2005 CHRYSLER CARAVAN battery location

CONDITION POSSIBLE CAUSES CORRECTION
Check for foreign matter preventing the
operation of handle assembly
Replace the handle if necessary
Inoperative latch assembly Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Replace latch assembly, if necessary
Inoperative outside handle cable
assemblyCheck cable for binding
Check cable for broken condition
Replace the cable, if necessary
Binding or sticking of components Check for foreign matter preventing the
operation of door
Establish location of binding
Replace necessary components
Sliding door will not
open/close manuallyBinding or sticking of components Establish location of binding. Disconnect flex
drive and recheck. Replace necessary
components
Inoperative latch assembly Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Replace latch assembly, if necessary
Sliding door will not
open/close under powerBinding or sticking of components Open and close door manually to assess
binding or high effort to move door. Establish
location of binding and replace necessary
components
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 latch assembly Check for blown fuse and wire connections
Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
Inoperative motor assembly Troubleshoot using body diagnostic manual
Inoperative full open switch assembly Troubleshoot using body diagnostic manual
Inoperative flex drive assembly Disconnect flex drive and check for broken
condition
Inoperative lower drive unit assembly Remove lower drive unit and check for
broken condition
8N - 44 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Wiring problems (system or vehicle) Troubleshoot using the appropriate wiring
information
Power loss during power
door operationWiring problems (system or vehicle) Troubleshoot using the appropriate wiring
information
Low battery voltage Charge battery
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 drive assembly Remove lower drive unit and check for no
drive condition
No latching in primary and/or
secondary positionsInoperative inside/outside handle
assemblyGo to that9POSSIBLE CAUSE9and review
9CORRECTIONS9
Inoperative latch assembly Check wire connections and for blown fuse
Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
Binding or sticking of components Establish location of binding and replace
necessary components
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
Door seal force too high Inspect seals for damage, mis-assembly,
foreign matter. (Refer to 8 - ELECTRICAL/
POWER DOORS - STANDARD
PROCEDURE) for door adjustment
procedure and specifications in the Body
section of the service manual for
specifications
Inoperative drive assembly Remove lower drive unit and check for no
drive condition
Inoperative striker Striker misaligned or loose
Striker damaged
Replace striker if necessary
Latch will not fully release
from primary positionInoperative latch assembly Check wire connections and for blown fuse
Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
RSPOWER SLIDING DOOR SYSTEM8N-45
POWER SLIDING DOOR 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)

CONDITION POSSIBLE CAUSES CORRECTION
Full open switch inoperative, replace hold
open latch assembly
Replace motor assembly. if necessary
Door does not stay open Inoperative hold open latch assembly Check wire/cable connections
Replace hold open latch, if necessary
Inoperative hold open latch striker Replace hold open latch striker, if necessary
High inside/outside opening
effortInoperative latch assembly Check wire connections and for blown fuse
Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
Inoperative inside/outside handle
assemblyGo to that9POSSIBLE CAUSE9and review
9CORRECTIONS9
Binding or sticking of components Establish location of binding and replace
necessary components
Door continues to cinch
closed during power modeInoperative latch assembly Check wire connections and for blown fuse
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
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
Wiring problems (system or vehicle) Troubleshoot using the appropriate wiring
information
Door continues to open
during power mode (runaway
motor)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 hold open latch assembly Check wire/cable connections
Replace hold open latch, if necessary
Inoperative drive assembly Remove lower drive unit and check for no
drive condition
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Door opens very slowly Inoperative door motor assembly Check wire/cable connections
Replace motor assembly, if necessary
RSPOWER SLIDING DOOR SYSTEM8N-47
POWER SLIDING DOOR SYSTEM (Continued)

LOWER DRIVE UNIT TRACK &
RACK
DESCRIPTION
The door track and rack assembly provides a mat-
ing rack gear (Fig. 22) for the lower drive unit to
engage. The track also accepts the lower hinge roll-
ers, which helps support the weight of the sliding
door as well as providing a smooth surface for the
hinge rollers to move upon. The lower door track is a
replaceable component.
OPERATION
With the start of a power sliding door open cycle,
the door motor drives the flex drive assembly. The
flex drive assembly drives the lower drive unit. A
metal drive gear which is part of the lower drive
unit, meshes with the door track rack teeth and
moves the sliding door into the full open position.
The same operation repeats itself, during a power
close cycle only the system rotates in the opposite
direction.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the side door sill plate, (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL).
(3) Remove the hold-open striker, (Refer to 23 -
BODY/DOORS - SLIDING/HOLD OPEN LATCH
STRIKER - REMOVAL).
(4) Position a floor jack, with a block of wood
under the leading edge of the side door to support it
(Fig. 23).
(5) Remove the lower hinge assembly from the
door, (Refer to 23 - BODY/DOORS - SLIDING/
LOWER ROLLER ARM - REMOVAL).
(6) Position the wire harness assembly out of door
opening, this will allow sufficient room to remove the
door track.
Fig. 22 RACK ACCESS HOLE LOCATIONS
1 - LOWER DOOR TRACK AND RACK ASSEMBLY
2 - WIRE HARNESS
3 - RACK ACCESS HOLE SEALING PATCHES
4 - LOWER DRIVE UNIT COVER
Fig. 23 Supporting Sliding Door
RSPOWER SLIDING DOOR SYSTEM8N-57

This sensor is integral to the passenger side front
seat belt lower anchor which is secured to the lower
B-pillar, on the passenger side (Fig. 6). The belt ten-
sion sensor consists of a molded plastic housing, a
metal seat belt anchor loop, and a short pigtail wire.
The electronic circuitry of the belt tension sensor is
concealed and protected within the molded plastic
housing.
The belt tension sensor cannot be repaired and, if
faulty or damaged, the entire passenger side front
seat belt and retractor unit must be replaced (Refer
to 8 - ELECTRICAL/RESTRAINTS/SEAT BELT
OUTBOARD FRONT - REMOVAL).
OPERATION
The belt tension sensor is designed to sense the
relative cinch load applied to the passenger side front
seat belt, which provides a logic input to the micro-
processor of the Occupant Classification Module
(OCM). When a load is applied to the seat belt, the
changes in the load are measured by the belt tension
sensor through the seat belt lower anchor. As the
load changes, the circuitry of the belt tension sensor
changes the output voltage of the sensor.
The belt tension sensor receives a nominal five
volts and a ground from the OCM. The OCM then
monitors the belt tension sensor output voltage.
WARNING: Do not connect the battery before per-
forming the OCS Verification Test using the scantool and the appropriate diagnostic information.
Personal injury or death may occur.
For further diagnosis and testing of the belt ten-
sion sensor, the OCM, and related occupant classifi-
cation system components, use a scan tool and the
appropriate diagnostic information.
CHILD RESTRAINT ANCHOR
DESCRIPTION
TheLower Anchors and Tether for CHildren,
or LATCHchild restraint anchorage system provides
for the installation of suitable child restraints in cer-
tain seating positions without using the seat belt pro-
vided for that seating position. The second seat in
these models are equipped with a fixed-position child
restraint upper tether anchor (Fig. 7) and child
restraint lower anchors (Fig. 8). The third seat is
equipped with only a fixed-position child restraint
upper tether anchor in the middle seating position.
Export vehicles are equipped with fixed-position child
restraint upper tether anchors only.
Fig. 6 BELT TENSION SENSOR LOCATION
1 - A-PILLAR
2 - SEAT BELT ANCHOR/BELT TENSION SENSOR
3 - BELT TENSION SENSOR CONNECTOR
Fig. 7 CHILD RESTRAINT UPPER TETHER/ANCHOR
- 2ND ROW
Fig. 8 CHILD RESTRAINT LOWER ANCHORS
SECOND ROW
RSRESTRAINTS8O-9
BELT TENSION SENSOR (Continued)

As the airbag cushion inflates it will drop down
from the roof rail between the edge of the headliner
and the side glass/body pillars to form a curtain-like
cushion to protect the vehicle occupants during a side
impact collision. The front and rear tethers keep the
side curtain bag taut, thus ensuring that the bag will
deploy in the proper position. Following the airbag
deployment, the airbag cushion quickly deflates by
venting the inert gas through the loose weave of the
cushion fabric, and the deflated cushion hangs down
loosely from the roof rail.
REMOVAL
(1) Open hood, disconnect and isolate the battery
negative cable.
(2)
WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to
do so may result in accidental airbag deployment,
personal injury or death.
Fig. 13 CURTAIN AIRBAG LOCATION - TYPICAL
Fig. 14 HEAD IMPACT COUNTER MEASURES
1 - SLIDING DOOR OPENING/ROOF RAIL
2 - CURTIAN AIRBAG
3 - HEAD IMPACT COUNTER MEASURES
8O - 14 RESTRAINTSRS
CURTAIN AIRBAG (Continued)

INSTALLATION
(1) Position curtain airbag over retaining holes in
roof rail and firmly snap into place (Fig. 17).
(2) Install the curtain airbag retaining bolts (Fig.
17).
(3) Engage the side curtain airbag front tether in
the A-pillar and install retaining bolt (Fig. 16).
(4) Install the bolt in the curtain airbag inflator
mounting bracket (Fig. 18).
(5) Install the retaining bolts at the d-pillar (Fig.
19).
(6) Connect the curtain airbag squib connector
(Fig. 15).
(7) Install the headliner into the vehicle (Refer to
23 - BODY/INTERIOR/HEADLINER - INSTALLA-
TION).
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
(8) Verify vehicle and system operation.
(9) Close hood.
DRIVER AIRBAG
DESCRIPTION
The injection molded, thermoplastic driver airbag
protective trim cover is the most visible part of the
driver airbag. The driver airbag is located in the cen-
ter of the steering wheel, where it is secured to the
steering wheel armature. Concealed beneath the
driver airbag trim cover are the horn switch, thefolded airbag cushion, the airbag cushion retainer,
the airbag housing, the airbag inflator, and the
retainers that secure the inflator to the airbag hous-
ing. The airbag cushion, housing, and inflator are
secured within an integral receptacle molded into the
back of the trim cover.
The resistive membrane-type horn switch is
secured with heat stakes to the inside surface of the
driver airbag trim cover, between the trim cover and
the folded airbag cushion. The horn switch ground
pigtail wire has a female spade terminal connector
that receives a path to ground through a male spade
terminal that is integral to the driver airbag housing
stamping and is located near the upper right corner
on the back of the housing. The horn switch feed pig-
tail wire has a white, molded plastic insulator that is
secured by an integral retainer to a mounting hole
located near the lower left corner on the back of the
housing, and is connected to the vehicle electrical
system through a take out and connector of the steer-
ing wheel wire harness.
The airbag is a multistage unit that deploys with
less force than those previously used. The airbag
inflator is a dual-initiator, non-azide, pyrotechnic-
type unit with four mounting studs and is secured to
the stamped metal airbag housing using four hex
nuts with washers. Two keyed and color-coded con-
nector receptacles on the driver airbag inflator con-
nect the two inflator initiators to the vehicle
electrical system through two yellow or black-jack-
eted, two-wire pigtail harnesses of the clockspring.
The driver airbag, trim cover, and horn switch unit
cannot be repaired, and must be replaced if deployed
or in any way damaged.
OPERATION
The Driver Airbag Trim Cover contains the horn
switch, inflator device, and a fabric bag. The driver
airbag trim cover/horn switch is not serviced sepa-
rately from the driver airbag components.
When the front airbag system is deployed, the fol-
lowingMUSTbe replaced:
²Complete Steering Column Assembly
²Lower Steering Column Coupler
²Steering Wheel.
²Clockspring.
²Driver Airbag
²Passenger Airbag
²Knee Blocker Airbag
²Upper Instrument Panel with Pad
²Front Seat Belt Buckles, both driver and passen-
ger with integral tensioners.
Fig. 19 CURTAIN AIRBAG D-PILLAR ATTACHMENT
1 - CURTAIN AIRBAG D-PILLAR ATTACHMENT LOCATIONS
2 - D-PILLAR
3 - ROOF RAIL AT REAR QUARTER GLASS
8O - 16 RESTRAINTSRS
CURTAIN AIRBAG (Continued)