2005 CHRYSLER CARAVAN Service Manual

oil capacity fuse box timing belt open hood radio controls spark plugs replace

Page 529 of 2339

CHRYSLER CARAVAN 2005 Service Manual the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(11) Install D-pillar trim cover.

the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(11) Install D-pillar trim cover.
(12) Install second seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(13) Install second seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(14) Install upper liftgate trim.
(15) Install liftgate sill plate.
(16) Install first row seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(17) Install first row seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(18) Install first and second row seats.
SEAT BELT & RETRACTOR -
SECOND ROW - LEFT
OUTBOARD
REMOVAL
(1) Remove first and second row seats.
(2) Remove first row seat belt lower anchor bolt.
(3) Remove first row seat belt upper anchor bolt.
(4) Remove liftgate sill plate.
(5) Remove upper liftgate trim.
(6) Remove second seat belt lower anchor bolt.
(7) Remove second seat belt upper anchor bolt.
(8) Remove D-pillar trim cover.
(9) Disconnect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(10) Remove quarter trim bolster.
(11) Remove quarter trim panel screws.
(12) Remove quarter trim panel.
(13) Remove retractor retaining bolt.
(14) Remove second row seat belt and retractor
from vehicle.
INSTALLATION
(1) Install second row seat belt and retractor.
Torque bolt to 39 N´m (29 ft. lbs.).
(2) Install quarter trim panel.
(3) Install quarter trim panel screws.
(4) Install quarter trim bolster.
(5) Connect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(6) Install D-pillar trim cover.
(7) Install second seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(8) Install second seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(9) Install upper liftgate trim.
(10) Install liftgate sill plate.
(11) Install first row seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(12) Install first row seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(13) Install first and second row seats.
Fig. 53 REAR HVAC MOUNTING
1 - REAR HVAC MODULE MOUNTING
2 - REAR EVAPORATOR LOWER HOUSING
3 - REAR EVAPORATOR UPPER HOUSING
8O - 42 RESTRAINTSRS
SEAT BELT & RETRACTOR - SECOND ROW - RIGHT OUTBOARD WITH REAR HVAC - LWB (Continued)

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CHRYSLER CARAVAN 2005 Service Manual SEAT BELT TENSIONER
DESCRIPTION
The seat belt system incorporates Seat Belt Ten-
sioners. The tensioner is designed to hold the occu-
pant in their respective seat by retracting the seat
belt up to fo

SEAT BELT TENSIONER
DESCRIPTION
The seat belt system incorporates Seat Belt Ten-
sioners. The tensioner is designed to hold the occu-
pant in their respective seat by retracting the seat
belt up to four inches. They are integral to the front
seat belt buckles and cannot be serviced. If found
defective they must be replaced. After an airbag
deployment, the tensioner must be replaced.
Seat Belt Tensioners supplement the dual front air-
bag system. The seat belt tensioners are integral to
the front seat belt buckles, which are secured to the
seat cushion frame on the inboard side. The seat belt
tensioners are controlled by the Occupant Restraint
Controller (ORC) and are connected to the vehicle
electrical system through the body wire harness.
The seat belt tensioners cannot be repaired and, if
faulty or damaged, the entire front seat belt buckle
must be replaced. The seat belt tensioners are not
intended for reuse and must be replaced following
any front airbag deployment.
OPERATION
WARNING: When the front airbag is deployed, the
tensioner will have deployed also and should be
replaced. Failure to do so could result in occupant
personal injury or death.
The seat belt tensioners are deployed by a signal
generated by the Occupant Restraint Controller
(ORC) through the driver or passenger seat belt ten-
sioner line 1 and line 2 (or squib) circuits. When the
ORC sends the proper electrical signal to the tension-
ers, the electrical energy generates enough heat to
initiate a small pyrotechnic gas generator.
Removing excess slack from the front seat belts not
only keeps the occupants properly positioned for an
airbag deployment following a frontal impact of the
vehicle, but also helps to reduce injuries that the
occupants of the front seat might experience in these
situations as a result of a harmful contact with the
steering wheel, steering column, instrument panel
and/or windshield.
The ORC monitors the condition of the seat belt
tensioners through circuit resistance, and will illumi-
nate the airbag indicator in the ElectroMechanical
Instrument Cluster (EMIC) and store a Diagnostic
Trouble Code (DTC) for any fault that is detected.
For proper diagnosis of the seat belt tensioners, use a
scan tool and the appropriate diagnostic information.
SEAT WEIGHT BLADDER &
PRESSURE SENSOR
DESCRIPTION
Vehicles equipped with the Occupant Classification
System (OCS) have a seat weight bladder and pres-
sure sensor unit (Fig. 54) that is integral to the pas-
senger front seat cushion. The bladder is sandwiched
between the seat cushion pan and seat cushion foam.
The bladder consists of two rectangular sheets of
an elastomeric material and a molded plastic elbow
fitting. The two sheets of material are sealed
together around their perimeter and heat staked to
each other at numerous regular points within their
field. The elbow fitting is sealed to a small round
hole in the lower surface of the bladder and is
pointed downward where it passes through a clear-
ance hole in the insulator pad and extends to just
below the seat cushion. The bladder is then filled
with a silicone fluid to become a pliable, quilted
membrane.
Under the seat cushion a short tube is securely
clamped at one end to the bladder nipple, and at the
other end to a nipple on the electronic pressure sen-
sor. The sensor housing features an integral mount
that snaps over a tab integral to the stamped steel
Occupant Classification Module (OCM) mounting
bracket welded to the underside of the passenger
front seat cushion frame.
Fig. 54 SEAT WEIGHT BLADDER AND PRESSURE
SENSOR - TYPICAL
1 - FASTENER (2)
2 - BLADDER
3-PAD
4 - TUBE
5 - PRESSURE SENSOR
RSRESTRAINTS8O-43

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CHRYSLER CARAVAN 2005 Service Manual The seat weight bladder and pressure sensor can-
not be adjusted or repaired. The components of the
passenger front seat cushion of a vehicle equipped
with the OCS including the cushion frame, seat
we

Page 532 of 2339

CHRYSLER CARAVAN 2005 Service Manual SPEED CONTROL
TABLE OF CONTENTS
page page
SPEED CONTROL
DESCRIPTION..........................1
OPERATION
OPERATION..........................1
OPERATION - INTERACTIVE SPEED
CONTROL (4 Speed EATX Only).

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

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CHRYSLER CARAVAN 2005 Service Manual 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 d

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)

Page 534 of 2339

CHRYSLER CARAVAN 2005 Service Manual OPERATION
The PCM on NGC vehicles first senses that the
speed control is set. If the set speed is exceeded by
more than 4 mph (6.5 km/hr) and the throttle is
closed, the PCM on NGC vehicles causes the

OPERATION
The PCM on NGC vehicles first senses that the
speed control is set. If the set speed is exceeded by
more than 4 mph (6.5 km/hr) and the throttle is
closed, the PCM on NGC vehicles causes the trans-
axle to downshift to THIRD gear. After downshifting,
the automatic speed control resumes normal opera-
tion. To ensure that an upshift is appropriate after
the set speed is reached, the PCM on NGC vehicles
waits until the speed control system opens the throt-
tle at least 6 degrees before upshifting to OVER-
DRIVE again.
If the driver applies the brakes, canceling auto-
matic speed control operation with the transaxle still
in THIRD gear, the PCM on NGC vehicles maintains
this gear until the driver opens the throttle at least 6
degrees to avoid an inappropriate upshift. The
upshift is also delayed for 2.5 seconds after reaching
the 6 degrees throttle opening in anticipation that
the driver might open the throttle enough to require
THIRD gear. This will avoid unnecessary and dis-
turbing transmission cycling. If the automatic speed
control RESUME feature is used after braking, the
upshift is delayed until the set speed is achieved to
reduce cycling and provide better response.
DIAGNOSIS AND TESTING - ROAD TEST
Perform a vehicle road test to verify reports of
speed control system malfunction. The road test
should include attention to the speedometer. Speed-
ometer operation should be smooth and without flut-
ter at all speeds.Flutter in the speedometer indicates a problem
which might cause surging in the speed control sys-
tem. The cause of any speedometer problems should
be corrected before proceeding. Refer to the Instru-
ment Cluster for speedometer diagnosis.
If a road test verifies an inoperative system, and
the speedometer operates properly, check for:
²A Diagnostic Trouble Code (DTC). If a DTC
exists, conduct tests per the Powertrain Diagnostic
Procedures manual.
²A misadjusted brake (stop) lamp switch. This
could also cause an intermittent problem.
²Loose or corroded electrical connections at the
servo. Corrosion should be removed from electrical
terminals and a light coating of Mopar Multipurpose
Grease, or equivalent, applied.
²Leaking vacuum reservoir.
²Loose or leaking vacuum hoses or connections.
²Defective one-way vacuum check valve.
²Secure attachment at both ends of the speed
control servo cable.
²Smooth operation of throttle linkage and throttle
body air valve.
²Conduct electrical test at PCM.
²Failed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Servo Mounting Bracket
Nuts14 10.3 123.9
Servo Mounting Bracket
Bolts14 10.3 123.9
Servo Mounting Nuts 6.7 60
RSSPEED CONTROL8P-3
SPEED CONTROL (Continued)

Page 535 of 2339

CHRYSLER CARAVAN 2005 Service Manual CABLE
DESCRIPTION
The speed control servo cable is connected between
the speed control vacuum servo diaphragm and the
throttle body control linkage.
OPERATION
This cable causes the throttle control li

CABLE
DESCRIPTION
The speed control servo cable is connected between
the speed control vacuum servo diaphragm and the
throttle body control linkage.
OPERATION
This cable causes the throttle control linkage to
open or close the throttle valve in response to move-
ment of the vacuum servo diaphragm.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove speed control cable from throttle cam
by sliding clasp out hole used for throttle cable.
(3) Compress the retaining tabs on the cable and
slide cable out of bracket.
(4) Disconnect electrical connectors and vacuum
hose from servo.
(5) Remove two nuts attaching speed control cable
and mounting bracket to servo.
(6) Pull cable away from servo to expose retaining
clip and remove clip attaching cable to servo.
(7) Remove speed control cable.
INSTALLATION
(1) Slide cable into throttle cable bracket and
engage retaining tabs.
(2) Rotate the throttle cam forward to the wide
open position and install speed control cable clasp.
(3) Rotate the throttle cam forward to the wide
open position and install throttle cable clasp.
(4) Install retaining clip that attaches cable to
servo.
(5) Insert servo studs through holes in the mount-
ing bracket and speed control cable.
(6) Install nuts, tighten to 6.7 N´m (60 in. lbs.).
(7) Connect vacuum hose to servo.
(8) Connect electrical connector.
(9) Install servo and bracket and tighten nuts and
bolt.
(10) Connect negative battery cable.
SERVO
DESCRIPTION
The servo unit consists of a solenoid valve body,
and a vacuum chamber. The solenoid valve body con-
tains three solenoids:
²Vacuum
²Vent
²Dump
The vacuum chamber contains a diaphragm with a
cable attached to control the throttle linkage.
OPERATION
The PCM controls the solenoid valve body. The
solenoid valve body controls the application and
release of vacuum to the diaphragm of the vacuum
servo. The servo unit cannot be repaired and is ser-
viced only as a complete assembly.
Power is supplied to the servo by the PCM through
the brake switch. The PCM controls the ground path
for the vacuum and vent solenoids.
The dump solenoid is energized anytime it receives
power. If power to the dump solenoid is interrupted,
the solenoid dumps vacuum in the servo. This pro-
vides a safety backup to the vent and vacuum sole-
noids.
The vacuum and vent solenoids must be grounded
by the PCM to operate. When the PCM grounds the
vacuum servo solenoid, the solenoid allows vacuum
to enter the servo and pull open the throttle plate
using the cable. When the PCM breaks the ground,
the solenoid closes and no more vacuum is allowed to
enter the servo. The PCM also operates the vent sole-
noid via ground. The vent solenoid opens and closes a
passage to bleed or hold vacuum in the servo as
required.
The PCM cycles the vacuum and vent solenoids to
maintain the set speed, or to accelerate and deceler-
ate the vehicle. To increase throttle opening, the
PCM grounds the vacuum and vent solenoids. To
decrease throttle opening, the PCM removes the
grounds from the vacuum and vent solenoids.
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect the negative battery cable.
(3) Disconnect the throttle and speed control cable
ends from throttle body (Fig. 2).
(4) Depress lock tabs holding speed control and
throttle cable casing to cable mount bracket.
(5) Disconnect vacuum line from speed control
servo that leads to the battery tray/vacuum reservoir.
(6) Remove battery tray/vacuum reservoir, refer to
the Battery section for more information (Fig. 3).
(7) Remove speed control servo and bracket (Fig.
4).
(8) Disconnect wire connector from speed control
servo.
(9) Remove speed control servo.
INSTALLATION
Transfer speed control cable to replacement speed
control servo.
(1) Install retaining clip to cable at servo.
(2) Install 2 nuts at cable to servo and servo
bracket, tighten to 7 N´m (60 ins. lbs.).
(3) Connect electrical connector to servo.
8P - 4 SPEED CONTROLRS

Page 536 of 2339

CHRYSLER CARAVAN 2005 Service Manual (4) Connect vacuum line to speed control servo
that leads to the battery tray/vacuum reservoir.
(5) Install speed control servo and bracket.
(6) Install battery tray/vacuum reservoir, refer to
the Bat

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