2005 CHRYSLER CARAVAN open hood

STARTER
MANUFACTURER NIPPONDENSO
Engine Application 2.4L /3.3/3.8L
Power rating 1.2 Kw
Voltage 12 VOLTS
No. of Fields 4
No. of Poles 4
Brushes 4
Drive Conventional Gear Train
Free running Test
Voltage 11
Amperage Draw 73 Amp
Minimum Speed 3401 RPM
SolenoidClosing Voltage 7.5 Volts
Cranking Amperage Draw
test150 - 200 Amps.
Engine should be up to operating temperature.
Extremely heavy oil or tight engine will increase
starter amperage draw.
STARTER MOTOR
REMOVAL
REMOVAL - 2.4L
(1) Release hood latch and open hood (Fig. 2).(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect solenoid wire connector from termi-
nal (Fig. 3).
(4) Remove nut holding B+ wire to terminal.
(5) Disconnect solenoid and B+ wires from starter
terminals.
(6) Remove the lower bolt.
(7) Remove the upper bolt and ground wire (Fig.
4).
Fig. 2 STARTER 2.4L
Fig. 3 BATTERY CABLE AND FIELD WIRE 2.4L
Fig. 4 Upper Bolt and Ground Wire
RSSTARTING8F-37
STARTING (Continued)

(8) Remove starter.
REMOVAL - 3.3/3.8L
(1) Release hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Hoist and support vehicle on safety stands.
(4) Remove nut holding B+ terminal to starter
solenoid (Fig. 5).
(5) Disconnect solenoid connector from starter.
(6) Remove bolts holding starter to transaxle bell-
housing (Fig. 6).(7) Remove starter from bellhousing (Fig. 7).
(8) Separate starter spacer from transaxle bell-
housing.
REMOVAL - 2.5L
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) Remove the lower engine splash shield.
(4) Remove the electrical connectors from the
starter (Fig. 8).Fig. 5 Starter
1 - SOLENOID CONNECTOR
2 - B+ CONNECTOR
Fig. 6 Starter Bolts
1-STARTER
2 - STARTER BOLTS
3 - TRANSAXLE
4 - ENGINE MOUNT
Fig. 7 STARTER 3.3/3.8L
1 - BELL HOUSING PLATE
2 - FLYWHEEL
3 - ENGINE MOUNT
4-STARTER
5 - SPACER
Fig. 8 STARTER LOCATION
8F - 38 STARTINGRS
STARTER MOTOR (Continued)

²Occupant Classification System- These
vehicles also include an Occupant Classification Sys-
tem (OCS) with components that are located on or in
the passenger front seat cushion. These components
include an Occupant Classification Module (OCM)
and a seat weight bladder and pressure sensor
assembly. In addition, this system includes a belt
tension sensor integral to the lower anchor of the
passenger side front seat belt. Vehicles equipped with
the OCS can be readily identified by a Passenger Air-
bag Disabled (PAD) indicator (Fig. 1) located in the
center stack on the instrument panel above HVAC
control head and radio.
²Curtain Airbags- Curtain airbags are avail-
able for this model when it is also equipped with
dual front airbags. This airbag system is a passive,
inflatable, Supplemental Restraint System (SRS) and
vehicles with this equipment can be readily identified
by a molded identification trim button with the ªSRS
- AIRBAGº logo (Fig. 2) located on the headliner
above each B-pillar.
This vehicle is equipped with a Frontal Impact Air-
bag System, which utilizes the driver/passenger air-
bags, driver knee blocker airbag, and seat belt
tensioners. This system is designed to protect occu-
pants in the event of a front impact collision. These
airbags and seat belt tensioners are all serviceable
parts. If these pyrotechnics are deployed or defective,
they must be replaced, as well as the OccupantRestraint Controller (ORC) must be diagnosed follow-
ing procedures outlined in the diagnostic information.
The Driver and Passenger Airbag System was
designed to reduce the likelihood of injury or death
in frontal collisions. Each separate system is supple-
mental (Fig. 2) orPassiveto the primary restraint
device, which are the seat belts.
²Airbag Indicator- The airbag indicator is inte-
gral to the Instrument Cluster, which is located on
the instrument panel in front of the driver.
²Belt Tension Sensor- Vehicles equipped with
the Occupant Classification System (OCS) include a
belt tension sensor. This sensor is integral to the pas-
senger side front seat belt lower anchor which is
secured to the floor, out board and rear of the front
passenger seat. -.....concealed beneath an access cover
on the seat belt assembly.
²Clockspring- The clockspring is located near
the top of the steering column, directly beneath the
steering wheel (Fig. 3).
²Curtain Airbag- A side curtain airbag is
located on each inside roof side rail above the head-
liner, and extends from the A-pillar to just beyond
the D-pillar.
²Driver Airbag- The driver airbag is located in
the center of the steering wheel, beneath the driver
airbag trim cover (Fig. 3).
²Front Impact Sensor- Two front impact sen-
sors are used on vehicles equipped with dual front
airbags, one left side and one right side. The sensors
are located on the rail tips, rearward of the bumper
attachments.
²Knee Blocker Airbag- The driver knee blocker
airbag is secured to the instrument panel behind the
steering column opening cover (Fig. 3).
Fig. 1 PAD INDICATOR
Fig. 2 SRS LOGO
Fig. 3 AIRBAG COMPONENT LOCATION -
INSTRUMENT PANEL
1 - DRIVER AIRBAG
2 - PASSENGER AIRBAG DISABLED (PAD) INDICATOR
3 - PASSENGER AIRBAG
4 - OCCUPANT RESTRAINT CONTROLLER (ORC)
5 - KNEE BLOCKER AIRBAG
RSRESTRAINTS8O-3
RESTRAINTS (Continued)

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)

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)

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)

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)