2005 CHRYSLER CARAVAN windshield wipers

(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(3) Disconnect and isolate the negative battery
cable.
(4) Remove the windshield wiper module from the
vehicle (Refer to 8 - ELECTRICAL/WIPERS/WASH-
ERS/WIPER MODULE - REMOVAL).
(5) Disconnect the liquid line and suction line from
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/LIQUID
LINE - REMOVAL) and (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - FRONT/SUC-
TION LINE - REMOVAL).
(6) Disconnect the heater hoses from the heater
core tubes (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/HEATER HOSE -
REMOVAL).
(7) On LHD models, remove the one bolt that
secures the HVAC housing to the dash panel (Fig.
12).
(8) Remove the nuts that secure the HVAC hous-
ing to the dash panel in the engine compartment.(9) Remove the instrument panel from the passen-
ger compartment (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL ASSEMBLY -
REMOVAL).
(10) Remove the floor distribution duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION - FRONT/FLOOR DISTRIBUTION DUCTS -
REMOVAL).
(11) Remove the bolt or bolts (depending on appli-
cation) that secure the HVAC housing to the passen-
ger compartment side of the dash panel (Fig. 13) or
(Fig. 14).
(12) Pull the HVAC housing rearward far enough
for the mounting studs to clear the dash panel and
remove the housing from the passenger compart-
ment.
DISSASEMBLY
(1) Remove the HVAC housing from the vehicle
and place it on a workbench (Refer to 24 - HEATING
& AIR CONDITIONING/DISTRIBUTION - FRONT/
HVAC HOUSING - REMOVAL).
(2) Remove the heater core tubes from the heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER CORE -
REMOVAL - HEATER CORE TUBES).
(3) Remove and discard the foam seal from the
HVAC housing seal flange around the fresh air inlet
opening and the expansion valve/evaporator tube
opening.
(4) Remove the expansion valve from the evapora-
tor inlet and outlet tube fittings (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - FRONT/
EXPANSION VALVE - REMOVAL).
Fig. 12 HVAC Housing Retainers - RS Shown
1 - HVAC HOUSING
2 - DASH PANEL
3 - STUD (3 RS models, 4 RG models)
4 - NUT (3 RS models, 4 RG models)
5 - BOLT (RS only)
Fig. 13 HVAC Housing - LHD Models
1 - HVAC HOUSING
2 - BOLT
3 - BRACKET
4 - DASH PANEL
RSDISTRIBUTION - FRONT24-51
HVAC HOUSING (Continued)

(7) Reconnect the heater hoses to the heater core
tubes (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER HOSE -
INSTALLATION).
(8) Reconnect the suction line and liquid line to
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/SUCTION
LINE - INSTALLATION) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - FRONT/
LIQUID LINE - INSTALLATION).
(9) Install the windshield wiper module (Refer to 8
- ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION).
(10) Reconnect the negative battery cable.
(11) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(12) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(13) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
INSTRUMENT PANEL
DEMISTER DUCTS
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Place the instrument panel face down on a
suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.
(4) Remove the fasteners that secure the demister
ducts to the instrument panel armature.
(5) Disengage the demister ducts from the demis-
ter outlets.
(6) Remove the demister ducts from the instru-
ment panel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Position the demister ducts to the instrument
panel.
(2) Engage the demister ducts to the demister out-
lets.
(3) Install the fasteners that secure the demister
ducts to the instrument panel armature.
(4) Reinstall the instrument panel into the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
24 - 54 DISTRIBUTION - FRONTRS
HVAC HOUSING (Continued)

VTSS/SKIS INDICATOR LAMP -OPERATION .......................... 8Q-8
WARNING - A/C SYSTEM ..............24-66
WARNING - ENGINE COOLING SYSTEM . . . 24-65
WARNING - INSTALLATION ............23-162
WARNING - INSTALLATION .............19-16
WARNING - REMOVAL ...............23-161
WARNING - REMOVAL ................19-11
WARNING - SAFETY PRECAUTIONS AND WARNINGS .......................... 23-1
WARNING - WARNINGS ................8O-5
WARNING - WARNINGS AND CAUTIONS . . 19-10, 19-26
WARNING - WINDSHIELD SAFETY PRECAUTIONS ...................... 23-161
WARNING, CHIME/BUZZER ..............8B-2
WARNING, DESCRIPTION ................5-4
WARNING, DESCRIPTION ..............19-37
WARNING, LAMPS/LIGHTING - EXTERIOR ........................... 8L-3
WARNING, OPERATION ...............24-114
WARNINGS AND CAUTIONS, WARNING . . 19-10, 19-26
WARNINGS, GENERAL ..............8W-01-7
WARNINGS, WARNING .................8O-5
WARNINGS, WARNING - SAFETY PRECAUTIONS ........................ 23-1
WASHER FLUID LEVEL SWITCH - INSTALLATION ...................... 8R-11
WASHER FLUID LEVEL SWITCH - REMOVAL .......................... 8R-11
WASHER HOSES - INSTALLATION .......8R-12
WASHER HOSES - REMOVAL ...........8R-11
WASHER PUMP MOTOR - INSTALLATION . 8R-12
WASHER PUMP MOTOR - REMOVAL .....8R-12
WASHER RESERVOIR - INSTALLATION . . . 8R-13
WASHER RESERVOIR - REMOVAL .......8R-12
WASHER SYSTEM - DIAGNOSIS AND TESTING ............................ 8R-5
WATER CHANNEL - INSTALLATION ......23-174
WATER CHANNEL - REMOVAL .........23-174
WATER LEAKS, DIAGNOSIS AND TESTING ............................ 23-1
WATER PUMP - 2.4L - CLEANING ........7-32
WATER PUMP - 2.4L - DESCRIPTION ......7-32
WATER PUMP - 2.4L - INSPECTION .......7-32
WATER PUMP - 2.4L - INSTALLATION .....7-32
WATER PUMP - 2.4L - REMOVAL .........7-32
WATER PUMP - 3.3/3.8L - CLEANING .....7-35
WATER PUMP - 3.3/3.8L - DESCRIPTION . . . 7-34
WATER PUMP - 3.3/3.8L - INSPECTION ....7-35
WATER PUMP - 3.3/3.8L - INSTALLATION ........................ 7-35
WATER PUMP - 3.3/3.8L - REMOVAL ......7-34
WATER PUMP INLET TUBE - 2.4L - DESCRIPTION ........................ 7-36
WATER PUMP INLET TUBE - 2.4L - INSTALLATION ........................ 7-36
WATER PUMP INLET TUBE - 2.4L - REMOVAL ........................... 7-36
WATER PUMP INLET TUBE - 3.3/3.8L - INSTALLATION ........................ 7-37
WATER PUMP INLET TUBE - 3.3/3.8L - REMOVAL ........................... 7-37
WATERSHIELD - INSTALLATION .........23-21
WATERSHIELD - REMOVAL .............23-21
WEAR - STANDARD PROCEDURE, MEASURING TIMING CHAIN ............9-155
WEAR INDICATORS - DIAGNOSIS AND TESTING, TREAD ..................... 22-16
WEAR PATTERNS - DIAGNOSIS AND TESTING, TIRE ...................... 22-16
WEATHERSTRIP - INSTALLATION, FRONT DOOR ............................ 23-168
WEATHERSTRIP - INSTALLATION, FRONT DOOR GLASS RUN .................. 23-166
WEATHERSTRIP - INSTALLATION, SLIDING DOOR ..................... 23-168
WEATHERSTRIP - REMOVAL, FRONT DOOR ............................ 23-168
WEATHERSTRIP - REMOVAL, FRONT DOOR GLASS RUN .................. 23-166WEATHERSTRIP - REMOVAL, SLIDING
DOOR ............................ 23-168
WEIGHT BLADDER & PRESSURE SENSOR - DESCRIPTION, SEAT .........8O-43
WEIGHT BLADDER & PRESSURE SENSOR - OPERATION, SEAT ...........8O-44
WELD LOCATIONS - FOLD-IN-FLOOR - SPECIFICATIONS .................... 23-350
WELD LOCATIONS - SPECIFICATIONS . . . 23-234
WHEEL - DESCRIPTION ...............22-18
WHEEL - INSPECTION, TONE ............5-94
WHEEL - INSTALLATION, STEERING ......19-24
WHEEL - REMOVAL, STEERING .........19-23
WHEEL ALIGNMENT - DESCRIPTION ......2-47
WHEEL ALIGNMENT - STANDARD PROCEDURE ......................... 2-52
WHEEL ALIGNMENT, SPECIFICATIONS .....2-56
WHEEL AND WHEEL TRIM CARE, CLEANING .......................... 22-19
WHEEL ASSEMBLY (ALUMINUM WHEEL) - INSTALLATION, TIRE .................22-8
WHEEL ASSEMBLY (ALUMINUM WHEEL) - REMOVAL, TIRE ..................... 22-8
WHEEL ASSEMBLY (STEEL WHEEL) - INSTALLATION, TIRE ................... 22-8
WHEEL ASSEMBLY (STEEL WHEEL) - REMOVAL, TIRE ...................... 22-8
WHEEL BALANCE - STANDARD PROCEDURE, TIRE .................... 22-5
WHEEL COVER - DESCRIPTION .........22-19
WHEEL COVER - INSTALLATION ..........22-20
WHEEL COVER - REMOVAL ............22-19
WHEEL CYLINDERS - INSPECTION ........5-62
WHEEL CYLINDERS - INSTALLATION ......5-62
WHEEL CYLINDERS - REMOVAL ..........5-62
WHEEL INSPECTION - DIAGNOSIS AND TESTING ........................... 22-19
WHEEL MATCH MOUNTING - STANDARD PROCEDURE, TIRE .................... 22-7
WHEEL MOUNTING STUDS - FRONT - INSTALLATION ....................... 22-21
WHEEL MOUNTING STUDS - FRONT - REMOVAL .......................... 22-21
WHEEL MOUNTING STUDS - REAR - INSTALLATION ....................... 22-22
WHEEL MOUNTING STUDS - REAR - REMOVAL .......................... 22-22
WHEEL ROTATION - STANDARD PROCEDURE, TIRE .................... 22-7
WHEEL RUNOUT, SPECIFICATIONS - TONE ............................... 5-91
WHEEL, SPECIFICATIONS ..............22-19
WHEEL SPEED SENSOR - AWD - INSTALLATION, REAR .................. 5-92
WHEEL SPEED SENSOR - AWD - REMOVAL, REAR ...................... 5-92
WHEEL SPEED SENSOR - FWD - INSTALLATION, REAR .................. 5-93
WHEEL SPEED SENSOR - FWD - REMOVAL, REAR ...................... 5-93
WHEEL SPEED SENSOR - INSTALLATION, FRONT .................5-92
WHEEL SPEED SENSOR - REMOVAL, FRONT .............................. 5-91
WHEEL SPEED SENSOR AIR GAP, SPECIFICATIONS ...................... 5-91
WHEEL TRIM CARE, CLEANING - WHEEL . . 22-19
WHEEL VIBRATION - DIAGNOSIS AND TESTING, TIRE ....................... 22-1
WHEELHOUSE SPLASH SHIELD - INSTALLATION, FRONT ................23-57
WHEELHOUSE SPLASH SHIELD - REMOVAL, FRONT .................... 23-57
WIND DEFLECTOR - INSTALLATION .....23-174
WIND DEFLECTOR - REMOVAL .........23-174
WIND NOISE, DIAGNOSIS AND TESTING . . . 23-2
WINDOW - INSTALLATION, QUARTER . . . 23-164
WINDOW - REMOVAL, QUARTER .......23-164
WINDOW CRANK - INSTALLATION .......23-21
WINDOW CRANK - REMOVAL ...........23-21
WINDOW DEFOGGER RELAY - DESCRIPTION, REAR .................. 8G-3WINDOW DEFOGGER RELAY -
INSTALLATION, REAR .................. 8G-4
WINDOW DEFOGGER RELAY - OPERATION, REAR .................... 8G-3
WINDOW DEFOGGER RELAY - REMOVAL, REAR ..................... 8G-4
WINDOW DEFOGGER SWITCH - DESCRIPTION, REAR .................. 8G-4
WINDOW DEFOGGER SWITCH - OPERATION, REAR .................... 8G-4
WINDOW MOTOR - REMOVAL ..........8N-62
WINDOW MOTOR, DIAGNOSIS AND TESTING - VENT ..................... 8N-62
WINDOW REGULATOR - MANUAL - INSTALLATION ....................... 23-23
WINDOW REGULATOR - MANUAL - REMOVAL .......................... 23-22
WINDOW REGULATOR - POWER - INSTALLATION ....................... 23-22
WINDOW REGULATOR - POWER - REMOVAL .......................... 23-22
WINDOW SWITCH, DIAGNOSIS AND TESTING ........................... 8N-63
WINDOWS - DESCRIPTION, POWER .....8N-61
WINDOWS - OPERATION, POWER .......8N-61
WINDOWS, DIAGNOSIS AND TESTING - POWER ............................ 8N-61
WINDSHIELD - DESCRIPTION ..........23-161
WINDSHIELD SAFETY PRECAUTIONS, WARNING ......................... 23-161
WIPER ARM - INSTALLATION, REAR .....8R-10
WIPER ARM - REMOVAL, REAR ..........8R-10
WIPER ARM ALIGNMENT - STANDARD PROCEDURE, FRONT .................. 8R-9
WIPER ARMS - INSTALLATION, FRONT ....8R-9
WIPER ARMS - REMOVAL, FRONT ........8R-9
WIPER BLADES - CLEANING ...........8R-13
WIPER BLADES - INSTALLATION ........8R-13
WIPER BLADES - REMOVAL ............8R-13
WIPER LINKAGE - INSTALLATION .......8R-14
WIPER LINKAGE - REMOVAL ...........8R-13
WIPER MODULE - INSTALLATION .......8R-14
WIPER MODULE - REMOVAL ...........8R-14
WIPER MOTOR - INSTALLATION, FRONT . . 8R-10
WIPER MOTOR - INSTALLATION, REAR . . . 8R-10
WIPER MOTOR - REMOVAL, FRONT ......8R-9
WIPER MOTOR - REMOVAL, REAR ......8R-10
WIPER SYSTEM - DIAGNOSIS AND TESTING, FRONT ..................... 8R-2
WIPER SYSTEM - DIAGNOSIS AND TESTING, REAR ...................... 8R-4
WIPERS/WASHERS - DESCRIPTION .......8R-1
WIPERS/WASHERS - OPERATION ........8R-2
WIPER/WASHER SWITCH - DESCRIPTION, REAR .................8R-10
WIPER/WASHER SWITCH - DIAGNOSIS AND TESTING, FRONT .................8R-2
WIPER/WASHER SWITCH - OPERATION, REAR .............................. 8R-11
WIRE SPLICING - STANDARD PROCEDURE .....................8W -01-15
WIRING - INSTALLATION, HEATER ......24-122
WIRING - REMOVAL, HEATER ..........24-122
WIRING DIAGRAMS - DESCRIPTION, HOW TO USE .....................8W -01-1
WIRING HARNESS - DESCRIPTION ......8N-59
WIRING HARNESS - DIAGNOSIS AND TESTING .........................8W -01-7
WIRING HARNESS - INSTALLATION ......8N-59
WIRING HARNESS - OPERATION ........8N-59
WIRING HARNESS - REMOVAL .........8N-59
WIRING/TERMINAL, SPECIAL TOOLS . . 8W-01-10
WORN THREADS - STANDARD PROCEDURE, REPAIR OF DAMAGED
OR............................. 9-10,9-88
ZONE, DESCRIPTION - MANUAL DUAL .....24-2
ZONE, DESCRIPTION - MANUAL SINGLE . . . 24-2
ZONE, DESCRIPTION - MANUAL THREE ....24-2
ZONE, OPERATION - MANUAL DUAL ......24-5
ZONE, OPERATION - MANUAL SINGLE .....24-4
ZONE, OPERATION - MANUAL THREE .....24-5
RS INDEX35
Description Group-Page Description Group-Page Description Group-Page