2005 CHRYSLER CARAVAN heater

HEATED SYSTEMS
TABLE OF CONTENTS
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HEATED GLASS........................... 1
HEATED MIRRORS......................... 6HEATED SEAT SYSTEM..................... 7
HEATED GLASS
TABLE OF CONTENTS
page page
HEATED GLASS
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING
ELECTRIC BACKLIGHT (EBL) SYSTEM.....2
REAR WINDOW DEFOGGER RELAY
DESCRIPTION..........................3
OPERATION............................3REMOVAL.............................4
INSTALLATION..........................4
REAR WINDOW DEFOGGER SWITCH
DESCRIPTION..........................4
OPERATION............................4
REAR WINDOW DEFOGGER GRID
STANDARD PROCEDURE
GRID REPAIR PROCEDURE..............5
HEATED GLASS
DESCRIPTION
CAUTION: Grid lines can be damaged or scraped
off with sharp instruments. Care should be taken in
cleaning glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.
The rear window defogger system, also known as
electrical backlight (EBL), consists of two vertical bus
bars linked by a series of grid lines fired onto the
inside surface of the rear window (Fig. 1).
The EBL system is turned ON or OFF by a control
switch located on the A/C-heater control at the center
of the instrument panel and by a rear window defog-
ger relay timing circuit integral to the integrated
power module (IPM) (Refer to 8 - ELECTRICAL/
HEATED GLASS/REAR WINDOW DEFOGGER
SWITCH - DESCRIPTION).
Circuit protection is provided by a 40 amp fuse
located in the IPM.
Fig. 1 Rear Window Defogger - Typical
1 - REAR DEFOGGER GRID
2 - REAR WINDOW
RSHEATED SYSTEMS8G-1

OPERATION
When the rear window defogger button is
depressed to the On position, current is directed to
the rear defogger grid lines and the heated power
mirrors (if equipped). The heated grid lines heat the
glass to help clear the rear window and side mirror
surfaces of fog or frost.
The electric backlight (EBL) system is controlled
by a momentary switch located in the A/C-heater
control on the instrument panel. A yellow indicator in
the switch will illuminate to indicate when the sys-
tem is turned on. The integrated power module (IPM)
contains the EBL system control circuitry.
NOTE: The rear window defogger turns off automat-
ically after approximately 10 minutes of initial oper-
ation. Each following activation cycle of the
defogger system will last approximately five min-
utes.
The EBL system will be automatically turned off
after a programmed time interval of about ten min-
utes. After the initial time interval has expired, if the
defogger switch is turned on again during the same
ignition cycle, the defogger system will automatically
turn off after about five minutes.
The EBL system will automatically shut off if the
ignition switch is turned to the Off position, or it can
be turned off manually by depressing the defogger
switch a second time.
DIAGNOSIS AND TESTING
ELECTRIC BACKLIGHT (EBL) SYSTEM
NOTE: Illumination of the defogger switch indicator
lamp means that there is electrical current available
at the output of the rear window defogger logic cir-
cuitry, but does not confirm that the electrical cur-
rent is reaching the rear glass heating grid lines.
NOTE: For circuit descriptions and diagrams of the
rear window defogger system, refer to 8W - WIRING
DIAGRAM INFORMATION.
Operation of the electrical backlight (EBL) system
can be confirmed by the following:(1) Turn the ignition switch to the On position. Set
the defogger switch in the On position. The rear win-
dow defogger operation can be checked by feeling the
rear window glass. A distinct difference in tempera-
ture between the grid lines and the adjacent clear
glass can be detected within three to four minutes of
operation.
(2) If a temperature difference is not detected, use
a 12-volt DC voltmeter and contact the rear glass
heating grid terminal B with the negative lead, and
terminal A with the positive lead (Fig. 2). The volt-
meter should read battery voltage. If the voltmeter
does not read battery voltage, check the following:
²Confirm that the ignition switch is in the On
position.
²Make sure that the rear glass heating grid feed
wire and ground wire are connected to the terminals.
Confirm that the ground wire has continuity to
ground.
²Check that fuse 13 (40 amp) in the integrated
power module (IPM) is OK. The fuse must be tight in
it's receptacle and all electrical connections must be
secure.
(3) When the above steps have been completed and
the rear glass heating grid is still inoperative, one or
more of the following is faulty. It may be necessary to
connect a DRBIIItscan tool to perform further diag-
nostics. Refer to Body Diagnostic Procedures.
²Rear window defogger switch in the A/C-heater
control.
²J1850 bus communication between the A/C-
heater control and the front control module (FCM).
²Rear window defogger (EBL) relay in the IPM.
²Rear window defogger (EBL) relay control circu-
ity in the IPM.
²Check for a loose wire connector or a wire
pushed out of a connector.
²Rear window grid lines (all grid lines would
have to be broken, or the power feed or ground wire
not connected, for the entire heating grid to be inop-
erative).
(4) If the system operation has been verified but
defogger switch LED indicator does not illuminate,
replace the A/C-heater control.
8G - 2 HEATED GLASSRS
HEATED GLASS (Continued)

REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the integrated power
module (IPM) (Fig. 4).
NOTE: Refer to the fuse and relay layout map on
the inner surface of the cover of the IPM for rear
window defogger (EBL) relay identification and
location.
(3) Remove the EBL relay from the IPM.
INSTALLATION
NOTE: Refer to the fuse and relay map on the inner
surface of the cover of the integrated power module
(IPM) for rear window defogger (EBL) relay identifi-
cation and location.
(1) Position the EBL relay into the proper recepta-
cle in the IPM.
(2) Align the EBL relay terminals with the termi-
nal cavities in the IPM receptacle.
(3) Push down firmly on the EBL relay until the
terminals are fully seated in the terminal cavities.
(4) Install the cover onto the IPM.
(5) Reconnect the negative battery cable.
REAR WINDOW DEFOGGER
SWITCH
DESCRIPTION
The switch for the EBL system is integrated into
the A/C-heater control located in the center of the
instrument panel (Fig. 5).
When the rear window defogger switch is turned to
the ON position, current is directed to the rear defog-
ger grid lines and the heated power mirrors (if
equipped). The heated grid lines heat the glass to
help clear the surface of fog or frost.
OPERATION
Depressing the rear window defogger switch ener-
gizes the A/C-heater control module which then
requests the front control module (FCM) to activate
the rear window defogger (EBL) relay via the com-
munication bus. The EBL relay controls the current
to flow to the grids of the rear window defogger and
the heated power side view mirrors. The EBL relay
will be on for approximately 10 minutes or until the
control switch or ignition is turned off. An amber
indicator lamp in the defogger switch illuminates to
indicate when the EBL system is On.
The rear window defogger switch and indicator
lamp cannot be repaired and, if faulty or damaged,
the entire A/C-heater control must be replaced.
Fig. 4 Rear Window Defogger (EBL) Relay
1 - INTEGRATED POWER MODULE (IPM)
2 - REAR WINDOW DEFOGGER (EBL) RELAY
3 - FRONT CONTROL MODULE (FCM)
Fig. 5 A/C-Heater Control - Typical
1 - TRIM BEZEL
2 - INFRARED TEMPERATURE SENSOR
3 - A/C REQUEST SWITCH
4 - EBL/HEATED MIRROR SWITCH
5 - FRONT WINDOW DEFROSTER SELECTOR
8G - 4 HEATED GLASSRS
REAR WINDOW DEFOGGER RELAY (Continued)

HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION..........................6OPERATION............................6
HEATED MIRRORS
DESCRIPTION
The optional heated mirror system is controlled by
the momentary rear window defogger switch which is
integral to the A/C-heater control (Fig. 1). An amber
indicator lamp in the switch will illuminate to indi-
cate when the rear window defogger (EBL) system is
turned on.
The heated mirror system only operates in concert
with the EBL system, and will be automatically shut
off after a programmed time interval of about 10
minutes. After the initial time interval has expired, if
the defogger switch is turned on again during the
same ignition cycle, the heated mirror system will
automatically shut off after about 5 minutes.
The heated mirror system will automatically shut
off if the ignition switch is turned to the Off position,
or it can be shut off manually by pressing the rear
window defogger switch a second time.
OPERATION
When the rear window defogger switch is pressed,
the rear window defogger (EBL) system becomes acti-
vated and an electric heater grid located behind the
glass of each of the outside rear view mirrors is ener-
gized. When energized, each of these heater grids
produce heat to help clear the outside rear view mir-
rors of ice, snow, or fog.If the outside mirror heating grids are both inoper-
ative, refer to DIAGNOSIS AND TESTING - REAR
WINDOW DEFOGGER SYSTEM in his group. If
only one of the outside mirror heating grids is inop-
erative, Refer to 8 - ELECTRICAL/POWER MIR-
RORS - DIAGNOSIS AND TESTING.
The heating grid behind each outside mirror glass
cannot be repaired and, if faulty or damaged, the
entire power mirror assembly must be replaced.
Fig. 1 A/C-Heater Control Panel
1 - TRIM BEZEL
2 - INFRARED TEMPERATURE SENSOR
3 - A/C REQUEST SWITCH
4 - EBL/HEATED MIRROR SWITCH
5 - FRONT WINDOW DEFROSTER SELECTOR
8G - 6 HEATED MIRRORSRS

Hard wired circuitry connects the heated seat sys-
tem components to each other through the electrical
system of the vehicle. These circuits may be con-
nected to each other, to the vehicle electrical system
and to the heated seat system components through
the use of a combination of soldered splices and
splice block connectors. Refer to the appropriate wir-
ing information for complete circuit schematic or con-
nector pin-out information.
OPERATION
The heated seat system components operate on
battery current received through a fuse in the Inte-
grated Power Module (IPM) on a fused ignition
switch output (run) circuit from the Body Control
Module (BCM). The system will only operate when
the ignition switch is in the On position. The heated
seat system will be turned Off automatically when-
ever the ignition switch is turned to any position
except On. Also, the heated seat system will not oper-
ate when the surface temperature of the seat cushion
cover at either heated seat sensor is above the
designed temperature set points of the system.
DIAGNOSIS AND TESTING
HEATED SEAT SYSTEM
The most efficient means of diagnosing the heated
seat system is by individual component. For diagno-
sis of a specific component refer to the following:
²Heated seat module, (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/MEMORY
HEATED SEAT/MIRROR MODULE - DIAGNOSIS
AND TESTING).
²Heated seat elements, (Refer to 8 - ELECTRI-
CAL/HEATED SEATS/HEATED SEAT ELEMENT -
DIAGNOSIS AND TESTING).
²Heated seat switch, (Refer to 8 - ELECTRICAL/
HEATED SEATS/DRIVER HEATED SEAT SWITCH
- DIAGNOSIS AND TESTING).
²Heated seat sensor, (Refer to 8 - ELECTRICAL/
HEATED SEATS/HEATED SEAT SENSOR - DIAG-
NOSIS AND TESTING).
Refer to the appropriate wiring information for
complete circuit schematic or connector pin-out infor-
mation.
HEATED SEAT SWITCH
DESCRIPTION
The heated seat switches are mounted in the
instrument panel center bezel (Fig. 2). The two three-
position rocker-type switches, one switch for each
front seat, are incorporated into one large switch
assembly that also includes the hazard, rear window
wiper and washer switches. Each heated seat switch
provides a resistor multiplexed signal to its respec-
tive Heated Seat Module (HSM) through separate
hard wired circuits. Each switch has an Off, Low,
and High position so that both the driver and the
front seat passenger can select a preferred seat heat-
ing mode. Each switch has two Light-Emitting
Diodes (LED) which light to indicate that the heater
for the seat is turned on.
The heated seat switches and their LEDs cannot
be repaired. If either switch or LED is faulty or dam-
aged, the entire switch assembly must be replaced.
Fig. 2 HEATED SEAT SWITCH LOCATION
1 - HEATED SEAT SWITCHES
8G - 8 HEATED SEAT SYSTEMRS
HEATED SEAT SYSTEM (Continued)

OPERATION
There are three positions that can be selected with
each of the heated seat switches: Off, Low, or High.
When the left side of the switch rocker is fully
depressed, the Low position is selected and the low
position LED indicator illuminates. When the right
side of the switch rocker is fully depressed, the High
position is selected and the high position LED indi-
cator illuminates. When the switch rocker is moved
to its neutral position (middle), Off is selected and
both LED indicators are extinguished.
Each switch provides separate resistor, hard wire
inputs to its respective Heated Seat Module (HSM) to
indicate the selected switch position. The heated seat
module responds to the heated seat switch status
messages by controlling the output to the seat heater
elements of the selected seat. The Low heat position
set point is about 36É C (97É F), and the High heat
position set point is about 41É C (105É F).
DIAGNOSIS AND TESTING
DRIVER HEATED SEAT SWITCH
Refer to the appropriate wiring information for
complete circuit schematic or connector pin-out infor-
mation.
WARNING: REFER TO THE RESTRAINTS SECTION
OF THIS MANUAL BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, SEAT OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CHECKING SWITCH SIGNAL AND WIRING AT THE
MODULE
(1) Disconnect and isolate the battery negative
cable.
(2) Access and disconnect the gray 4-way connector
from the heated seat module. Visually inspect wiring
terminals for damage that would prevent positive
connection. If not OK, repair or replace the necessary
components.(3) Connect the battery negative cable. Place the
heated seat switch in the LO position. Using an
Ohmmeter, check the resistance between cavities 2
and 3 of the gray connector noted above. Resistance
should be about 3.5 kilohms (3500 ohms). If not OK,
check resistance directly at switch, as noted below. If
OK, proceed to the next step. If not OK, replace the
faulty switch.
(4) Place the heated seat switch in the HI position.
Using an ohmmeter, check the resistance between
cavities 2 and 3 of the gray connector noted above.
Resistance should be about 1.4 kilohms (1400 ohms).
If not OK, check resistance directly at the switch, as
indicated in the Heated Seat Switch Test Table. If
OK, proceed. If not OK replace the faulty switch.
(5) With the system ON in the HI position, check
for battery voltage and ground at cavities 4 and 1. If
OK, proceed with testing remaining components. If
not OK, repair open or shorted wiring.
CHECKING SWITCH ONLY
(1) Disconnect and isolate the battery negative
cable. Remove the center bezel from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL -
REMOVAL). Check for continuity between the
ground circuit cavity (#10) of the instrument panel
center bezel switch electrical connector and a good
ground. There should be continuity. If OK, go to Step
2. If not OK, repair the open ground circuit to ground
as required.
(2) Connect the battery negative cable. Turn the
ignition switch to the On position. Check for battery
voltage at the fused ignition switch output (run) cir-
cuit cavity of the instrument panel center bezel
switch electrical connector (#4). If OK, turn the igni-
tion switch to the Off position, and go to Step 3. If
not OK, repair the open fused ignition switch output
(run) circuit as required.
(3) Test the heated seat switch as shown in the
Heated Seat Switch Test chart and the connector pin-
out below (Fig. 3). If OK, go to Step 4. If not OK,
replace the instrument panel center bezel switch
assembly.
RSHEATED SEAT SYSTEM8G-9
HEATED SEAT SWITCH (Continued)

FIRING ORDERAUTO SHUT DOWN RELAY
DESCRIPTION
The relay is located in the Power Distribution Cen-
ter (PDC). For the location of the relay within the
PDC, refer to the PDC cover for location. Check elec-
trical terminals for corrosion and repair as necessary
OPERATION
The engine switched battery (NGC vehicles)
informs the PCM when the ASD relay energizes. A 12
volt signal at this input indicates to the PCM that
the ASD has been activated. This input is also used
to power certain drivers on NGC vehicles.
When energized, the ASD relay on NGC vehicles
provides power to operate the injectors, ignition coil,
generator field, O2 sensor heaters (both upstream
and downstream), evaporative purge solenoid, EGR
solenoid (if equipped) wastegate solenoid (if
equipped), and NVLD solenoid (if equipped).
The ASD relay also provides a sense circuit to the
PCM for diagnostic purposes. If the PCM does not
receive 12 volts from this input after grounding the
control side of the ASD relay, it sets a Diagnostic
Trouble Code (DTC). The PCM energizes the ASD
any time there is an engine speed that exceeds a pre-
determined value (typically about 50 rpm). The ASD
relay can also be energized after the engine has been
turned off to perform an O2 sensor heater test, if
vehicle is equipped with OBD II diagnostics.
As mentioned earlier, the PCM energizes the ASD
relay during an O2 sensor heater test. On NGC vehi-
cles it checks the O2 heater upon vehicle start. The
PCM still operates internally to perform several
checks, including monitoring the O2 sensor heaters.
FIRING ORDER 2.4L
Firing Order 1-2-3-4-5-6 3.3/3.8L
1 - Electrical Connector
RSIGNITION CONTROL8I-3
IGNITION CONTROL (Continued)

INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - SELF-
DIAGNOSTICS.........................2
DIAGNOSIS AND TESTING - CLUSTER
DIAGNOSIS...........................3REMOVAL.............................11
INSTALLATION.........................11
CLUSTER LENS
REMOVAL.............................11
INSTALLATION.........................11
INSTRUMENT CLUSTER
DESCRIPTION
The instrumentation gauges are contained in a
subdial assembly within the instrument cluster. The
individual gauges are not serviceable. If one of the
cluster gauges becomes faulty, the entire cluster
would require replacement.
The Mechanical Instrument Cluster (MIC) with a
tachometer is equipped with a electronic vacuum flu-
orescent transmission range indicator (PRND3L),
odometer, and trip odometer display.
The MIC without a tachometer is equipped with a
Light Emitting Diode (LED) transmission range indi-
cator (PRND3L) and a vacuum fluorescent odometer
display.
The MIC is equipped with the following warning
lamps.
²Lift Gate Ajar
²Low Fuel Level
²Low Windshield Washer Fluid Level
²Cruise
²Battery Voltage
²Fasten Seat Belt
²Door Ajar
²Coolant Temperature
²Anti-Lock Brake
²Brake
²Oil Pressure
²MIL (Malfunction Indicator Lamp)
²VTSS/SKIS Indicator
²Airbag
²Traction Control
²Autostick
Export Only- uses a message center that displays
the following telltales:
²Turns Signals
²High Beam
²Tire Pressure Monitoring (TPM)²Glow Plug (Export Only)
²Supplemental Cabin Heater (Export Only)WATER IN FUEL LAMP - EXPORT
The Water In Fuel Lamp is located in the message
center. When moisture is found within the fuel sys-
tem, the sensor sends a message via the PCI data
bus to the instrument cluster. The MIC illuminates
the bulb in the message center, The sensor is located
underneath the vehicle, directly above the rear axle.
The sensor is housed within the fuel filter/water sep-
arator assembly cover. The sensor is not serviced sep-
arately. If found defective, the entire assembly cover
must be replaced.
OPERATION
Refer to the vehicle Owner's Manual for operation
instructions and conditions for the Instrument Clus-
ter Gauges.
WATER IN FUEL LAMP/SENSOR - EXPORT
The Water In Fuel Sensor is a resistive type
switch. It is calibrated to sense the different resis-
tance between diesel fuel and water. When water
enters the fuel system, it is caught in the bottom of
the fuel filter/water separator assembly, where the
sensor is located. Water has less resistance than die-
sel fuel. The sensor then sends a PCI data bus mes-
sage to the instrument cluster to illuminate the
lamp.
If the lamp is inoperative, perform the self diag-
nostic test on the instrument cluster to check the
lamp operation before continuing diagnosis.
RSINSTRUMENT CLUSTER8J-1