2005 CHRYSLER CARAVAN service

(7) Verify power liftgate system and handle switch
operation. Cycle the power liftgate through one com-
plete open and close cycle, this will allow the power
liftgate control module to relearn its cycle with the
new components.
FULL OPEN SWITCH
DESCRIPTION
The full open switch is located on the gear motor
housing (Fig. 7) and is used to signal the power lift-
gate control module when the power liftgate is in the
full open position. Two wires are used from the full
open switch contacts to the gear motor assemblies
main electrical connector. The full open switch is a
serviceable component.
OPERATION
When the power liftgate reaches the full open posi-
tion, the gear motor housing mounted full open
switch electrical contacts close. This sends a ground
signal to the power liftgate control module, telling
the module that the liftgate has reached the full open
position.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the lift gear and link rod assembly
from the vehicle(Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - REMOVAL).(3) Cut the two wires leading to the full open
switch or back the wires out of the electrical connec-
tor.
(4) Remove the full open switch retaining screw
and remove the full open switch from the gear motor
housing assembly.
INSTALLATION
(1) Perform a wiring repair on the full open switch
wires following the approved procedure in the Wiring
section of the service manual. Or install new termi-
nals on the wire ends and reinstall in the main lift-
gate motor electrical connector.
(2) Position and install the full open switch retain-
ing screw.
(3) Install the power liftgate lift gear and link rod
assembly. (Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - INSTALLATION)
(4) Connect the battery negative cable.
(5) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
(6) Verify power liftgate system and full open
switch operation. Cycle the power liftgate through
one complete open and close cycle, this will allow the
power liftgate control module to relearn its cycle with
the new components.
Fig. 6 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
Fig. 7 FULL OPEN SWITCH LOCATION
1 - FULL OPEN SWITCH
2 - GEAR MOTOR ASSEMBLY RETAINING BOLT (1 OF 3)
RSPOWER LIFTGATE SYSTEM8N-11
EXTERIOR HANDLE SWITCH (Continued)

LATCH
DESCRIPTION
The power cinch/release latch performs the same
features as a manual liftgate latch as well as the
power cinch and / or release capability. A second type
of power latch can also be found on some vehicles,
this latch is designed to perform a power release
only. The power cinch and release capability is
accomplished by an actuator mounted to the leading
edge of the latch assembly. The latch is located in the
lower center of the power liftgate assembly (Fig. 8)
and contains integral pawl and ratchet switches. The
ratchet switch also acts as a liftgate ajar switch. The
power latch assembly can be serviced as a complete
assembly, latch without actuator or just the actuator.
OPERATION
On the power cinch/release latch, the latch
mounted actuator provides the torque required to
close the power liftgate from the secondary to the pri-mary closed and latched position. On the power
cinch/release latch and the power release only latch,
the actuator releases the liftgate from the primary
closed and latched position to the fully unlatched and
movable position.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Open the liftgate and remove the liftgate trim
panel, (Refer to 23 - BODY/DECKLID/HATCH/LIFT-
GATE/TAILGATE/TRIM PANEL - REMOVAL).
(3) Disconnect the power latch electrical connector
(Fig. 9).
(4) Remove the power latch retaining bolts.
(5) Disconnect the liftgate lock cylinder link rod
(Fig. 9) from the key cylinder or latch assembly. To
disconnect from latch, rotate the plastic retaining clip
90 É to unsnap clip from linkrod. Then pull link rod
straight out of latch arm.
(6) Remove the power latch from the vehicle.
Fig. 8 POWER LATCH ORIENTATION
1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
Fig. 9 POWER LATCH ORIENTATION
1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
8N - 12 POWER LIFTGATE SYSTEMRS

INSTALLATION
(1) Position the power latch in the vehicle.
(2) Connect the liftgate lock cylinder link rod (Fig.
10) on the cinch latch assembly. Rotate the plastic
retaining clip 90 É to lock retaining clip onto the link
rod.
(3) Connect the link rod on the lock cylinder.
(4) Install three new power latch retaining bolts.
Torque to 10 N´m (90 in. lbs.).
(5) Connect the power latch electrical connector
and secure push pin retainers.
(6) Connect the battery negative cable.
(7) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes related to the power latch.
(8) Verify power liftgate system and power cinch /
release latch operation. Cycle the power liftgate
through one complete open and close cycle, this will
allow the power liftgate control module to relearn its
cycle with the new components.
(9) Verify power liftgate manual operation. Using
liftgate key rotate the lock cylinder to verify door
operation. Pull door open using exterior liftgate han-
dle / switch.
(10) Install the liftgate trim panel, (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - INSTALLATION).
LATCH ACTUATOR
DESCRIPTION
The power cinch and/or power release latch (Fig.
11) is made possible by a latch actuator attached to
the leading edge of the power latch assembly. This 12
volt latch actuator contains a small drive gear that
meshes with the latch assemblies internal gears to
perform the power cinch close / power release opera-
tions. (Refer to 8 - ELECTRICAL/POWER DOORS/
LATCH - DESCRIPTION) for additional information.
The power cinch/release actuator is serviceable com-
ponent.
OPERATION
During a power close cycle, the power cinch actua-
tor provides the torque required to close the power
liftgate from the secondary to the primary closed and
latched position. During a power open cycle, the
power release actuator releases the liftgate from the
primary closed and latched position to the fully
unlatched and movable position.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
Fig. 10 POWER LATCH ORIENTATION
1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
Fig. 11 POWER LATCH ORIENTATION
1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
RSPOWER LIFTGATE SYSTEM8N-13
LATCH (Continued)

LIFTGATE MOTOR
DESCRIPTION
The gear motor assembly (Fig. 14) consists of a DC
motor, hall effect sensor, engage actuator, full open
switch, lift gear, aluminum housing, drive gears and
wire harness. The gears and motor portion of the
assembly provides the power and torque required to
open or close the liftgate. The hall effect sensor is used
to provide the liftgate control module with a speed read-
ing, which is used to monitor the resistance of liftgate
travel. This speed reading also allows the power liftgate
control module to detect obstructions and move the lift-
gate accordingly. The engage actuator is used to toggle
between power open/close mode and full manual mode
when desired. The full open switch is used to let the
power liftgate control module know when the liftgate is
approaching the full open position.
Serviceable components of the power liftgate gear/mo-
tor assembly are the complete gear/motor assembly,
motor and wire harness, lift gear and control rod,
engage actuator, full open switch and the transverse
bracket.
OPERATION
With the push of a power liftgate command switch
(liftgate closed), the power liftgate control module
will signal the latch assembly to release the liftgate
from its primary closed and latched position to the
released and movable position. The liftgate motor-
mounted engage actuator then engages the liftgatemotor assembly, which moves the liftgate into the
open position. The liftgate motor provides the torque
and power to move the door to its full open or closed
position(Refer to 8 - ELECTRICAL/POWER DOORS -
OPERATION) for additional information.
REMOVAL
The power liftgate gear/motor assembly is serviced
in two ways: the complete gear/motor assembly, or
the motor, aluminum housing, drive gears and wire
harness assembly. To perform this service, use the
following procedure to remove the gear/motor assem-
bly from the vehicle. Then refer to the other proce-
dures called out in this section to transfer the
remaining components (engage actuator, full open
switch, transverse bracket and lift gear and rod) to
the replacement gear/motor assembly.
(1)
Disconnect and isolate the battery negative cable.
(2) Remove the left rear D-pillar trim panel from
the vehicle, (Refer to 23 - BODY/INTERIOR/LEFT
D-PILLAR TRIM PANEL - REMOVAL).
(3) Disconnect the wire harness connector from the
motor assembly (Fig. 15).
(4) Remove the two bolts from the motor housing
and the one bolt from the transverse mount bracket.
(5) Grab the liftgate motor assembly and lift
upward and out to unhook the motor assembly from
the D-pillar.
(6) Remove the liftgate motor assembly from the
vehicle.
Fig. 14 POWER LIFTGATE COMPONENTS
1 - POWER LIFTGATE GEAR MOTOR/ASSEMBLY
2 - POWER LIFTGATE CONTROL MODULE
3 - ELECTRICAL GROUND LOCATION
Fig. 15 POWER LIFTGATE COMPONENTS
1 - POWER LIFTGATE GEAR MOTOR/ASSEMBLY
2 - POWER LIFTGATE CONTROL MODULE
3 - ELECTRICAL GROUND LOCATION
RSPOWER LIFTGATE SYSTEM8N-15

INSTALLATION
(1) Using the motor housing tab, hook the liftgate
motor assembly on the D-pillar.
(2) Install the three motor assembly retaining
bolts. Torque the two rear most bolts first to 9.5 N´m
(85 in. lbs.). Torque the remaining bolt next to the
window actuator to 9.5 N´m (85 in. lbs.).
(3) Connect the liftgate motor assembly electrical
connector.
(4) Install the D-pillar trim panel on the vehicle,
(Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR
TRIM PANEL - INSTALLATION).
(5) Connect the battery negative cable.
(6) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes related to the door motor assembly.
(7) Verify power liftgate system operation. Cycle
the power liftgate through one complete open and
close cycle, this will allow the power liftgate control
module to relearn its cycle with the new components.
LIFT GEAR & LINK ROD
DESCRIPTION
The lift gear and rod assembly are located in the
left rear of the vehicle and are visible without remov-ing the D-pillar trim (Fig. 16). The lift gear provides
the leverage to move the liftgate from the closed to
the open position. The lift gear attaches to a bearing
on the gear motor assembly with four bolts. On the
outboard side of the lift gear are riveted on teeth,
which mesh with the gear motor assembly drive
gears during a open or close operation. The rod
assembly is a steel shaft, equipped with two spheri-
cal rod ends which attaches the lift gear to the lift-
gate. The lift gear and rod assembly are serviceable
components.
OPERATION
One end of the rod assembly is attached to the lift-
gate, the other attached to the lift gear. When the lift
gear is driven by the gear motor assembly the lift-
gate is moved to the open or closed position.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the left rear D-pillar trim panel from
the vehicle, (Refer to 23 - BODY/INTERIOR/LEFT
D-PILLAR TRIM PANEL - REMOVAL).
(3) Remove the lift gear retaining bolts (Fig. 17).
(4) Remove the lift gear and rod from the vehicle.
Fig. 16 LIFTGATE GEAR/MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Fig. 17 LIFTGATE GEAR MOTOR ASSEMBLY
1 - ENGAGE ACTUATOR RETAINING SCREWS
2 - LIFT GEAR RETAINING BOLTS
8N - 16 POWER LIFTGATE SYSTEMRS
LIFTGATE MOTOR (Continued)

TRANSVERSE BRACKET
DESCRIPTION
The transverse bracket (Fig. 22) is used to support
and secure the power liftgate gear/motor assembly to
the left rear body D-pillar. The transverse bracket is
a serviceable power liftgate component.
OPERATION
The power liftgate transverse bracket supports the
gear motor assembly by supplying an additional
attachment point. Located on the leading edge of the
gear motor assembly, one end of the transverse
bracket attaches to the motor assembly the other to
the leading edge of the vehicles D-pillar.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the left D-pillar trim from the vehicle,
(Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR
TRIM PANEL - REMOVAL).
(3) Disconnect the gear motor assembly electrical
connector and disengage retaining pushpin.
(4) Loosen the gear motor assembly retaining bolts
to allow room for transverse bracket to be removed.
(5) Remove the transverse bracket retaining bolts
(Fig. 23).
(6)
Remove the transverse bracket from the vehicle.
INSTALLATION
(1) Position the transverse bracket in the vehicle.
Be certain the transverse bracket is properly posi-
tioned. The bracket should just touch the engage
actuator arm and be positioned between the actuator
arm and the motor housing.
(2) Torque the transverse bracket retaining bolts
to the gear motor assembly to 9.5 N´m (85 in. lbs.).
Do not tighten the transverse bracket retaining bolt,
located under the window actuator at this time.
(3) Torque the gear motor assembly retaining bolts
to 9.5 N´m (85 in. lbs.).
(4) Torque the final transverse bracket retaining
bolt to 9.5 N´m (85 in. lbs.).
(5) Connect the gear motor assembly electrical con-
nector and engage retaining pushpin.
(6) Install the left D-pillar trim, (Refer to 23 -
BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL -
INSTALLATION).
(7) Connect the battery negative cable.
(8) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes related to the door motor assembly.
(9) Verify power liftgate system operation. Cycle
the power liftgate through one complete open and
close cycle, this will allow the power liftgate control
module to relearn its cycle with the new components.
Fig. 22 LIFTGATE GEAR/MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Fig. 23 LIFTGATE GEAR MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
RSPOWER LIFTGATE SYSTEM8N-19

The lock function works from the RKE transmitter
even in an out of synchronization condition, therefore
it could be verified by pressing the LOCK button on
the RKE key fob.
DOOR CYLINDER LOCK
SWITCH - EXPORT
DESCRIPTION
The Door Cylinder Lock Switch (If equipped) is
used to:
²Unlock/Lock all the doors via the Central Lock-
ing feature.
²Arm/Disarm the Vehicle Theft Security System.
²Trigger the Illuminated Entry feature.
The door cylinder lock switch is mounted to the
rear of the driver door lock cylinder. When installed
on the rear of the cylinder, there is a tab on the lock
cylinder that aligns with the switch to prevent it
from turning. An anti-rotating device. The door cylin-
der lock switch is a one time use switch. Once it is
removed from the rear of the door lock cylinder, it
may not be reinstalled and a new switch must be
used.
OPERATION
When the Door Cylinder Lock Switch is turned
either way using the door key cylinder, the BCM
reads a direct message signal from the switch.
If turning the key cylinder once, toward the front
of the vehicle, this will:
(1) Mechanically unlock the door lock.
(2) Disarm the Vehicle Theft Security System (if
equipped).
(3) Turn on the Illuminated Entry (if equipped) for
approximately 30 seconds.
If the key cylinder is turned to the unlock position
(toward the front of vehicle) twice within two sec-
onds, all the doors and liftgate will unlock (if
equipped with the central locking feature).
To lock the vehicle using the door cylinder lock
switch, turn the key cylinder toward the rear of the
vehicle once. This will lock the door that you are
using the key on. If equipped with the central locking
feature, this will lock all the other doors and liftgate.
Furthermore, this will arm the vehicle theft security
system and turn off the illuminated entry.
DIAGNOSIS AND TESTING
DOOR CYLINDER LOCK SWITCH - EXPORT
Any diagnosis of the power lock system
should begin with the use of the DRB IIItdiag-
nostic tool. For information on the use of theDRB IIIt, refer to the appropriate Diagnostic
Service Manual.
For complete circuit diagrams, refer to the appro-
priate wiring information.
(1) Visually inspect the switch for proper installa-
tion. Make sure it is seated on the rear of the key
cylinder, with the tab of the door key cylinder prop-
erly aligned with the slot on the door cylinder lock
switch.
(2) Disconnect the switch at the harness connector
and check the resistance in each switch position.
CAUTION: Do not disconnect the switch from the
rear of the door key cylinder. This switch is a one
time use switch. Once it is removed from the rear of
the switch, it is not reusable and must be replaced.
Test the switch at the harness connector.
DOOR CYLINDER LOCK SWITCH RESISTANCE
SWITCH POSITION RESISTANCE VALUE
COUNTERCLOCKWISE 5.4K OHMS
NEUTRAL 18.4K OHMS
CLOCKWISE 2K OHMS
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the door trim panel of the effected door
cylinder lock switch (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - REMOVAL).
(3) Close the door window.
(4) Disconnect the door cylinder lock switch wire
connector from the door harness, and wiring clip
from the impact beam.
(5) Remove the outer door handle from the door.
(6) Remove the switch from the key cylinder in the
door handle and remove from vehicle.
INSTALLATION
(1) Install the switch on the key cylinder in the
door handle.
(2) Install the door handle.
(3) Connect the door cylinder lock switch wire con-
nector to the door harness, and the wiring clip to the
impact beam.
(4) Install the door trim panel of the affected door
cylinder lock switch (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION).
(5) Connect the battery negative cable.
(6) Verify system operation.
8N - 22 POWER LOCKSRS
POWER LOCKS (Continued)

DOOR LOCK MOTOR
DIAGNOSIS AND TESTING
DOOR LOCK MOTOR
Any diagnosis of the power lock system
should begin with the use of the DRB IIItdiag-
nostic tool. For information on the use of the
DRB IIIt, refer to the appropriate Diagnostic
Service Manual.
For complete circuit diagrams, refer to the appro-
priate wiring information.
Verify battery condition before testing door lock
motor(s).
To determine which motor is faulty, check each
individual door for electrical lock and unlock or dis-
connect the motor connectors one at a time, while
operating the door lock switch. In the event that
none of the motors work, the problem may be caused
by a shorted motor or a faulty switch. Disconnecting
the faulty motor will allow the others to work.
To test an individual door lock motor, disconnect
the electrical connector from the motor. To lock the
door, connect a fused 12 volt power source to the pos-
itive pin of the lock motor and a ground wire to the
other pin. To unlock the door reverse the wire con-
nections at the motor pin terminals. If these results
are not obtained, replace the door latch.
DOOR LOCK SWITCH
DIAGNOSIS AND TESTING
DOOR LOCK SWITCH
(1) Remove door trim panel. Refer to Body, Door -
Front, Trim Panel, Removal and Installation.
(2) Disconnect wire connector from back of door
lock switch.
(3) Depress switch to LOCK position.
(4) Using an ohmmeter, test switch resistance
between Pins 2 and 3. Refer to the DOOR LOCK
SWITCH CONTINUITY test and (Fig. 1).
(5) Depress switch to UNLOCK position.
(6) Test resistance between Pins 2 and 3.
(7) Test resistance between pins 2 and 3 while
switch is in its normal unactuated mode.
(8) If resistance values are not within the param-
eters shown replace the door lock switch.
DOOR LOCK SWITCH CONTINUITY
SWITCH
POSITIONCONTINUITY
BETWEENRESISTANCE
VALUE
LOCK 2 and 3 5.3K Ohm   5%
UNLOCK 2 and 3 2.0K Ohm   5%
UNACTUATED 2 and 3 18.3K Ohms  
5%
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove door trim panel. Refer to Body, Door -
Front, Trim Panel, Removal.
(3) Disconnect wire connector from back of door
lock switch.
(4) Remove two screws to door lock switch.
(5) Remove switch from vehicle.
INSTALLATION
(1) Install the switch into the vehicle.
(2) Install the two screws to door lock switch.
(3) Connect wire connector to back of door lock
switch.
(4) Install door trim panel. Refer to Body, Door -
Front, Trim Panel, Installation.
(5) Connect the battery negative cable.
Fig. 1 DOOR LOCK SWITCH
RSPOWER LOCKS8N-23