2005 CHRYSLER CARAVAN Service Manual

dead battery ignition warning lights oil dipstick tire pressure reset door lock

Page 457 of 2339

CHRYSLER CARAVAN 2005 Service Manual that axis may have an open, short or be incorrectly
connected. Check the wiring to that axis (module to
motor). Repair any wiring problems and retry that
axis. Refer to the appropriate wiring informat

that axis may have an open, short or be incorrectly
connected. Check the wiring to that axis (module to
motor). Repair any wiring problems and retry that
axis. Refer to the appropriate wiring information for
complete circuit schematic or connector pin-out infor-
mation.
SEAT SWITCH
DESCRIPTION
Vehicles equipped with a driver side power seat
utilize an eight-way power seat switch. Vehicles
equipped with a passenger side power seat utilize a
four-way power seat switch. These power seat
switches features two knobs ganged together on the
outboard seat cushion side shield (Fig. 2).
The switch is secured to the back of the seat cush-
ion side shield with two screws. However, the control
knobs for the seat switch unit must be removed
before the seat switch can be removed from the side
shield.The power seat switch cannot be repaired. If one
switch is damaged or faulty, the entire power seat
switch unit must be replaced.
OPERATION
When a power seat switch control knob or knobs
are actuated, a battery feed and a ground path are
applied through the switch contacts to the power seat
track or recliner adjuster motor. The selected
adjuster motor operates to move the seat track or
recliner through its drive unit in the selected direc-
tion until the switch is released, or until the travel
limit of the adjuster is reached. When the switch is
moved in the opposite direction, the battery feed and
ground path to the motor are reversed through the
switch contacts. This causes the adjuster motor to
run in the opposite direction.
No power seat switch should be held applied in any
direction after the adjuster has reached its travel
limit. The power seat adjuster motors each contain a
self-resetting circuit breaker to protect them from
overload. However, consecutive or frequent resetting
of the circuit breaker must not be allowed to con-
tinue, or the motor may be damaged.
DIAGNOSIS AND TESTING
DRIVER SEAT SWITCH
(1) Remove the power seat switch, (Refer to 8 -
ELECTRICAL/POWER SEATS/DRIVER SEAT
SWITCH - REMOVAL).
(2) Using an ohmmeter, check pin #1 of the power
seat switch wire harness connector for continuity to
ground. It should be present. If OK, go to Step 3. If
not OK, repair the open ground circuit as required.
(3) Using a voltmeter, check pin #5 of the power
seat switch wire harness connector for battery cur-
rent. It should be present. If OK, go to Step 4. If not
OK, repair the open voltage supply circuit as
required.
(4) Using an ohmmeter, test the power seat switch
for continuity, refer to SEAT SWITCH CONTINUITY
TEST TABLE (Fig. 3). If continuity is not present as
indicated, replace the power seat switch.
Fig. 2 POWER SEAT SWITCH LOCATION
1 - POWER SEAT SWITCH
2 - SEAT CUSHION SIDE SHIELD
8N - 34 POWER SEAT SYSTEMRS
POWER SEAT SYSTEM (Continued)

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CHRYSLER CARAVAN 2005 Service Manual SEAT SWITCH CONTINUITY TEST TABLE
SWITCH
POSITIONCONTINUITY BETWEEN PINS CONTINUITY BETWEEN PINS
DRIVER PASSENGER
OFF PIN1&4
PIN1&3
PIN1&2
PIN1&10
PIN1&9
PIN1&8
PIN1&7
PIN1&6PIN1&4
PIN1&3
PIN1&2
PIN1&

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CHRYSLER CARAVAN 2005 Service Manual REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Using a push pin remover or other suitable
wide flat-bladed tool, gently pry the power seat and
power recliner switch knobs off of th

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Using a push pin remover or other suitable
wide flat-bladed tool, gently pry the power seat and
power recliner switch knobs off of the switch levers
(Fig. 4).
(3) Remove the screws that secure the outboard
seat cushion side cover to the seat cushion frame,
(Refer to 23 - BODY/SEATS/SEAT CUSHION SIDE
COVERS - REMOVAL).
(4) Pull the outboard seat cushion side cover away
from the seat cushion frame far enough to access the
power seat switch wire harness connector.
(5) Disconnect the power seat wire harness connec-
tor from the power seat switch connector receptacle.
(6) Remove the screws that secure the power seat
switch to the inside of the outboard seat cushion side
cover.
(7) Remove the power seat switch from the out-
board seat cushion side cover.
INSTALLATION
(1) Position the power seat switch onto the out-
board seat cushion side cover.
(2) Install and tighten the screws that secure the
power seat switch to the inside of the outboard seat
cushion side cover. Tighten the screws to 1.5 N´m (14
in. lbs.).
(3) Reconnect the power seat wire harness connec-
tor to the power seat switch connector receptacle.(4) Install the outboard seat cushion side cover,
(Refer to 23 - BODY/SEATS/SEAT CUSHION SIDE
COVERS - INSTALLATION).
(5) Install the power seat and power recliner
switch knobs onto the switch control levers.
(6) Reconnect the battery negative cable.
MEMORY SWITCH
DESCRIPTION
Vehicles equipped with the memory system have a
memory switch mounted to the driver side front door
trim panel (Fig. 5). This switch is used to set and recall
all of the memory system settings for up to two drivers.
The memory switch is a resistor multiplexed unit that
is hard wired to the Body Control Module (BCM). The
BCM sends out the memory system set and recall
requests to the other electronic modules over the Pro-
grammable Communications Interface (PCI) data bus.
The memory switch cannot be adjusted or repaired
and, if faulty or damaged, it must be replaced.
OPERATION
The memory switch has three momentary switch
buttons labeled Set, 1 and 2. When the memory set
switch is depressed, a resistance value is sent to the
Body Control Module (BCM) via hard wired connec-
tions. When the memory system is in ªsetº mode a
chime will be generated by the BCM.
Fig. 4 REMOVING SWITCH CONTROL KNOBS -
TYPICAL
Fig. 5 MEMORY SWITCH LOCATION
1 - MEMORY SWITCH
2 - SWITCH BEZEL
8N - 36 POWER SEAT SYSTEMRS
SEAT SWITCH (Continued)

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CHRYSLER CARAVAN 2005 Service Manual DIAGNOSIS AND TESTING
MEMORY SWITCH
(1) Remove the memory switch from the drivers
door panel (Refer to 8 - ELECTRICAL/POWER
SEATS/MEMORY SET SWITCH - REMOVAL).
(2) Using an ohmmeter, check the continu

DIAGNOSIS AND TESTING
MEMORY SWITCH
(1) Remove the memory switch from the drivers
door panel (Refer to 8 - ELECTRICAL/POWER
SEATS/MEMORY SET SWITCH - REMOVAL).
(2) Using an ohmmeter, check the continuity of the
memory select switch MUX circuit between the C2
wire harness connector for the Body Control Module
(BCM) and the wire harness connector for the mem-
ory switch. There should be continuity. If OK, go to
Step 3. If not OK, repair the open or shorted MUX
circuit as required.
(3) Using an ohmmeter, check the continuity of the
memory select switch return circuit between the C2
wire harness connector for the BCM and the wire
harness connector for the memory switch. There
should be continuity. If OK, go to Step 4. If not OK,
repair the open or shorted return circuit as required.
(4) Using an ohmmeter, test the resistances of the
memory switch, refer to the MEMORY SWITCH
TEST TABLE. If OK, (Refer to 8 - ELECTRICAL/
POWER SEATS - DIAGNOSIS AND TESTING -
MEMORY SYSTEM). If not OK, replace the memory
switch, (Refer to 8 - ELECTRICAL/POWER SEATS/
MEMORY SET SWITCH - REMOVAL).
MEMORY SWITCH TEST TABLE
MEMORY
SWITCH
POSITIONRESISTANCE
BETWEEN
PINSRESISTANCE
RANGE
(OHMS)
NEUTRAL 1&2 24650 5%
(24.65 k)
MEMORY 1 1&2 6850 5%
(6.85 k)
MEMORY 2 1&2 2100 5%
(2.10 k)
SET 1&2 4490 5%
(4.49 k)
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the front door trim panel switch bezel
from the driver side front door. Using a thin flat-
bladed pry tool, gently pry the switch bezel away
from the drivers door trim panel.
(3) Disconnect the memory switch wire harness
connector from the memory switch.
(4) Remove the two screws that secure the memory
switch to the back of the driver side front door trim
panel switch bezel.
(5) Remove the memory switch.
INSTALLATION
(1) Position the memory switch and install and
tighten the two screws that secure the memory
switch to the back of the driver side front door trim
panel switch bezel. Tighten the screws to 2.2 N´m (20
in. lbs.).
(2) Reconnect the memory switch wire harness
connector to the memory switch.
(3) Install the trim panel switch bezel onto the
driver side front door.
(4) Reconnect the battery negative cable.
POWER SEAT TRACK
DESCRIPTION
The power seat option includes an electrically oper-
ated power seat track located under the front seat. If
equipped with Memory System, the front power seat
track on the driver side of the vehicle also provides
the mounting location for the Memory Seat/Mirror
Module (MSMM). The power seat circuit breakers are
mounted on the rear of the power seat track, just
behind the seat rear trim panel. The lower half of the
power seat track is secured to the floor panel via four
studs and nuts that must be accessed from the
underside of the vehicle. Four bolts secure the bot-
tom of the seat cushion pan to the upper half of the
power seat track unit. Four additional bolts secure
the seat back frame to the power seat track unit.
The eight-way power seat track unit includes four
reversible electric motors that are secured to the
upper half of the track unit. Each motor moves the
seat adjuster through a combination of worm-drive
gearboxes and screw-type drive units. Each of the
four power seat track motors used on models
equipped with the optional memory system incorpo-
rate a position potentiometer integral to the motor
assembly, which electronically monitors the motor
position. This enables the memory system to function
by referencing the motor positions programmed into
the memory seat/mirror module.
The front and rear of the seat are operated by two
separate vertical adjustment motors. These motors
can be operated independently of each other, tilting
the entire seat assembly forward or rearward. They
can also be operated in unison by selecting the
proper power seat switch functions, which will raise
or lower the entire seat assembly. A third motor is
the horizontal adjustment motor, which moves the
seat track in the forward and aft directions. The
forth motor is the recliner adjustment motor, which
moves the seat back in the forward and rearward
directions.
The four-way power seat track unit includes two
reversible electric motors that are secured to the
RSPOWER SEAT SYSTEM8N-37
MEMORY SWITCH (Continued)

Page 461 of 2339

CHRYSLER CARAVAN 2005 Service Manual upper half of the track unit. Each motor moves the
seat adjuster through a combination of worm-drive
gearboxes and screw-type drive units. The horizontal
adjustment motor moves the seat track in the f

upper half of the track unit. Each motor moves the
seat adjuster through a combination of worm-drive
gearboxes and screw-type drive units. The horizontal
adjustment motor moves the seat track in the for-
ward and aft directions. The recliner adjustment
motor moves the seat back in the forward and rear-
ward directions.
The power seat track unit cannot be repaired, and
is serviced only as a complete unit. If any component
in this unit is faulty or damaged, the entire power
seat track unit must be replaced.
OPERATION
When the power seat switch control knob or knobs
are actuated, a battery feed and a ground path are
applied through the switch contacts to the power seat
track or recliner adjuster motor. The selected
adjuster motor operates to move the seat track or
recliner through its drive unit in the selected direc-
tion until the switch is released, or until the travel
limit of the adjuster is reached. When the switch is
moved in the opposite direction, the battery feed and
ground path to the motor are reversed through the
switch contacts. This causes the adjuster motor to
run in the opposite direction.
No power seat switch should be held applied in any
direction after the adjuster has reached its travel
limit. The power seat adjuster motors each contain a
self-resetting circuit breaker to protect them from
overload. However, consecutive or frequent resetting
of the circuit breaker must not be allowed to con-
tinue, or the motor may be damaged.
DIAGNOSIS AND TESTING
POWER SEAT TRACK
WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
UTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
Actuate the power seat switch to move the power
seat track adjusters in each direction. The power seat
track adjusters should move in each of the selected
directions. If a power seat track adjuster operates in
one direction only, move the adjuster a short distance
in the opposite direction and test again to be certainthat the adjuster is not at its travel limit. If the
power seat track adjuster still operates in one direc-
tion only, (Refer to 8 - ELECTRICAL/POWER
SEATS/DRIVER SEAT SWITCH - DIAGNOSIS AND
TESTING). If the power seat track adjuster does not
operate in more than one direction, perform the fol-
lowing tests.
TESTING POWER SEAT TRACK MOTORS
(1) Check the power seat circuit breaker under the
seat. If OK, go to Step 2. If not OK, replace the
faulty power seat circuit breaker.
(2) Check for battery voltage at the power seat cir-
cuit breaker under the seat. If OK, go to Step 3. If
not OK, repair the open fused B(+) circuit to the fuse
in the Integrated Power Module (IPM) as required.
(3) Remove the outboard seat cushion side cover,
(Refer to 23 - BODY/SEATS/SEAT CUSHION SIDE
COVERS - REMOVAL). Disconnect the wire harness
connector from the power seat switch. Check for bat-
tery voltage at the fused B(+) circuit cavity of the
power seat switch wire harness connector. If OK, go
to Step 4. If not OK, repair the open fused B(+) cir-
cuit to the power seat circuit breaker under the seat
as required.
(4) Check for continuity between the ground cir-
cuit cavity of the power seat switch wire harness con-
nector and a known good ground. There should be
continuity. If OK, go to Step 5. If not OK, repair the
open ground circuit as required.
(5) Test the power seat switch, (Refer to 8 - ELEC-
TRICAL/POWER SEATS/DRIVER SEAT SWITCH -
DIAGNOSIS AND TESTING). If the switch tests OK,
test the circuits of the power seat wire harness
between the inoperative power seat track adjuster
motor and the power seat switch for shorts or opens.
If the circuits check OK, replace the faulty power
seat track unit. If the circuits are not OK, repair the
power seat wire harness as required.
REMOVAL
WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
UTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
8N - 38 POWER SEAT SYSTEMRS
POWER SEAT TRACK (Continued)

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CHRYSLER CARAVAN 2005 Service Manual (2) Remove the appropriate seat from the vehicle
and place it on a clean work surface, (Refer to 23 -
BODY/SEATS/SEAT - REMOVAL).
(3) Remove the Memory Seat/Mirror Module
(MSMM) mounting fasteners (if

Page 463 of 2339

CHRYSLER CARAVAN 2005 Service Manual POWER SLIDING DOOR SYSTEM
TABLE OF CONTENTS
page page
POWER SLIDING DOOR SYSTEM
DESCRIPTION.........................40
OPERATION...........................41
DIAGNOSIS AND TESTING
POWER SLIDING DOOR S

POWER SLIDING DOOR SYSTEM
TABLE OF CONTENTS
page page
POWER SLIDING DOOR SYSTEM
DESCRIPTION.........................40
OPERATION...........................41
DIAGNOSIS AND TESTING
POWER SLIDING DOOR SYSTEM........42
STANDARD PROCEDURE
POWER SLIDING DOOR LEARN CYCLE....48
PUSH-PIN GROMMET REPLACEMENT.....48
POWER SLIDING DOOR ADJUSTMENT....49
LATCH
DESCRIPTION.........................49
OPERATION...........................49
REMOVAL.............................49
INSTALLATION.........................50
SLIDING DOOR MOTOR
DESCRIPTION.........................51
OPERATION...........................51
REMOVAL.............................51
INSTALLATION.........................51
FULL OPEN SWITCH
DESCRIPTION.........................52
OPERATION...........................52
B-PILLAR SWITCH
DESCRIPTION.........................52OPERATION...........................52
REMOVAL.............................52
INSTALLATION.........................52
LOWER DRIVE UNIT
DESCRIPTION.........................53
OPERATION...........................53
REMOVAL.............................53
INSTALLATION.........................54
FLEX DRIVE
DESCRIPTION.........................55
OPERATION...........................55
REMOVAL.............................55
INSTALLATION.........................56
LOWER DRIVE UNIT TRACK & RACK
DESCRIPTION.........................57
OPERATION...........................57
REMOVAL.............................57
INSTALLATION.........................58
WIRING HARNESS
DESCRIPTION.........................59
OPERATION...........................59
REMOVAL.............................59
INSTALLATION.........................59
POWER SLIDING DOOR
SYSTEM
DESCRIPTION
Some vehicles are equipped with a power sliding
door system. Vehicles may be equipped with only a
right side power sliding door or a right and left side
power sliding doors. The components of the power
sliding door system are:
²Door motor assembly
²Latch assembly
²Sliding door control module
²Lower drive unit assembly
²Flex drive assembly
²Wire harness and track
²Lower drive unit track and rack assembly
²Full open switch
²B-pillar switch
²Overhead console switch
²Key fob switches (Fig. 1)
²Pawl switch
²Ratchet switch
²Child lockout and handle switchesEach power sliding door has its own door control
module, located in the center of the door behind the
door trim panel. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/DOOR CONTROL
MODULE - DESCRIPTION) The power sliding door
motor is located in the front portion of the door, on
the inner door panel sheet metal. The latch assembly
is located in the rear of the power sliding door, near
the body line. The lower drive unit is attached to the
lower door hinge. The flex drive assembly connects
the door motor to the lower drive unit. The wire har-
ness and track and the lower drive unit track are vis-
ible with the door open in the lower door sill area.
The power sliding door full open switch is located
under the lower drive unit and is part of the hold
open latch assembly. The pawl, ratchet, handle and
child lockout switches are all located on the power
sliding door latch assembly. The B-pillar switch is an
open and close command switch located on the inte-
rior B-pillar trim. The overhead console switch, is an
open and close command switch located in the vehi-
cle's overhead console.
Software technology has enabled the power sliding
door control module to detect resistance to door
8N - 40 POWER SLIDING DOOR SYSTEMRS

Page 464 of 2339

CHRYSLER CARAVAN 2005 Service Manual travel. This allows the power sliding door to stop and
reverse direction any time an obstruction is felt or
any of the command switches are operated (while
closing only). Battery voltage is supplied t

travel. This allows the power sliding door to stop and
reverse direction any time an obstruction is felt or
any of the command switches are operated (while
closing only). Battery voltage is supplied to the power
sliding door system through a 40 amp fuse, located in
the Integrated Power Module (IPM) assembly. The
child lockout switch prevents children from opening
or actuating the power sliding door system when
desired. In the unlikely event that the power sliding
door system develops a fault, the power sliding door
can still be operated manually from the interior or
exterior door handle, just like a standard manual
sliding door.
The power sliding door control module communi-
cates on the Programmable Communication Interface
(PCI) Data Bus Circuit. Therefore, the power sliding
door control module can generate and store its own
Diagnostic Trouble Codes (DTC). A diagnostic scan
tool, such as the DRB IIItis used to read and diag-
nose these trouble codes.
NOTE: It may be possible to generate Sliding Door
Diagnostic Trouble Codes during normal power
sliding door operation. Refer to the Body Diagnos-
tic Manual for a complete list of diagnostic routines.
For additional information, (Refer to 8 - ELECTRI-
CAL/POWER DOORS - OPERATION). Refer to the
appropriate wiring information for complete circuit
schematic or connector pin-out information.WARNING: BE CERTAIN TO READ ALL WARNINGS
AND CAUTIONS IN POWER SLIDING DOOR OPER-
ATION BEFORE ATTEMPTING ANY SERVICE OF
THE POWER SLIDING DOOR SYSTEM OR COMPO-
NENTS.
OPERATION
With the push of a power sliding door open/close
command switch (key fob, overhead console or B-pil-
lar mounted) a signal is sent out to the Body Control
Module (BCM). The BCM then sends a signal out on
the Programmable Communication Interface (PCI)
Data Bus circuit to the power sliding door module.
The power sliding door module then signals the
power sliding door latch to release the door to the
unlatched and movable position. The motor then
starts an open cycle.
During the door cycle, if the power sliding door
module detects sufficient resistance to door travel,
such as an obstruction in the door's path, the power
sliding door module will immediately stop door move-
ment and reverse door travel to the full open or
closed position. The ability for the power sliding door
module to detect resistance to door travel is accom-
plished by hall effect sensors detecting the door
motor speed.
The power sliding door control module has the abil-
ity to learn. Anytime a door is opened or closed using
the power sliding door system the module learns
from its cycle. If a replacement power sliding door
component is installed or a door adjustment is made,
the module must re-learn the effort required to open
or close the door. A learn cycle can be performed with
a complete cycle of the door, using any one of the
command switches or with the DRB IIIt, or equiva-
lent scan tool. (Refer to 8 - ELECTRICAL/POWER
DOORS - STANDARD PROCEDURE - LEARN
CYCLE) for detailed instructions.
The power sliding door system is designed with a
number of system inhibitors. These inhibitors are
necessary for safety and/or feasibility of the power
sliding door system. The power sliding door system
inhibitors are:
²The power sliding door must be in thefullopen
or closed position in order for the power sliding door
system to start a cycle. If the door is not in this posi-
tion (based on the input from the full open, pawl or
ratchet switches) the door control module will not
respond to command switch inputs.
²The transmission must be inpark or neutral
in order for the power sliding door system to start a
cycle.
²The child lockout switch must be in the
ªUNLOCKEDº position in order for the power sliding
door systems B-pillar switches to function.
Fig. 1 KEY FOB
1 - LEFT SLIDING DOOR SWITCH
2 - RIGHT SLIDING DOOR SWITCH
3 - LIFTGATE SWITCH
RSPOWER SLIDING DOOR SYSTEM8N-41
POWER SLIDING DOOR SYSTEM (Continued)

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