2005 CHRYSLER CARAVAN torque

INSTALLATION
(1) Push belt through seat cushion.
(2) While looking at the bottom of the seat, locate
retaining bolt hole on the left side of the seat riser.
Install retaining bolt into seat riser (Fig. 45). Torque
anchor bolt to 39 N´m (29 ft. lbs.).
(3) Place seat into track and on front anchors.
(4) Pull #3 strap and install seat onto latching
area.
(5) Pull seat assembly down firmly and snap into
track.
(6) Pull handle #1 and fold seat back rearward.
(7) Close rear liftgate.
SEAT BELT HEIGHT
ADJUSTER-BORC-PILLAR
REMOVAL
(1) Remove turning loop retaining bolt.
(2) Remove B or C-pillar trim cover.
(3) Remove two screws attaching shoulder belt
height adjuster to pillar.
(4) Remove height adjuster from vehicle.
INSTALLATION
(1) Place height adjuster into position.
(2) Install screws attaching shoulder belt height
adjuster to pillar.
(3) Install B or C-pillar trim cover.
(4) Install turning loop to height adjuster. Torque
anchor bolt to 39 N´m (29 ft. lbs.).
SEAT BELT HEIGHT
ADJUSTER KNOB
REMOVAL
(1) Disengage clips attaching clam shell cover to
seat belt turning loop and open cover.
(2) Using a trim tool (special tool #C-4755), gently
pry knob from seat belt height adjuster.
INSTALLATION
(1) Place seat belt height adjuster knob in position
on height adjuster.
(2) Firmly push knob on until retainers engage.
(3) Reinstall turning loop clam shell cover.
(4) Verify seat belt operation. Make sure it moves
through loop without binding.
SEAT BELT & RETRACTOR -
OUTBOARD - FRONT
REMOVAL
(1) Open door.
(2) Move seat all the way forward.
(3) Open hood.
(4) Disconnect and isolate the battery negative
cable.
(5)
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.
(6) Remove shoulder harness height adjuster knob
by pulling it straight away from adjuster (Fig. 48).
(7) Remove cover from seat belt turning loop (Fig.
48).
(8) Remove bolt attaching turning loop to shoulder
belt height adjuster (Fig. 48).
(9) Remove upper B-pillar trim cover (Fig. 48).
NOTE: If equipped with the Occupant Classification
System (OCS), there is a Belt Tension Sensor
located on the lower seat belt anchor on the pas-
senger front seat belt.
Fig. 48 SEAT BELT - OUTBOARD FRONT
1 - B-PILLAR TRIM LOWER
2 - BELT
3 - B-PILLAR TRIM UPPER
4 - HEIGHT ADJUSTER
5 - KNOB
6 - B-PILLAR TRIM LOWER
7 - FLOOR ANCHOR
8 - FLOOR ANCHOR
9 - 30É OUTBOARD
10 - RETRACTOR
8O - 38 RESTRAINTSRS
SEAT BELT BUCKLE - SECOND ROW INBOARD - 50/50 BENCH (Continued)

(10) Remove the lower seat belt anchor bolt (Fig.
49).
(11) Disconnect the electrical connector if equipped
with OCS (Fig. 49).
(12) Remove front door sill plate (Fig. 48).
(13) Remove sliding door sill plate (Fig. 48).
(14) Remove lower B-pillar trim cover (Fig. 48).
(15) Disconnect the seat belt retractor electrical
connector (Fig. 48).
(16) Remove seat belt retractor attaching bolt (Fig.
48).
(17) Remove the seat belt and retractor from vehi-
cle.
INSTALLATION
WARNING: Inspect the condition of the shoulder
belt and lap belt. Replace any belt that is cut,
frayed, torn, or damaged in any way. Also, replace
the shoulder belt if the retractor is either damaged
or inoperative.
(1) Place seat belt and retractor into position (Fig.
48).
(2) Install bolt attaching seat belt retractor to
B-pillar (Fig. 48). Torque bolt to 39 N´m (29 ft. lbs.).
(3) Connect the seat belt retractor electrical con-
nector (Fig. 48).
(4) Install the lower B-pillar trim cover (Fig. 48).
(5) Install the sliding door sill plate (Fig. 48).
(6) Install the front door sill plate (Fig. 48).(7) Install the lower seat belt anchor bolt (Fig. 49).
Torque bolt to 39 N´m (29 ft. lbs.).
NOTE: If equipped with the Occupant Classification
System (OCS), there is a Belt Tension Sensor
located on the lower seat belt anchor on the pas-
senger front seat belt.
(8) Connect the belt tension sensor connector (if
equipped with OCS) (Fig. 49).
(9) Install the upper B-pillar trim cover (Fig. 48).
(10) Install the bolt attaching turning loop to
shoulder belt height adjuster (Fig. 48). Torque bolt to
39 N´m (29 ft. lbs.).
(11) Install the cover to the seat belt turning loop
(Fig. 48).
(12) Install the shoulder harness height adjuster
knob by pushing it straight onto the adjuster (Fig.
48).
(13) Move seat back to approximate customer posi-
tion.
WARNING: If equipped with the OCS, do not con-
nect the battery negative cable (Refer to 8 - ELEC-
TRICAL/RESTRAINTS - DIAGNOSIS AND TESTING -
AIRBAG SYSTEM). Personal injury or death may
result if the system test is not performed first.
WARNING: If equipped with the OCS, following suc-
cessful completion of the Airbag System test proce-
dure, the Occupant Classification System
Verification Test must be done using a scan tool
and the appropriate diagnostic information.
(14) Verify vehicle and system operation.
(15) Close hood.
SEAT BELT & RETRACTOR -
FIRST ROW - OUTBOARD
REMOVAL
(1) Remove first and second row seats.
(2) Remove first row seat belt lower anchor bolt.
(3) Remove first row seat belt upper turning loop
anchor bolt.
(4) Remove liftgate sill plate.
(5) Remove upper liftgate trim.
(6) Remove second seat lower anchor bolt.
(7) Remove second seat upper turning loop anchor
bolt.
(8) Remove D-pillar trim cover.
(9) Disconnect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
Fig. 49 BELT TENSION SENSOR/LOWER SEAT
BELT ANCHOR
1 - A-PILLAR
2 - SEAT BELT ANCHOR/BELT TENSION SENSOR
3 - BELT TENSION SENSOR CONNECTOR
RSRESTRAINTS8O-39
SEAT BELT & RETRACTOR - OUTBOARD - FRONT (Continued)

accessible from the rear after the D-pillar trim is
removed.
(10) Remove quarter trim bolster.
(11) Remove quarter trim panel screws.
(12) Remove quarter trim panel.
(13) Remove first row seat belt and retractor
retaining bolt.
(14) Remove first row seat belt and retractor from
vehicle.
INSTALLATION
(1) Install first row seat belt and retractor. Torque
bolt to 39 N´m (29 ft. lbs.).
(2) Install quarter trim panel.
(3) Install quarter trim panel screws.
(4) Install quarter trim bolster.
(5) Connect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(6) Install D-pillar trim cover.
(7) Install second seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(8) Install second seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(9) Install upper liftgate trim.
(10) Install liftgate sill plate.
(11) Install first row seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(12) Install first row seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(13) Install first and second row seats.
SEAT BELT BUCKLE - SECOND
ROW - THREE PASSENGER
BENCH
REMOVAL
(1) Remove bolt attaching seat belt buckle to seat
rear frame rail (Fig. 50).
(2) Remove seat belt buckle from seat.
INSTALLATION
(1) Place seat belt buckle in position on seat.
(2) Install bolt to attach seat belt buckle to seat
rear frame rail. Tighten all seat belt bolts to 39 N´m
(29 ft. lbs.) torque.
SEAT BELT & RETRACTOR -
SECOND ROW - RIGHT
OUTBOARD
REMOVAL
(1) Remove first and second row seats.
(2) Remove first row seat belt lower anchor bolt.
(3) Remove first row seat belt upper anchor bolt.
(4) Remove liftgate sill plate.
(5) Remove upper liftgate trim.
(6) Remove second seat belt lower anchor bolt.
(7) Remove second seat belt upper anchor bolt.
(8) Remove D-pillar trim cover.
(9) Disconnect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(10) Remove quarter trim bolster.
(11) Remove quarter trim panel screws.
(12) Remove quarter trim panel.
(13) Remove retractor retaining bolt.
(14) Remove second row seat belt and retractor.
INSTALLATION
(1) Install second row seat belt and retractor.
Torque bolt to 39 N´m (29 ft. lbs.).
(2) Install quarter trim panel.
(3) Install quarter trim panel screws.
(4) Install quarter trim bolster.
(5) Connect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
Fig. 50 SEAT BELT BUCKLE - SECOND ROW -
THREE PASSENGER BENCH
1 - ANCHOR BOLT
2 - SEAT BELTS
3 - ANCHOR
4 - RISER
8O - 40 RESTRAINTSRS
SEAT BELT & RETRACTOR - FIRST ROW - OUTBOARD (Continued)

the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(6) Install D-pillar trim cover.
(7) Install second seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(8) Install second seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(9) Install upper liftgate trim.
(10) Install liftgate sill plate.
(11) Install first row seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(12) Install first row seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(13) Install first and second row seats.
SEAT BELT & RETRACTOR -
SECOND ROW - RIGHT
OUTBOARD WITH REAR HVAC
-LWB
REMOVAL
(1) Remove first and second row seats.
(2) Remove first row seat belt lower anchor bolt.
(3) Remove first row seat belt upper anchor bolt.
(4) Remove liftgate sill plate.
(5) Remove upper liftgate trim.
(6) Remove second seat belt lower anchor bolt.
(7) Remove second seat belt upper anchor bolt.
(8) Remove D-pillar trim cover.
(9) Disconnect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(10) Remove quarter trim bolster.
(11) Remove quarter trim panel screws.
(12) Remove quarter trim panel.
(13) Loosen HVAC unit enough to gain access to
seat belt retractor fasteners.
(a) Remove bracket around HVAC unit (Fig. 51).
(b) Remove air duct (Fig. 52).
(c) Remove fasteners attaching HVAC unit to
inner quarter panel (Fig. 53).
(d) Gently pry out on rear HVAC unit to gain
access to the seat belt and retractor.
(14) Remove bolts attaching seat belt guide loop to
inner quarter panel.
(15) Pull outward on HVAC unit and remove bolt
attaching retractor to inner quarter panel.
(16) Remove second row seat belt and retractor
from vehicle.
INSTALLATION
(1) Position second row seat belt and retractor to
vehicle.
(2) Pull outward on HVAC unit and install bolt
attaching retractor to inner quarter panel. Torque
bolt to 39 N´m (29 ft. lbs.).
(3) Install bolts attaching seat belt guide loop to
inner quarter panel.
(4) Install fasteners attaching HVAC unit to inner
quarter panel.
(5) Install air duct.
(6) Install trim panel retaining bracket around
HVAC unit.
(7) Install quarter trim panel.
(8) Install quarter trim panel screws.
(9) Install quarter trim bolster.
(10) Connect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
Fig. 51 TRIM PANEL MOUNTING BRACKET
1 - TRIM PANEL MOUNTING BRACKET
Fig. 52 LOWER HEATER DUCT
1 - LOWER HEAT DUCT MOUNTING
RSRESTRAINTS8O-41
SEAT BELT & RETRACTOR - SECOND ROW - RIGHT OUTBOARD (Continued)

the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(11) Install D-pillar trim cover.
(12) Install second seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(13) Install second seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(14) Install upper liftgate trim.
(15) Install liftgate sill plate.
(16) Install first row seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(17) Install first row seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(18) Install first and second row seats.
SEAT BELT & RETRACTOR -
SECOND ROW - LEFT
OUTBOARD
REMOVAL
(1) Remove first and second row seats.
(2) Remove first row seat belt lower anchor bolt.
(3) Remove first row seat belt upper anchor bolt.
(4) Remove liftgate sill plate.
(5) Remove upper liftgate trim.
(6) Remove second seat belt lower anchor bolt.
(7) Remove second seat belt upper anchor bolt.
(8) Remove D-pillar trim cover.
(9) Disconnect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(10) Remove quarter trim bolster.
(11) Remove quarter trim panel screws.
(12) Remove quarter trim panel.
(13) Remove retractor retaining bolt.
(14) Remove second row seat belt and retractor
from vehicle.
INSTALLATION
(1) Install second row seat belt and retractor.
Torque bolt to 39 N´m (29 ft. lbs.).
(2) Install quarter trim panel.
(3) Install quarter trim panel screws.
(4) Install quarter trim bolster.
(5) Connect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(6) Install D-pillar trim cover.
(7) Install second seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(8) Install second seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(9) Install upper liftgate trim.
(10) Install liftgate sill plate.
(11) Install first row seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(12) Install first row seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(13) Install first and second row seats.
Fig. 53 REAR HVAC MOUNTING
1 - REAR HVAC MODULE MOUNTING
2 - REAR EVAPORATOR LOWER HOUSING
3 - REAR EVAPORATOR UPPER HOUSING
8O - 42 RESTRAINTSRS
SEAT BELT & RETRACTOR - SECOND ROW - RIGHT OUTBOARD WITH REAR HVAC - LWB (Continued)

SPEED CONTROL
TABLE OF CONTENTS
page page
SPEED CONTROL
DESCRIPTION..........................1
OPERATION
OPERATION..........................1
OPERATION - INTERACTIVE SPEED
CONTROL (4 Speed EATX Only)...........2
DIAGNOSIS AND TESTING - ROAD TEST.....3
SPECIFICATIONS - TORQUE...............3
CABLE
DESCRIPTION..........................4
OPERATION............................4
REMOVAL.............................4
INSTALLATION..........................4
SERVO
DESCRIPTION..........................4OPERATION............................4
REMOVAL.............................4
INSTALLATION..........................4
SWITCH
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................6
VACUUM RESERVOIR
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................6
INSTALLATION..........................6
SPEED CONTROL
DESCRIPTION
The speed control system is electronically con-
trolled and vacuum operated. The electronic control
is integrated into the Powertrain Control Module.
The controls are located on the steering wheel. The
ON/OFF, and SET buttons are located on the left side
of the airbag module. The RESUME/ACCEL, CAN-
CEL and COAST buttons are located on the right
side of the airbag module (Fig. 1).The system is designed to operate at speeds above
30 mph (48 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIP-
PERY.
OPERATION
OPERATION
When speed control is activated by depressing the
ON switch, the PCM allows a set speed to be stored
in RAM for speed control. To store a set speed,
depress and release the SET switch while the vehicle
is moving at a speed between 25 and 85 mph. In
order for the speed control to engage, the brakes can-
not be applied, nor can the gear selector be indicat-
ing the transmission is in Park or Neutral (ATX) or
1st/2nd gear (MTX). The speed control can be disen-
gaged manually by:
²Stepping on the brake pedal
²Depressing the OFF switch
²Depressing the CANCEL switch.
²Depressing the clutch pedal
²Operating in 1st or 2nd gear (autostick, if
equipped)
Fig. 1 SPEED CONTROL SWITCHES - Typical
RSSPEED CONTROL8P-1

OPERATION
The PCM on NGC vehicles first senses that the
speed control is set. If the set speed is exceeded by
more than 4 mph (6.5 km/hr) and the throttle is
closed, the PCM on NGC vehicles causes the trans-
axle to downshift to THIRD gear. After downshifting,
the automatic speed control resumes normal opera-
tion. To ensure that an upshift is appropriate after
the set speed is reached, the PCM on NGC vehicles
waits until the speed control system opens the throt-
tle at least 6 degrees before upshifting to OVER-
DRIVE again.
If the driver applies the brakes, canceling auto-
matic speed control operation with the transaxle still
in THIRD gear, the PCM on NGC vehicles maintains
this gear until the driver opens the throttle at least 6
degrees to avoid an inappropriate upshift. The
upshift is also delayed for 2.5 seconds after reaching
the 6 degrees throttle opening in anticipation that
the driver might open the throttle enough to require
THIRD gear. This will avoid unnecessary and dis-
turbing transmission cycling. If the automatic speed
control RESUME feature is used after braking, the
upshift is delayed until the set speed is achieved to
reduce cycling and provide better response.
DIAGNOSIS AND TESTING - ROAD TEST
Perform a vehicle road test to verify reports of
speed control system malfunction. The road test
should include attention to the speedometer. Speed-
ometer operation should be smooth and without flut-
ter at all speeds.Flutter in the speedometer indicates a problem
which might cause surging in the speed control sys-
tem. The cause of any speedometer problems should
be corrected before proceeding. Refer to the Instru-
ment Cluster for speedometer diagnosis.
If a road test verifies an inoperative system, and
the speedometer operates properly, check for:
²A Diagnostic Trouble Code (DTC). If a DTC
exists, conduct tests per the Powertrain Diagnostic
Procedures manual.
²A misadjusted brake (stop) lamp switch. This
could also cause an intermittent problem.
²Loose or corroded electrical connections at the
servo. Corrosion should be removed from electrical
terminals and a light coating of Mopar Multipurpose
Grease, or equivalent, applied.
²Leaking vacuum reservoir.
²Loose or leaking vacuum hoses or connections.
²Defective one-way vacuum check valve.
²Secure attachment at both ends of the speed
control servo cable.
²Smooth operation of throttle linkage and throttle
body air valve.
²Conduct electrical test at PCM.
²Failed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Servo Mounting Bracket
Nuts14 10.3 123.9
Servo Mounting Bracket
Bolts14 10.3 123.9
Servo Mounting Nuts 6.7 60
RSSPEED CONTROL8P-3
SPEED CONTROL (Continued)

FRONT WIPER ARMS
STANDARD PROCEDURE - FRONT WIPER ARM
ALIGNMENT
(1) Verify wiper blade element condition and wiper
arm spring tension. Run wipers in low speed mode
while applying water to the windshield. Observe the
wiper blade that is chattering or skipping across the
windshield. If the wiper element is not rolling over
when the wiper direction reverses, align the wiper
arm. The extension bar portion of the wiper arm
must be twisted in the proper direction to allow the
wiper element to roll over when the direction
reverses.
(2) Place two small adjustable wrenches placed 50
mm (2 in.) apart on the wiper arm extension rod.
(3) Twist the extension rod slightly in the opposite
direction that the element is laying on the wind-
shield while holding the wrench closest to the pivot
stationary.
(4) Repeat Step 1, and align as necessary until
wiper stops chattering and wipes the windshield
clear.
REMOVAL
CAUTION: The driver side wiper arm must be
parked above the passenger side. Failure to do so
will result in damage to the arms, blades or system.
(1) Lift the arm cap upward.
(2) Remove the nut holding wiper arm to the wiper
pivot.
(3) Using a suitable two jaw puller, separate the
wiper arm from the wiper pivot (Fig. 1).
INSTALLATION
(1) Verify that the wiper motor and linkage are in
the park position.
(2) Place the wiper arm in position over the wiper
pivot (Fig. 2).
(3) Install the nut to hold the wiper arm to the
wiper pivot. Torque nut to 35 N´m (26 ft. lbs.).
CAUTION: It is important to torque the wiper arm
nut properly to insure that the wiper arm head does
not strip and damage the arm, blade, and pivot of
both wiper arms.
(4) Push the arm cap cover down.
FRONT WIPER MOTOR
REMOVAL
(1) Remove the front wiper motor from vehicle
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - REMOVAL).
(2) Remove four backwall bolts and four brace
nuts.
(3) Remove wiper linkage from wiper module.
(4) Disconnect wire connectors from back of wiper
motor.
Fig. 1 WIPER ARM REMOVAL
1 - WASHER NOZZLE
2 - HOOD
3 - COWL COVER
4 - WINDSHIELD
5 - TWO JAW PULLER
6 - ARM CAP
7 - WINDSHIELD WIPER ARM
Fig. 2 WIPER ARM ADJUSTMENT
1 - WIPER BLADES
2 - WINDSHIELD
3 - WASHER NOZZLES
4 - WIPER ARMS
RSWIPERS/WASHERS8R-9