2005 CHRYSLER CARAVAN bulb

CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM
WITH ENGINE
RUNNING ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system. Refer to
Electrical, Charging.
2. Poor lighting circuit Z349/Z248
ground.2. Test for voltage drop across Z349/Z248
ground locations. Refer to Electrical, Wiring
Information.
3. High resistance in fog lamp
circuit.3. Test amperage draw of fog lamp circuit.
FOG LAMPS FLASH
RANDOMLY1. Poor lighting circuit Z349/Z248
ground.1. Test for voltage drop across Z349/Z248
ground locations. Refer to Electrical, Wiring
Information.
2. Variable resistance in fog lamp
circuit.2. Test amperage draw of fog lamp circuit.
3. Faulty fog lamp switch (part of
headlamp switch).3. Replace headlamp switch.
4. Loose or corroded terminals or
splices in circuit.4. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
5. Is relay engaging properly? 5. Verify function of fog lamp relay in IPM.
6. PCI Bus Communication. 6. Verify PCI bus message (fog lamp info)
transmitted from BCM and received by FCM.
FOG LAMPS DO NOT
ILLUMINATE1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Electrical, Wiring
Information.
2. No Z349/Z248 ground at fog
lamps.2. Repair circuit ground. Refer to Electrical,
Wiring Information.
3. Faulty fog lamp switch (part of
headlamp switch).3. Replace headlamp switch.
4. Broken connector terminal or
wire splice in fog lamp circuit.4. Repair connector terminal or wire splice.
5. Faulty or burned out bulb. 5. Replace bulb.
6. Is relay engaging? 6. Verify function of fog lamp relay in IPM.
7. PCI Bus Communication. 7. Verify PCI bus message (fog lamp info)
transmitted from BCM and received by FCM.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) From behind the bumper fascia, twist bulb
counter-clockwise, and remove bulb.
(3) Remove the wire connector from the fog lamp
bulb.
INSTALLATION
(1) Reconnect wire harness to bulb.
(2) Install bulb and twist clockwise.
(3) Install battery negative cable.
8L - 8 LAMPS/LIGHTING - EXTERIORRS
FRONT FOG LAMP (Continued)

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) From behind the bumper fascia, disconnect the
wire harness from the fog lamp bulb.
(3) Remove mounting screws.
INSTALLATION
(1) Install mounting screws.
(2) Reconnect the wire harness to the fog lamp
bulb.
(3) Reconnect the battery negative cable.
Fig. 9 FOG LAMP UNIT ALIGNMENT - EXPORT
1 - HIGH INTENSITY AREA 4 - 200 MM
2 - CENTER OF VEHICLE 5 - 10 METERS
3 - HORIZONTAL CENTER OF FOG LAMP UNIT 6 - FRONT OF FOG LAMP UNIT
8L - 10 LAMPS/LIGHTING - EXTERIORRS
FRONT FOG LAMP UNIT (Continued)

HEADLAMP
DIAGNOSIS AND TESTING - HEADLAMP
When a vehicle experiences problems with the
headlamp system, verify the condition of the battery
connections, fuses, charging system, headlamp bulbs,
wire connectors, relay, high beam switch, dimmer
switch, and headlamp switch. Refer to the appropri-
ate 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 socketwhen 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.
HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS 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 Z343/Z344-
ground.6. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Diagram Information.
HEADLAMP BULBS
BURN OUT
FREQUENTLY.1. Integrated Power Module (IPM)
not controlling voltage.1. Test and repair Integrated Power Module.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
HEADLAMPS ARE DIM
WITH ENGINE
RUNNING ABOVE IDLE.1. Charging system output too low. 1. Test and repair charging system, refer to
Electrical, Wiring Information.
2. Poor lighting circuit Z343/Z344-
ground.2. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Information.
3. High resistance in headlamp
circuit.3. Test amperage draw of headlamp circuit.
RSLAMPS/LIGHTING - EXTERIOR8L-11

CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS FLASH
RANDOMLY1. Poor lighting circuit Z343/Z344-
ground.1. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Information.
2. Variable resistance in headlamp
circuit.2. Test amperage draw of headlamp circuit.
3. Loose or corroded terminals or
splices in circuit.3. Inspect and repair all connectors and splices,
refer to Electrical, Wiring Information.
4. Faulty headlamp switch. 4. Replace headlamp switch.
HEADLAMPS DO NOT
ILLUMINATE.1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to
Electrical, Wiring Information.
2. No Z343/Z344-ground at
headlamps.2. Repair circuit ground, refer to Electrical,
Wiring Information.
3. Broken connector terminal or
wire splice in headlamp circuit.3. Repair connector terminal or wire splice.
4. Faulty or burned out bulb. 4. Replace headlamp bulb(s).
5. Body Control Module
malfunction.5. Refer to appropriate Body Control Module
diagnostics.
6. PCI Bus Communication 6. Verify messages being transmitted by BCM
and received by FCM.
7. IPM/FCM Malfunction. 7. Refer to appropriate IPM/FCM diagnostics.
HEADLAMPS ON WITH
IGNITION IN RUN, WITH
HEADLAMP SWITCH
OFF.1. Faulty headlamp switch. 1. Replace headlamp switch (review BCM
logged faults).
2. Diagnostic tool indicates (4.7 -
5.0V) on headlamp switch input to
BCM.2. Inspect and repair terminals, connectors and
open circuits.
3. PCI Bus Communication. 3. Verify messages being transmitted by BCM
and received by FCM.
REMOVAL
DODGE
(1) Disconnect and isolate the battery negative
cable.
(2) Remove headlamp unit retaining screws.
(3) Remove headlamp unit to expose back of unit.
(4) Remove wiring connector from bulb.
(5) Rotate headlamp bulb retaining ring counter-
clockwise.
(6) Pull headlamp bulb and remove from headlamp
unit (Fig. 10).
CHRYSLER
(1) Disconnect and isolate the battery negative
cable.
(2) Remove headlamp unit retaining screws.
(3) Remove headlamp unit to expose back of unit.
Fig. 10 HEADLAMP - DODGE
1 - HEADLAMP
2 - HEADLAMP UNIT
8L - 12 LAMPS/LIGHTING - EXTERIORRS
HEADLAMP (Continued)

(4) Remove wiring connector from bulb by sliding
red latch lock rearward and then depressing release
tab.
(5) Rotate headlamp bulb retaining ring counter-
clockwise.
INSTALLATION
DODGE
(1) Install headlamp bulb to the headlamp unit.
(2) Install headlamp bulb retaining ring.
(3) Connect wiring connector to bulb.
(4) Install the headlamp unit.
(5) Install headlamp unit retaining screws.
(6) Connect the battery negative cable.
CHRYSLER
(1) Install headlamp bulb to the headlamp unit.
(2) Rotate bulb clockwise to lock bulb in headlamp
unit.
(3) Connect wiring connector to bulb and slide red
latch lock forward.
(4) Install the headlamp unit.
(5) Install headlamp unit retaining screws.
(6) Connect the battery negative cable.
HEADLAMP SWITCH
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH
Using a Digital Multi-meter, perform the HEAD-
LAMP SWITCH CONTINUITY test and refer to (Fig.
11).
If the Headlamp Switch is not within specifications
replace the switch.
HEADLAMP SWITCH CONTINUITY
HEADLAMP
SWITCH
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
OFF 11 TO 6 3651 - 3729V
PARKING
LAMPS ON11 TO 6 1697 - 2517V
PARKING
LAMPS WITH
FRONT FOG
LAMPS ON11 TO 6 5765 - 5886V
HEADLAMPS
ON11 TO 6 788 - 809V
AUTO ON 11 TO 6 10056 - 10264V
HEADLAMPS
ON WITH
FRONT FOG
LAMPS11 TO 6 1171 - 1200V
AUTO ON WITH
FRONT FOG
LAMPS ON11 TO 6 24278 - 24773V
DIMMER
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
DOME 12 TO 6 15568 - 23357V
PARADE 12 TO 6 5168 - 7757V
DIM HIGH 12 TO 6 2288 - 3437V
DIM LOW 12 TO 6 688 - 1037V
OFF 12 TO 6 240 - 365V
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Removal.
(3) Reach up behind the left side of the instrument
panel and depress spring clip on top or bottom of
headlamp switch. Firmly push out on the headlamp
switch assembly.
(4) Disconnect the wiring connectors.
(5) Remove switch from vehicle.
INSTALLATION
(1) Connect the wiring connectors.
(2) Place headlamp switch assembly into position
and firmly snap into place.
(3) Install the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Installation.
(4) Connect the battery negative cable.
Fig. 11 HEADLAMP SWITCH CONNECTOR
RSLAMPS/LIGHTING - EXTERIOR8L-13
HEADLAMP (Continued)

HEADLAMP UNIT ADJUSTMENT
The low beam headlamp will project on the screen
upper edge of the beam (cut-off) at the horizontal
lamp centerline   50 mm (2 in.). Horizontal aim is
preset and can not be adjusted. The high beam pat-
tern should be correct when the low beams are
aligned properly (Fig. 12). To adjust headlamp verti-
cal alignment, rotate adjustment screw (Fig. 13) to
achieve the specified low beam cut-off location.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the three retaining screws (Fig. 14).
(3) Disconnect the wiring harness from the bulbs
(Fig. 15).(4) Remove wire harness retainer from back of
headlamp unit.
(5) Remove the headlamp unit.
INSTALLATION
(1) Reconnect wire harness to the bulbs.
(2) Install wire harness retainer to headlamp unit.
(3) Install the three retaining screws.
(4) Reconnect the battery negative cable.
HEADLAMP UNIT - EXPORT
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT - EXPORT
HEADLAMP UNIT ALIGNMENT PREPARATION
(1) Verify that the headlamp leveling switch is in
the ª0º position.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(6) Vehicles equipped with automatic load leveling
suspension should be driven normally for approxi-
mately 5 km (3 miles) before attempting a proper
headlamp unit alignment.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
Fig. 13 HEADLAMP UNIT ADJUSTMENT
1 - ADJUSTMENT LOCATION
2 - HEADLAMP UNIT
Fig. 14 HEADLAMP UNIT FASTENERS
1 - HEADLAMP UNIT RETAINING SCREW
2 - HEADLAMP UNIT
Fig. 15 HEADLAMP UNIT
1 - HEADLAMP UNIT
2 - HEADLAMP
3 - PARK/TURN SIGNAL LAMP
4 - WIRE HARNESS RETAINER
RSLAMPS/LIGHTING - EXTERIOR8L-15
HEADLAMP UNIT (Continued)

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the three retaining screws.
(3) Disconnect the central wiring harness connec-
tor from the headlamp unit.
(4) Remove the headlamp unit from the vehicle by
rotating the turn signal area out and towards the
center of the vehicle.
INSTALLATION
(1) Connect the wiring harness to the headlamp
unit's central connector.
(2) Place the headlamp unit in the headlamp unit
pocket in front end first by placing the inboard side
behind the fascia. Complete the installation by rotat-
ing the turn signal area of the headlamp into place.
(3) Place headlamp unit into headlamp unit pocket
in front end.
(4) Install the three retaining screws.
(5) Connect the battery negative cable.
(6) Verify vehicle and system operation.
LICENSE LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove two screws (Fig. 18).
(3) Twist bulb socket and remove (Fig. 19).
(4) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket.
(2) Install socket into lamp.
(3) Install two screws.
(4) Reconnect the battery negative cable.
MULTI-FUNCTION SWITCH
DESCRIPTION - TURN SIGNAL SYSTEM
The turn signals are actuated with a lever on
Multi-Function Switch, located on the left side of the
steering wheel. The signals are automatically turned
off by a canceling cam (two lobes molded to the clock
spring mechanism). The cam comes in contact with
the cancel actuator on the turn signal (multi-func-
tion) switch assembly. Either cam lobe, pushing on
the cancel actuator, returns the switch to the OFF
position. The multi-function switch is a resistive
MUX switch that feeds inputs to the BCM.
OPERATION - TURN SIGNAL SYSTEM
Lane change signaling is actuated by applying par-
tial turn signal stalk movement toward the direction
desired until the indicator lamps flashes in the
instrument cluster. When the switch stalk is released
the stalk will spring back into the neutral position
turning OFF the turn signal.
With the ignition switch ON and the turn signal
switch stalk actuated left or right, current flows
through the:
²Multi-function switch
²Body Control Module
²Integrated Power Module (IPM)
²Turn indicator lamp
²Front and rear turn signal bulbs.
A chime will sound after the vehicle has traveled a
distance of approximately 1.0 mile and a speed of 15
mph, with the turn signal ON.
Fig. 18 LICENSE PLATE LAMP UNITS
1 - SCREW
2 - LICENSE PLATE LAMP
Fig. 19 LICENSE PLATE LAMP - REMOVE/INSTALL
1 - LICENSE PLATE LAMP UNIT
2 - BULB
RSLAMPS/LIGHTING - EXTERIOR8L-17
HEADLAMP UNIT - EXPORT (Continued)

DIAGNOSIS AND TESTING - MULTI-FUNCTION
SWITCH
To test turn signal, headlamp beam select and opti-
cal horn portion of the multi-function switch:
(1) Remove the multi-function switch, refer to
Electrical, Lamps/Lighting - Exterior, Multi-Function
Switch, Removal, and Installation.
(2) Using an ohmmeter check the resistance read-
ings between multi-function switch pins. Refer to
Wiring Diagrams for proper pin numbers and the
MULTI-FUNCTION SWITCH RESISTANCE table.
MULTI-FUNCTION SWITCH RESISTANCE
SWITCH
POSITIONPIN NUMBER RESISTANCE
LEFT 2 AND 3 2.7V 5%
RIGHT 2 AND 3 1KV 5%
OPTICAL
HORN2 AND 4 1.7KV 5%
HI BEAM 2 AND 4 2.32KV 5%
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove upper and lower steering column
shrouds. Refer to Steering, Column, Shroud,
Removal.
(3) Disconnect wire connector from back of multi-
function switch.
(4) Remove screws holding multi-function switch to
steering column adapter collar.
(5) Remove the multi-function switch.
INSTALLATION
(1) Position the switch on to the steering column.
(2) Install the two retaining screws.
(3) Connect the wire harness connector.
(4) Install the upper and lower steering column
shrouds. Refer to Steering, Column, Shroud, Installa-
tion.
(5) Connect the battery negative cable.
PARK/TURN SIGNAL LAMP
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove headlamp retaining screws.
(3) Twist socket counter - clockwise and remove
(Fig. 20).
(4) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket.
(2) Twist socket into headlamp.
(3) Install headlamp retaining screws.
(4) Reconnect battery negative cable.
TAIL LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the tail lamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - REMOVAL).
(3) Squeeze the tabs on the bulb socket and
remove from tail lamp unit (Fig. 21).
(4) Pull bulb from lamp socket.
Fig. 20 PARK/TURN SIGNAL LAMP
1 - PARK/TURN SIGNAL LAMP
2 - LAMP SOCKET
Fig. 21 TAIL LAMP SOCKET
1 - LAMP SOCKET
2 - TAIL LAMP UNIT
8L - 18 LAMPS/LIGHTING - EXTERIORRS
MULTI-FUNCTION SWITCH (Continued)