2005 CHRYSLER CARAVAN service

Service replacement clocksprings are shipped pre-
centered and with a molded plastic shield that snaps
onto the rotor over the release button. The release
button secures the centered clockspring rotor to the
clockspring case and the shield prevents the release
button from being inadvertently depressed during
shipment and handling, but the shield must be
removed from the clockspring after it is installed on
the steering column (Refer to 8 - ELECTRICAL/RE-
STRAINTS/CLOCKSPRING - STANDARD PROCE-
DURE).
The clockspring cannot be repaired. If the clock-
spring is faulty, damaged, or if the driver airbag has
been deployed, the clockspring must be replaced.
OPERATION
The clockspring is a mechanical electrical circuit
component that is used to provide continuous electri-
cal continuity between the fixed instrument panel
wire harness and the electrical components mounted
on or in the rotating steering wheel. The rotating
electrical components include the driver airbag, the
horn switch, the speed control switches, and the
remote radio switches, if the vehicle is so equipped.
The clockspring case is positioned and secured to the
upper steering column housing near the top of the
steering column. The connector receptacles on the
tail of the clockspring case connect the clockspring to
the vehicle electrical system through two connectors
from the instrument panel wire harness.
The clockspring rotor is movable and is keyed by
the tower formation that is molded onto the upper
surface of the rotor hub to an opening that is cast
into the steering wheel armature. Rubber bumper
blocks on either side of the clockspring tower forma-
tion eliminate contact noise between the clockspring
tower and the steering wheel. The lobe of the turn
signal cancel cam on the lower surface of the clock-
spring rotor hub contacts a turn signal cancel actua-
tor of the multi-function switch to provide automatic
turn signal cancellation. The yellow or black-sleeved
pigtail wires on the upper surface of the clockspring
rotor connect the clockspring to the driver airbag,
while a steering wheel wire harness connects the
connector receptacle on the upper surface of the
clockspring rotor to the horn switch and, if the vehi-
cle is so equipped, to the optional speed control
switches and remote radio switches on the steering
wheel.
The clockspring tape has travel limits and can be
damaged by being wound too tightly during full stop-
to-stop steering wheel rotation. To prevent this from
occurring, the clockspring is centered when it is
installed on the steering column. Centering the clock-
spring indexes the clockspring tape to the movable
steering components so that the tape can operatewithin its designed travel limits. However, if the
clockspring is removed from the steering column or if
the steering shaft is disconnected from the steering
gear, the clockspring spool can change position rela-
tive to the movable steering components and must be
re-centered following completion of the service or the
tape may be damaged (Refer to 8 - ELECTRICAL/
RESTRAINTS/CLOCKSPRING - STANDARD PRO-
CEDURE).
Service replacement clocksprings are shipped pre-
centered and with a plastic shield installed over the
clockspring release button. This shield should not be
removed and the release button should not be
depressed until the clockspring has been installed on
the steering column. If the release button is
depressed before the clockspring is installed on a
steering column, the clockspring centering procedure
must be performed (Refer to 8 - ELECTRICAL/RE-
STRAINTS/CLOCKSPRING - STANDARD PROCE-
DURE).
STANDARD PROCEDURE - CLOCKSPRING
CENTERING
If the rotating tape (wire coil) in the clockspring is
not positioned properly with the steering wheel and
the front wheels, the clockspring may fail. The fol-
lowing procedure MUST BE USED to center the
clockspring if it is not known to be properly posi-
tioned, or if the front wheels were moved from the
straight ahead position.
(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) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(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 (if equipped).
(8) Disconnect the 4±way harness connector from
the speed control (if equipped)/horn harness to the
clockspring.
(9) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(10) Rotate the clockspring rotor clockwise until
the rotor stops. Do not apply excessive force.
(11) From the end of travel, rotate the rotor two
turns counterclockwise until the wires end up at the
top.
RSRESTRAINTS8O-11
CLOCKSPRING (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)

The hybrid-type inflator for each airbag is secured
to the roof rail just behind the C-pillar. The inflator
bracket and the airbag cushion are secured with both
plastic push-in fasteners and screws to the roof rail.
A short pigtail wire harness connects the curtain air-
bag inflator to the body wire harness.
The curtain airbag cannot be adjusted or repaired
and must be replaced if deployed, faulty, or in any
way damaged. Once a curtain airbag has been
deployed, the complete airbag unit (Refer to 8 -
ELECTRICAL/RESTRAINTS - STANDARD PROCE-
DURE - SERVICE AFTER AN AIRBAG DEPLOY-
MENT), headliner, upper A/B/C and D-pillar trim,
and all other visibly damaged components must be
replaced (Refer to Section 23 - BODY/INTERIOR for
complete body interior Removal and Installation pro-
cedures). Refer to the appropriate diagnostic informa-
tion for complete diagnosis and testing or the curtain
airbags.The curtain airbags also contain Head Impact
Counter Measures (Fig. 14). These injection molded
plastic components help to reduce the likelihood of
injury or death in the event of a side impact event.
They are attached to the curtain airbag and are also
used to mount the curtain to the inside roof rail.
Their purpose is to maintain a flat surface in which
the deployed airbag to be pressed against when inte-
rior occupants/forces are pushing outwards.
OPERATION
Each curtain airbag is deployed individually by an
electrical signal generated by the Occupant Restraint
Controller (ORC) to which it is connected through
left or right curtain airbag line 1 and line 2 (or
squib) circuits. The hybrid-type inflator assembly for
each airbag contains a small canister of highly com-
pressed inert gas. When the ORC sends the proper
electrical signal to the airbag inflator, the electrical
energy creates enough heat to ignite chemical pellets
within the inflator. Once ignited, these chemicals
burn rapidly and produce the pressure necessary to
rupture a containment disk in the inert gas canister.
The inflator and inert gas canister are sealed and
connected to a tubular manifold so that all of the
released gas is directed into the folded curtain airbag
cushion, causing the cushion to inflate.
Fig. 11 CURTAIN AIRBAG
Fig. 12 SRS LOGO
RSRESTRAINTS8O-13
CURTAIN AIRBAG (Continued)

As the airbag cushion inflates it will drop down
from the roof rail between the edge of the headliner
and the side glass/body pillars to form a curtain-like
cushion to protect the vehicle occupants during a side
impact collision. The front and rear tethers keep the
side curtain bag taut, thus ensuring that the bag will
deploy in the proper position. Following the airbag
deployment, the airbag cushion quickly deflates by
venting the inert gas through the loose weave of the
cushion fabric, and the deflated cushion hangs down
loosely from the roof rail.
REMOVAL
(1) Open hood, disconnect and isolate the battery
negative cable.
(2)
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.
Fig. 13 CURTAIN AIRBAG LOCATION - TYPICAL
Fig. 14 HEAD IMPACT COUNTER MEASURES
1 - SLIDING DOOR OPENING/ROOF RAIL
2 - CURTIAN AIRBAG
3 - HEAD IMPACT COUNTER MEASURES
8O - 14 RESTRAINTSRS
CURTAIN AIRBAG (Continued)

INSTALLATION
(1) Position curtain airbag over retaining holes in
roof rail and firmly snap into place (Fig. 17).
(2) Install the curtain airbag retaining bolts (Fig.
17).
(3) Engage the side curtain airbag front tether in
the A-pillar and install retaining bolt (Fig. 16).
(4) Install the bolt in the curtain airbag inflator
mounting bracket (Fig. 18).
(5) Install the retaining bolts at the d-pillar (Fig.
19).
(6) Connect the curtain airbag squib connector
(Fig. 15).
(7) Install the headliner into the vehicle (Refer to
23 - BODY/INTERIOR/HEADLINER - INSTALLA-
TION).
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.
(8) Verify vehicle and system operation.
(9) Close hood.
DRIVER AIRBAG
DESCRIPTION
The injection molded, thermoplastic driver airbag
protective trim cover is the most visible part of the
driver airbag. The driver airbag is located in the cen-
ter of the steering wheel, where it is secured to the
steering wheel armature. Concealed beneath the
driver airbag trim cover are the horn switch, thefolded airbag cushion, the airbag cushion retainer,
the airbag housing, the airbag inflator, and the
retainers that secure the inflator to the airbag hous-
ing. The airbag cushion, housing, and inflator are
secured within an integral receptacle molded into the
back of the trim cover.
The resistive membrane-type horn switch is
secured with heat stakes to the inside surface of the
driver airbag trim cover, between the trim cover and
the folded airbag cushion. The horn switch ground
pigtail wire has a female spade terminal connector
that receives a path to ground through a male spade
terminal that is integral to the driver airbag housing
stamping and is located near the upper right corner
on the back of the housing. The horn switch feed pig-
tail wire has a white, molded plastic insulator that is
secured by an integral retainer to a mounting hole
located near the lower left corner on the back of the
housing, and is connected to the vehicle electrical
system through a take out and connector of the steer-
ing wheel wire harness.
The airbag is a multistage unit that deploys with
less force than those previously used. The airbag
inflator is a dual-initiator, non-azide, pyrotechnic-
type unit with four mounting studs and is secured to
the stamped metal airbag housing using four hex
nuts with washers. Two keyed and color-coded con-
nector receptacles on the driver airbag inflator con-
nect the two inflator initiators to the vehicle
electrical system through two yellow or black-jack-
eted, two-wire pigtail harnesses of the clockspring.
The driver airbag, trim cover, and horn switch unit
cannot be repaired, and must be replaced if deployed
or in any way damaged.
OPERATION
The Driver Airbag Trim Cover contains the horn
switch, inflator device, and a fabric bag. The driver
airbag trim cover/horn switch is not serviced sepa-
rately from the driver airbag components.
When the front airbag system is deployed, the fol-
lowingMUSTbe replaced:
²Complete Steering Column Assembly
²Lower Steering Column Coupler
²Steering Wheel.
²Clockspring.
²Driver Airbag
²Passenger Airbag
²Knee Blocker Airbag
²Upper Instrument Panel with Pad
²Front Seat Belt Buckles, both driver and passen-
ger with integral tensioners.
Fig. 19 CURTAIN AIRBAG D-PILLAR ATTACHMENT
1 - CURTAIN AIRBAG D-PILLAR ATTACHMENT LOCATIONS
2 - D-PILLAR
3 - ROOF RAIL AT REAR QUARTER GLASS
8O - 16 RESTRAINTSRS
CURTAIN AIRBAG (Continued)

CARE OF UNDEPLOYED AIRBAGS
WARNING: Airbags must be stored in their original
special container until used for service. At no time
should a source of electricity be permitted near the
inflator on the back of an airbag. When carrying or
handling an undeployed airbag, the trim side of the
airbag should be pointing toward the body to mini-
mize possibility of injury if accidental deployment
occurs. Do not place undeployed airbag face down
on a solid surface, the airbag will propel into the air
if accidental deployment occurs.
REMOVAL
DEPLOYED AIRBAG
(1) Clean powder residue from interior of vehicle
(Fig. 4).
(2) Position steering wheel and front wheels
straight ahead.
(3) Release hood latch and 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 two screws retaining driver airbag to
steering wheel.
(7) Disconnect wire connectors from back of driver
airbag.
(8) Disconnect the 2±way connector from remote
radio control harness.
(9) Disconnect the 4±way harness connector from
the speed control/horn harness to the clockspring.
(10) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(11) Remove steering column shrouds and discon-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - REMOVAL).
(12) Disconnect 4-way and 6-way connectors
between the clockspring and the instrument panel
wiring harness.
(13) Remove clockspring from column assembly by
removing the two retaining screws that attach the
clockspring to the column.
WARNING: The clockspring, steering wheel, and
complete steering column assembly w/lower steer-
ing column coupler must be replaced also in theevent of a driver airbag deployment. Personal injury
or death may result if not replaced.
UNDEPLOYED AIRBAG
(1) Release hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
WARNING: Wait two minutes for the system reserve
capacitor to discharge before beginning any airbag
component service. Personal injury or death may
result.
(3) Remove two screws retaining driver airbag to
steering wheel.
(4) Disconnect wire connectors from back of driver
airbag (Fig. 20).
(5) Disconnect the 2±way connector from remote
radio control harness.
(6) Disconnect the 4±way harness connector from
the speed control/horn harness to the clockspring.
(7) Remove driver airbag from vehicle.
WARNING: When carrying or handling an unde-
ployed airbag, the trim side of the airbag should be
pointing toward the body to minimize the possibility
of injury if accidental deployment occurs. Do not
place undeployed airbag face down on a solid sur-
face, the airbag will propel into the air if accidental
deployment occurs. Failure to do this may result in
personal injury or death.
Fig. 20 DRIVER AIRBAG WIRE CONNECTIONS
1 - AIRBAG SQUIB CONNECTORS
2 - DRIVER AIRBAG
3 - HORN/SPEED CONTROL CONNECTOR
4 - CLOCK SPRING
RSRESTRAINTS8O-17
DRIVER AIRBAG (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)

SIDE IMPACT SENSORS
Three side impact sensors (Fig. 22) are used on
each side of the vehicle. These sensors are mounted
remotely from the bi-directional safing sensor that is
internal to the Occupant Restraint Controller (ORC).
The side and front impact sensors are identical in
construction and calibration and each impact sensor
is secured with two screws. Each side impact sensor
is secured with two screws. The first row side impact
sensor is located in the B-pillar, just above the front
seat belt retractor (Fig. 23). The second row side
impact sensor is located in the sliding door opening,in the lower door track area (Fig. 23). The third row
side impact sensor is located behind the quarter trim
panel, above the rear tire wheel well, between the C
and D-pillars (Fig. 23).
The impact sensor housing has an integral connec-
tor. A cavity in the center of the molded black plastic
impact sensor housing contains the electronic cir-
cuitry of the sensor which includes an electronic com-
munication chip and an electronic impact sensor.
Potting material fills the cavity to seal and protect
the internal electronic circuitry and components. The
side impact sensors are each connected to the vehicle
electrical system through a connector of the body
harness.
The side impact sensors cannot be repaired or
adjusted. If damaged or faulty, they must be
replaced. Refer to the proper body diagnostic infor-
mation for diagnosis and testing.
REMOVAL
FRONT IMPACT SENSOR
The right and left front impact sensors are
mounted identically on the front rail tips.
(1) Open hood, disconnect and isolate the battery
negative cable.
(2)
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.
Fig. 23 SIDE IMPACT SENSOR LOCATION
1 - FRONT ROW SIDE IMPACT SENSOR 3 - THIRD ROW SIDE IMPACT SENSOR
2 - SECOND ROW SIDE IMPACT SENSOR
Fig. 22 SIDE IMPACT SENSOR
RSRESTRAINTS8O-19
IMPACT SENSOR (Continued)