2005 CHRYSLER CARAVAN clutch

RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) is
connected to battery voltage and should be hot at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the PDC fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the starter solenoid field coils. There should be
continuity between the cavity for relay terminal 87
and the starter solenoid terminal at all times. If OK,
go to Step 4. If not OK, repair the open circuit to the
starter solenoid as required.
(4) The coil battery terminal (85) is connected to
the electromagnet in the relay. It is energized when
the ignition switch is held in the Start position and
the clutch pedal is depressed (manual trans). Check
for battery voltage at the cavity for relay terminal 86
with the ignition switch in the Start position and the
clutch pedal is depressed (manual trans), and no
voltage when the ignition switch is released to the
On position. If OK, go to Step 5. If not OK, check for
an open or short circuit to the ignition switch and
repair, if required. If the circuit to the ignition switch
is OK, see the Ignition Switch Test procedure in this
group.
(5) The coil ground terminal (86) is connected to
the electromagnet in the relay. It is grounded by the
PCM if the conditions are right to start the car. For
automatic trans. cars the PCM must see Park Neu-
tral switch low and near zero engine speed (rpm).
For manual trans. cars the PCM only needs to see
near zero engine speed (rpm) and low clutch inter-
lock input and see near zero engine speed (rpm). To
diagnose the Park Neutral switch of the trans range
sensor refer to the transaxle section. Check for conti-
nuity to ground while the ignition switch is in the
start position and if equipped the clutch pedal
depressed. If not OK and the vehicle has an auto-
matic trans. verify Park Neutral switch operation. If
that checks OK check for continuity between PCM
and the terminal 86. Repair open circuit as required.
Also check the clutch interlock switch operation if
equipped with a manual transmission. If OK, the
PCM may be defective.
SAFETY SWITCHES
For diagnostics of the Transmission Range Sensor,
refer to the Transaxle section for more information.
If equipped with Clutch Interlock/Upstop Switch,
refer to Diagnosis and Testing in the Clutch section.
IGNITION SWITCH
After testing starter solenoid and relay, test igni-
tion switch and wiring. Refer to the Ignition Section
or Wiring Diagrams for more information. Check all
wiring for opens or shorts, and all connectors for
being loose or corroded.
BATTERY
For battery diagnosis and testing, refer to the Bat-
tery section for procedures.
ALL RELATED WIRING AND CONNECTORS
Refer to Wiring Diagrams for more information.
DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE TEST
Before proceeding with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter,
accurate to 1/10 of a volt.
CAUTION: Ignition and Fuel systems must be dis-
abled to prevent engine start while performing the
following tests.
(1) To disable the Ignition and Fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(2) Gain access to battery terminals.
(3) With all wiring harnesses and components
properly connected, perform the following:
(a) Connect the negative lead of the voltmeter to
the battery negative post, and positive lead to the
battery negative cable clamp. Rotate and hold the
ignition switch in the START position. Observe the
voltmeter. If voltage is detected, correct poor con-
tact between cable clamp and post.
(b) Connect positive lead of the voltmeter to the
battery positive post, and negative lead to the bat-
tery positive cable clamp. Rotate and hold the igni-
tion switch key in the START position. Observe the
voltmeter. If voltage is detected, correct poor con-
tact between the cable clamp and post.
(c) Connect negative lead of voltmeter to battery
negative terminal, and positive lead to engine
block near the battery cable attaching point.
Rotate and hold the ignition switch in the START
position. If voltage reads above 0.2 volt, correct
poor contact at ground cable attaching point. If
voltage reading is still above 0.2 volt after correct-
ing poor contacts, replace ground cable.
(4) Connect positive voltmeter lead to the starter
motor housing and the negative lead to the battery
negative terminal. Hold the ignition switch key in
RSSTARTING8F-35
STARTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Inoperative Power Liftgate Module or
BCMDisconnect then reconnect the battery
negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Binding or sticking of components Establish location of binding and replace
components as necessary
Key fob, Outside Handle or
overhead console switches
do not power operate
liftgateBlown Fuse Check fuse and replace
Battery voltage low Charge or replace battery in key fob or
vehicle
Inoperative latch assembly Check for foreign matter preventing the
operation of latch assembly
Check wire connection
Pawl and/or ratchet switch inoperative.
Replace latch as necessary
Inoperative BCM Check electrical connections
Refer to the appropriate diagnostic
information for additional checks
Replace BCM as necessary
Inoperative key fob Verify inoperative key fob by trying other
key fob functions
Replace key fob battery
Reprogram key fob
Replace key fob as necessary
Inoperative Power Liftgate Module Disconnect then reconnect the battery
negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Inoperative liftgate motor assembly Check for foreign matter preventing the
operation of gear motor assembly
Check wire connections
Motor clutch does not engage. Replace
liftgate motor assembly
Full open switch inoperative, replace switch
as necessary
Liftgate does not stay open Inoperative liftgate prop rods Check for broken attachments. Replace
prop rods as necessary
High inside/outside opening
effortInoperative liftgate prop rods Check for broken attachments. Replace
prop rods as necessary
8N - 6 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Inoperative fuel filler door lockout
mechanismCheck operation of fuel filler door lockout
mechanism.
Inoperative sliding door control module
or BCMDisconnect then reconnect battery negative
cable to reset module. Cycle door, if no
function exists check for loose wire
connections, see Body Diagnostic Manual for
detailed procedures
Inoperative striker Striker misaligned or loose
Striker damaged
Replace striker if necessary
Cables worn and stretched Replace cables as necessary
Binding or sticking of components Establish location of binding and replace
necessary components
Key fob, B-pillar or overhead
console switch does not
operate power sliding doorBlown Fuse Check fuse and replace
Battery voltage low Charge or replace battery
Inoperative latch assembly Check for foreign matter preventing the
operation of latch assembly
Check wire connection
Pawl and/or ratchet switch inoperative
Replace latch if necessary
Wiring problems (system or vehicle) Troubleshoot using the appropriate wiring
information
Inoperative BCM Check electrical connections
Refer to the body diagnostic manual for
additional checks
Replace BCM if necessary
Inoperative key fob Verify inoperative key fob by trying other key
fob functions
Replace key fob battery
Reprogram key fob
Replace key fob if necessary
Inoperative sliding door control module Disconnect then reconnect battery negative
cable to reset module. Cycle door, if no
function exists check for loose wire
connections, see Body Diagnostic Manual for
detailed procedures
Inoperative door motor assembly Check for foreign matter preventing the
operation of gear motor assembly
Check wire connections
Gear motor clutch does not engage, replace
assembly
8N - 46 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)

SLIDING DOOR MOTOR
DESCRIPTION
The door motor is located in the center of the
power sliding door (Fig. 8) and is comprised of three
parts. The three parts of the door motor assembly are
the motor, gear reduction and clutch assembly. The
door motor assembly provides the power and torque
to move the sliding door from the open/closed posi-
tion to full closed/open position, after the power
latching mechanism has released.
The door motor is replaced as a complete assembly,
which includes the DC motor, gear reduction and
clutch assemblies.
OPERATION
With the push of a power sliding door command
switch, the power sliding door control module will
signal the latch assembly to release the door from its
primary locked position. The door motor will then
take over to provide the power to open the door to its
full open or closed position. The gear reduction por-
tion of the motor assembly reduces the speed of the
motor from 5800 to 260 rpm and also increases the
torque to the lower drive unit. The clutch portion of
the motor assembly engages the motor to drive thedoor under power and disengages it so the door can
be moved easily under manual operation.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the door trim panel from the appropri-
ate door, (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - REMOVAL).
(3) Remove the water shield as necessary to gain
access to motor assembly.
(4) Remove retaining clip holding flex drive assem-
bly to the motor (Fig. 9). Pull flex drive cable straight
out of the motor assembly.
(5) Disconnect door motor electrical connector.
(6) Using a trim stick (special tool #C-4755) or
equivalent, gently pry out push-pin fasteners retain-
ing the door motor.
(7) Remove the door motor assembly from the
vehicle.
INSTALLATION
(1) Position the door motor assembly on the door
inner panel.
(2) Install the push-pin fasteners retaining the
motor assembly to the power sliding door.
Fig. 8 POWER SLIDING DOOR COMPONENTS
1 - POWER SLIDING DOOR CONTROL MODULE
2 - MODULE RETAINING SCREW
3 - MODULE ELECTRICAL CONNECTORS
4 - DOOR MOTOR ASSEMBLY
5 - FLEX DRIVE ASSEMBLY
6 - DOOR MOTOR RETAINING FASTENERS
7 - DOOR MOTOR ELECTRICAL CONNECTOR
Fig. 9 FLEX DRIVE RETAINING CLIP
1 - FLEX DRIVE CABLE RETAINING CLIP
2 - FLEX DRIVE CABLE
3 - DOOR MOTOR ASSEMBLY
RSPOWER SLIDING DOOR SYSTEM8N-51

NOTE: Push in on the push-pins at the clutch hous-
ing (plastic side) until you hear one click. Push in
on the push-pin fasteners at the motor mount
(sheet metal side) until you hear two clicks. This
assures proper installation/attachment of the motor
to the sliding door.
(3) Install the flex shaft by lining up the square
shaped drive shaft with the corresponding hole in the
door motor drive unit and push straight in.
(4) Install the E-clip to secure flex-shaft.
(5) Install the weather shield as necessary.
(6) Install the door trim panel on the sliding door,
(Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - INSTALLATION) for the procedure.
(7) Connect the battery negative cable.
FULL OPEN SWITCH
DESCRIPTION
The full open switch is located in the hold open
latch (Fig. 10) under the sliding door lower hinge.
When the power sliding door control module receives
a ground signal input from the full open switch, and
as long as the cinching latch actuator is not in power
mode or the handle switch is open, the signal indi-
cates that the door is at the full open position.The full open switch is incorporated into the hold
open latch. If the full open switch is inoperative, the
entire hold open latch assembly must be replaced.
OPERATION
The full open switch is triggered by a pawl lever in
the hold open latch. When the full open switch is
closed (circuit to ground) the ratchet has engaged on
the hold open striker and the pawl lever has engaged
on the ratchet, locking the latch from opening and
holding the door in the full open position.
B-PILLAR SWITCH
DESCRIPTION
The B-pillar switches are located on the interior of
the vehicle, on the B-pillar trim panels. These
switches serve as an open and close command switch
for the appropriate power sliding door.
OPERATION
When the B-pillar switch is depressed a signal is
sent to the Body Control Module (BCM), this signal
is then sent to the power sliding door control module,
telling it to start a power open or close cycle. The
child lockout feature must be disabled and the slid-
ing door must be unlocked in order for the B-pillar
switch to function.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Using a trim stick (special tool # C-4755) or
equivalent, gently pry the leading upper edge of the
B-pillar switch away from the B-pillar trim.
(3) Once the upper edge is free from B-pillar trim,
rock the switch out of the switch opening.
(4) Disconnect the B-pillar switch electrical con-
nector. First, slide the connector lock away from the
switch then, depress connector retaining tab while
pulling straight apart.
(5) Remove the B-pillar switch from the vehicle.
INSTALLATION
(1) Connect the B-pillar switch electrical connector.
Slide connector lock toward the switch to lock in
place.
(2) Hook the lower edge of the B-pillar switch on
the B-pillar trim and then push the switch firmly
into position.
(3) Connect the battery negative cable.
Fig. 10 FULL OPEN SWITCH POSITION &
ORIENTATION
1 - HOLD OPEN LATCH ASSEMBLY
2 - HOLD OPEN LATCH CABLE
3 - FULL OPEN SWITCH
8N - 52 POWER SLIDING DOOR SYSTEMRS
SLIDING DOOR MOTOR (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

NOTE: Turning the system off by depressing the
OFF switch or turning off the ignition switch will
erase the set speed stored in the PCM.
For added safety, the speed control system is pro-
grammed to disengage for any of the following condi-
tions:
²An indication of Park or Neutral
²A rapid increase rpm (indicates that the clutch
has been disengaged)
²Excessive engine rpm (indicates that the trans-
mission may be in a low gear)
²The speed signal increases at a rate of 10 mph
per second (indicates that the co-efficient of friction
between the road surface and tires is extremely low)
²The speed signal decreases at a rate of 10 mph
per second (indicates that the vehicle may have
decelerated at an extremely high rate)
²If the actual speed is greater than 20 mph over
the set speed.
²Autostick shifts into 1st or 2nd gear (autostick,
if equipped)
Once the speed control has been disengaged,
depressing the RESUME switch when speed is
greater than 20 mph allows the vehicle to resume
control to the target speed that was stored in the
PCM.
While the speed control is engaged, the driver can
increase the vehicle speed by depressing the ACCEL
switch. The new target speed is stored in the PCM
when the ACCEL switch is released. The PCM also
has a9tap-up9feature in which target speed
increases by 2 mph for each momentary switch acti-
vation of the ACCEL switch. The PCM also provides
a means to decelerate to a new lower target speed
without disengaging speed control. Depress and hold
the COAST switch until the desired speed is reached,
then release the switch.
The PCM also has a ªTap Downº feature in which
target speed decreases at 1 mph for each momentary
switch activation of the coast switch.
OPERATION - INTERACTIVE SPEED CONTROL
(4 Speed EATX Only)
Interactive means that communication between the
PCM and the TCM is taking place, this communica-
tion is internal to the PCM on NGC vehicles. Inter-
active speed control avoids unnecessary shifting for
smoother, quieter operation and when downshifts are
required, makes the shifts smoother.
CLIMBING A GRADE
DESCRIPTION
When climbing a grade the interactive speed con-
trol tries to maintain the set speed by increasing thethrottle opening, while inhibiting/delaying down-
shifts.
OPERATION
If opening the throttle alone cannot maintain the
set speed and the vehicle speed drops more than
three mph below the set speed, the transmission will
downshift to third gear. If the vehicle continues to
lose speed, by more than 6 mph, the transmission
will downshift again to maintain the set speed. After
the vehicle encounters a less-steep grade, or has
crested the grade (reduced the load on the power-
train) and can maintain the set speed at a reduced
throttle position, the transmission will upshift, as
appropriate, until the set speed can be maintained in
Overdrive.
GRADE HUNTING
DESCRIPTION
All vehicles equipped with a four speed automatic
transmission have a grade hunting feature for the
2nd to 3rd gear upshift and the 3rd to Overdrive
upshift.
OPERATION
The PCM on NGC vehicles identifies the power-
train loading conditions and selects the proper gear
to maintain the current vehicle speed. Under moder-
ate loading conditions the transaxle will stay in 3rd
gear until the top of the grade is reached or the pow-
ertrain loading is reduced.
If powertrain loading is severe, the transaxle may
shift into 2nd gear and remain there until power-
train loading is reduced, then a 2nd to 3rd gear
upshift will be scheduled. Grade hunting features
always operate regardless of whether or not the
interactive speed control is engaged.If the interac-
tive speed control is not engaged and power-
train loading is not reduced, the driver may
have to completely lift off of the throttle before
an upshift will occur. If the driver does lift off the
throttle to induce an upshift under these conditions,
vehicle speed will reduce and the Overdrive to 3rd
and 3rd to 2nd gear downshifts will reoccur when the
throttle is reapplied. If grade hunting is repeatedly
induced by the driver, transaxle damage may result.
AUTOMATIC SPEED CONTROL OVERSPEED
REDUCTION
DESCRIPTION
Transmission control software includes an auto-
matic speed control overspeed reduction feature. This
maintains vehicle speed at the selected set point
when descending a grade.
8P - 2 SPEED CONTROLRS
SPEED CONTROL (Continued)

8W-02 COMPONENT INDEX
Component Page
A/C Compressor Clutch................. 8W-42
A/C Compressor Clutch Relay............ 8W-42
A/C Pressure Sensor................... 8W-42
A/C-Heater Control.................... 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Accessory Relay....................... 8W-10
Adjustable Pedals Motor................ 8W-56
Adjustable Pedals Relay................ 8W-56
Adjustable Pedals Sensor............... 8W-56
Adjustable Pedals Switch............... 8W-56
Airbag.............................. 8W-43
Airbag On/Off Indicator Lamp............ 8W-43
Airbag Squibs........................ 8W-43
Ambient Temperature Sensor............ 8W-49
Amplifier............................ 8W-47
Antenna............................ 8W-47
ATC Remote Sensor.................... 8W-42
Auto Shut Down Relay................. 8W-30
Auto Temp Control.................... 8W-42
B-Pillar Switches...................... 8W-61
Back-Up Lamp Switch.................. 8W-51
Battery............................. 8W-20
Battery Temperature Sensor............. 8W-20
Belt Tension Sensor.................... 8W-43
Blend Door Actuators.................. 8W-42
Blower Motors........................ 8W-42
Blower Motor Relays................... 8W-42
Blower Motor Resistor.................. 8W-42
Body Control Module................... 8W-45
Boost Pressure Sensor.................. 8W-30
Brake Fluid Level Switch............... 8W-35
Brake Lamp Switch................. 8W-30, 51
Brake Transmission Shift Interlock
Solenoid........................... 8W-31
Cabin Heater Assist................... 8W-30
Camshaft Position Sensor............... 8W-30
CD Changer......................... 8W-47
Center High Mounted Stop Lamp......... 8W-51
Cinch/Release Motors.................. 8W-61
Clockspring.............. 8W-30, 33, 41, 43, 47
Clutch Pedal Interlock Switch............ 8W-21
Clutch Pedal Upstop Switch............. 8W-30
Controller Antilock Brake............... 8W-35
Crank Case Ventilation Heater........... 8W-30
Crankshaft Position Sensor.............. 8W-30
Cylinder Lock Switches................. 8W-39
Data Link Connector................... 8W-18
Defogger Relay....................... 8W-48
Door Ajar Switches.................... 8W-39
Door Courtesy Lamps.................. 8W-44
Door Lock Motor/Ajar Switches........... 8W-61
Door Lock Switches.................... 8W-61Component Page
Dosing Pump......................... 8W-30
DVD Screen.......................... 8W-47
DVD/CD Changer..................... 8W-47
ECM/PCM Relay...................... 8W-30
EGR Solenoid........................ 8W-30
Electronic Control Unit................. 8W-64
Engine Control Module................. 8W-30
Engine Coolant Temp Sensor............. 8W-30
Engine Oil Pressure Sensor.............. 8W-30
Engine Oil Pressure Switch.............. 8W-30
EVAP/Purge Solenoid.................. 8W-30
Evaporator Temperature Sensor.......... 8W-42
Floor Console Lamp................... 8W-44
Fog Lamps.......................... 8W-50
Folding Mirror Relay................... 8W-62
Front Blower Module.................. 8W-42
Front Cigar Lighter.................... 8W-41
Front Control Module.................. 8W-10
Front Fog Lamp Relay................. 8W-50
Front Intrusion Sensor................. 8W-39
Front Reading Lamps/Switch............ 8W-44
Front Wiper High/Low Relay............. 8W-53
Front Wiper On/Off Relay............... 8W-53
Fuel Heater.......................... 8W-30
Fuel Heater Relay..................... 8W-30
Fuel Injectors........................ 8W-30
Fuel Pressure Sensor.................. 8W-30
Fuel Pressure Solenoid................. 8W-30
Fuel Pump Module.................... 8W-30
Fuel Pump Relay...................... 8W-30
Full Open Switches.................... 8W-61
Fuselink............................ 8W-10
Fuses............................... 8W-10
Generator........................... 8W-20
Glow Plug Relay...................... 8W-30
Glow Plugs.......................... 8W-30
Grounds............................ 8W-15
Hands Free Module................. 8W-47, 55
Headlamp Leveling Motors.............. 8W-50
Headlamp Switch..................... 8W-50
Headlamp Washer Pump Motor.......... 8W-53
Headlamp Washer Relay................ 8W-53
Headlamps.......................... 8W-50
Heated Seat Backs.................... 8W-63
Heated Seat Cushions.................. 8W-63
Heated Seat Modules.................. 8W-63
High Beam Lamps..................... 8W-50
High Note Horn....................... 8W-41
Hood Ajar Switch..................... 8W-39
Horn Relay.......................... 8W-41
Horn Switch......................... 8W-41
Idle Air Control Motor.................. 8W-30
RS8W-02 COMPONENT INDEX8W-02-1