSINSTRUMENT CLUSTER8J-11
INSTRUMENT CLUSTER (Continued)

DAYTIME RUNNING LAMPS
Power is reduced using pulse-width modulation to
the high beams, where by the power is switched on
and off rapidly instead of remaining on continuously.
The duration and interval of the power pulses is pro-
grammed into the FCM. Daytime running lamps are
functional when 450 rpm's are reached.
HEADLAMP SYSTEM
The headlamp system will default to headlamps
ON position when ignition switch is ON and when an
open or short circuit failure occurs on the headlamp
switch input or PCI data bus communication between
the BCM and the FCM fails. The system will return
to normal operation when the open or short is
repaired. A fault will be reported by the BCM when a
failure occurs on the dimmer or headlamp switch
input.
If the exterior lamps are ON and the headlamp
switch is in any position other than OFF or AUTO
and with the ignition switch OFF (LOCK) after 3
minutes the BCM sends a message via PCI bus to
the FCM informing the FCM to turn off the head-
lamps, park lamps and fog lamps. This feature pre-
vents the vehicle battery from being discharged when
the vehicle lights have been left ON.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is activated by
turning the headlamps ON (high or low beam) while
the engine is running, turning the ignition switch
OFF, and then turning the headlamp switch OFF
within 45 seconds. The system will not activate if
more than 45 seconds elapse between ignition switch
OFF and headlamp switch OFF. The BCM will allow
the headlamps to remain ON for 90 seconds (config-
urable) before they automatically turn off (If the key
is in the ignition during the headlamp time delay
mode, then both the headlamps and park lamps
(including panel dimming) will be ON). Refer to the
Owner's Manual for more information.
If the headlamp switch is in the Auto Headlamp
Position, the headlamps are ON due to the night sig-
nal from the CMTC and the ignition switch is in any
position other than run/start, the BCM shall enter a
90 second (configurable) Auto Headlamps time delay
mode. If the key is in the ignition during the head-
lamp time delay mode, then both the headlamps and
park lamps (including panel dimming) will be ON. If
the key is not in the ignition, then only the head-
lamps will be ON. The BCM will allow the head-
lamps to remain ON for 90 seconds before they
automatically turn OFF. Refer to the Owner's Man-
ual for more information.
OPTICAL HORN/HIGH BEAMS
When the multi-function switch is pulled to the
first detent (optical horn) signal, the headlamps are
ON, key-in the ignition the BCM shall send a mes-
sage via PCI bus to the FCM to turn on the head-
lamps drivers to illuminate all four filaments (Low
and High beams). When the multi-function switch is
pulled to the second detent (high beam) signal and
the headlamps are ON, the BCM shall send a mes-
sage via PCI bus to the FCM to turn on the head-
lamps drivers. The High Beams are illuminated and
the Low Beams and Fog Lamps (if ON) are extin-
guished. If the headlamps were in the high beam
configuration when power was removed from the
headlamps, the headlamps will be configured as low
beam the next time they are activated.
NOTE: For RG - Export vehicles, the low beams and
front fog lamps will remain ON when high beams
are activated.
WARNING
Eye protection should be used when servicing
glass components. Personal injury or death can
result.
Do not touch the glass of halogen bulbs with
fingers or other possibly oily surface, reduced
bulb life will result. Do not use bulbs other
than those indicated in the Bulb Application
table. Damage to lamp and/or Daytime Running
Lamp Module can result. Do not use fuses, cir-
cuit breakers or relays having greater amper-
age value than indicated on the fuse panel or in
the Owners Manual.
Do not use bulbs other than those listed in
the Bulb Application Table. Damage to lamp
can result. Do not touch halogen bulbs with fin-
gers or other oily surfaces. Bulb life will be
reduced.
SPECIFICATIONS
EXTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
BACK-UP 3057
CHMSL 921
FRONT SIDE MARKER/PARK/
TURN (DODGE)3157A
FRONT SIDE MARKER/PARK/
TURN (CHRYSLER)3157AK
RSLAMPS/LIGHTING - EXTERIOR8L-3
LAMPS/LIGHTING - EXTERIOR (Continued)

(3) Gently push the plunger on the brake lamp
switch in until it stops.
(4) With the switch in this depressed position
(plunger pushed in), use an ohmmeter to test each of
the three internal switches as shown (Fig. 2). You
should achieve the results as listed in the figure.
If you do not achieve the results as listed in both
figures, the switch is faulty and must be replaced.
Refer to Removal And Installation in this section.
If the switch is found to be operating properly, it
may be misadjusted. Do not reinstall the switch,
replace it. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
INSTALLATION)
CAUTION: The switch can only be adjusted once.
That is during initial installation of the switch. If the
switch is not adjusted properly or has beenremoved for any reason, a new switch must be
installed and adjusted.
REMOVAL
(1) Disconnect and isolate the battery negative
cable from its post on the battery.
(2) Remove silencer panel below steering column
and knee blocker.
(3) Remove the brake lamp switch by rotating the
switch in a counterclockwise direction approximately
30 degrees and pulling it out of the bracket (Fig. 3).
(4) Release the locking tab and disconnect the wir-
ing connector from the switch.
(5) Discard the brake lamp switch. It must not be
reused.
INSTALLATION
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(1) Mount and adjust the NEW brake lamp switch
using the following procedure:
(a) Connect the wiring connector to the switch
and latch the locking tab.
Fig. 1 SWITCH TEST - RELEASED POSITION
Fig. 2 SWITCH TEST - DEPRESSED POSITION
Fig. 3 Brake Lamp Switch And Pedal With Bracket
1 - BRAKE LAMP SWITCH
2 - WIRING CONNECTOR
3 - PEDAL AND BRACKET
RSLAMPS/LIGHTING - EXTERIOR8L-5
BRAKE LAMP SWITCH (Continued)

(b) Install the switch in its bracket by aligning
the index tab on the switch with the slot in the
mounting bracket.
(c) When the switch is fully seated in its
bracket, rotate the switch clockwise approximately
30É to lock the switch into place.
(d) With the brake pedal in the fully released
position, move the lever on the back of the brake
lamp switch from the angled non-adjusted position
to the full vertical position as shown (Fig. 4). This
will adjust the brake lamp switch to the vehicle.
(2) Install silencer panel below steering column
knee blocker.
(3) Reconnect the battery negative terminal.
(4) Check the stop lamps to verify they are operat-
ing properly and not staying on when the pedal is in
the released position.
(5) Road test the vehicle to ensure proper opera-
tion of the brakes including ABS and speed control (if
equipped).
CENTER HIGH MOUNTED
STOP LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove two retaining screws (Fig. 5).
(3) Twist socket counter-clockwise and remove
from lamp.
(4) Pull bulb from socket (Fig. 7).
INSTALLATION
(1) Push bulb into socket.
(2) Install socket into the lamp unit.
(3) Install the retaining screws.
(4) Reconnect the battery negative cable.
CENTER HIGH MOUNTED
STOP LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the two retaining screws (Fig. 5).
(3) Disconnect the rear window washer nozzle
assembly (Fig. 6).
(4) Disconnect CHMSL electrical connector from
bulb socket (Fig. 7).
INSTALLATION
(1) Connect electrical connector to CHMSL bulb
socket.
(2) Reconnect the rear window washer nozzle
assembly.
Fig. 4 Adjustment Lever Movement
Fig. 5 CHMSL UNIT
1 - CHMSL UNIT
2 - LIFTGATE
Fig. 6 REAR WASHER NOZZLE ASSEMBLY
1 - BARREL IN CHMSL
2 - NOZZLE ASSEMBLY
3 - SQUEEZE ARMS TO RELEASE NOZZLE ASSEMBLY
4 - HOSE
8L - 6 LAMPS/LIGHTING - EXTERIORRS
BRAKE LAMP SWITCH (Continued)

(3) Install the retaining screws.
(4) Reconnect the battery negative cable.
FRONT FOG LAMP
DIAGNOSIS AND TESTING - FRONT FOG LAMP
When a vehicle experiences problems with the
front fog lamp system, verify the condition of the bat-
tery connections, fuses, charging system, fog lamp
bulbs, wire connectors, relay, high beam switch, and
headlamp switch. Refer to the appropriate wiring
information.
Each vehicle is equipped with various lamp assem-
blies. A good ground is necessary for proper lighting
operation. Grounding is provided by the lamp socket
when it comes in contact with the metal body, or
through a separate ground wire.
When changing lamp bulbs check the socket for
corrosion. If corrosion is present, clean it with a wire
brush.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges are not holding the com-
ponent in place.
FRONT FOG LAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM
WITH ENGINE IDLING
OR IGNITION TURNED
OFF.1. Loose or corroded battery
cables.1. Clean and secure battery cable clamps and
posts.
2. Loose or worn generator drive
belt.2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer to
Electrical, Charging,
4. Battery has insufficient charge. 4. Test battery state-of-charge. Refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Electrical, Battery
System.
6. Poor lighting circuit Z349/Z248
ground.6. Test for voltage drop across Z349/248
ground locations. Refer to Electrical, Wiring
Information.
FOG LAMP BULBS
BURN OUT
FREQUENTLY1. Charging system output too
high.1. Test and repair charging system. Refer to
Electrical, Charging.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
Fig. 7 CHMSL ELECTRICAL CONNECTOR
1 - CHMSL UNIT
2 - CHMSL ELECTRICAL CONNECTOR
RSLAMPS/LIGHTING - EXTERIOR8L-7
CENTER HIGH MOUNTED STOP LAMP UNIT (Continued)