2005 CHRYSLER CARAVAN audio

(8) Remove the steering wheel using a standard
wheel puller (Fig. 5).
(9) Remove the knee blocker/steering column open-
ing cover (Refer to 23 - BODY/INSTRUMENT PAN-
EL/STEERING COLUMN OPENING COVER -
REMOVAL).(10) Remove the parking brake release handle
link.
(11) Remove the knee blocker/steering column
cover plate (Refer to 23 - BODY/INSTRUMENT PAN-
EL/KNEE BLOCKER - REMOVAL).
(12) Remove the upper shroud mounting screws
(Fig. 6). Using hands on each side of the column,
gently press inward at seams between the two
shrouds at points of contact to disengage inner lock-
ing tabs, then remove upper shroud. If the vehicle is
equipped with traction control, the lower shroud will
need to be removed once the upper shroud is unfas-
tened in order to disconnect the traction control wir-
Fig. 3 Driver Airbag Wiring Connections
1 - DRIVER AIRBAG
2 - SQUIB CONNECTORS
3 - SPEED CONTROL/HORN WIRING CONNECTOR
4 - CLOCKSPRING
Fig. 4 Steering Wheel Mounting
1 - STEERING WHEEL
2 - REMOTE AUDIO CONTROL WIRING CONNECTOR (IF
EQUIPPED)
3 - RETAINING BOLT
4 - DAMPER
Fig. 5 Steering Wheel Removal
1 - STEERING WHEEL
2 - PULLER
Fig. 6 Upper Shroud Mounting
1 - UPPER SHROUD
2 - LOWER SHROUD
3 - MOUNTING SCREWS
19 - 12 COLUMNRS
COLUMN (Continued)

(19) Position the lower shroud on the column (Fig.
8). Install the lower shroud mounting screw. Tighten
the screw to 2 N´m (17 in. lbs.) torque.
(20) If equipped with adjustable pedals, Connect
the wiring connector for the switch (Fig. 7) to the col-
umn wiring harness.
(21) Position the upper shroud on top of the lower
shroud and snap it into place. Install the upper
shroud mounting screws (Fig. 6). Tighten the screws
to 2 N´m (17 in. lbs.) torque.
(22) Inspect shroud mating surfaces for excessive
gaps and correct as necessary.
(23) Install the cluster trim bezel (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
INSTALLATION).
(24) Install the knee blocker/steering column cover
plate. (Refer to 23 - BODY/INSTRUMENT PANEL/
KNEE BLOCKER - INSTALLATION)
(25) Install the parking brake handle link.
(26) Install the knee blocker/steering column open-
ing cover. (Refer to 23 - BODY/INSTRUMENT PAN-
EL/STEERING COLUMN OPENING COVER -
INSTALLATION)
(27) Align the splines and install the steering
wheel on the steering column shaft(Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(28) Install the damper over the steering column
shaft (Fig. 4).
(29) Install the steering wheel retaining bolt (Fig.
4). Tighten the bolt to 61 N´m (45 ft. lbs.) torque.
(30) If the steering wheel is equipped with remote
audio controls, connect the wiring connector to the
clockspring (Fig. 4).
(31) Connect the two squib connectors to the
driver airbag (Fig. 3). The connectors are color coded
to avoid connector mix-up.
(32) Connect the speed control and horn connector
to the clockspring (Fig. 3).
(33) Install the airbag to the steering wheel.
Install the driver airbag mounting screws (Fig. 2).
Tighten screws to 10 N´m (90 in. lbs.) torque.
(34) Connect the battery negative (ground) cable to
battery post following special Diagnosis And Testing
procedure. (Refer to 8 - ELECTRICAL/RESTRAINTS
- DIAGNOSIS AND TESTING)
(35) Check operation of all steering column
mounted components.
(36) Road test vehicle to ensure proper operation
of steering.SPECIFICATIONS
COLUMN FASTENER TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Driver Airbag Mounting Screws 10 Ð 90
Multi-Function Switch Mounting
Housing Set-Screw14 Ð 124
Shroud Attaching Screws - Fixed 3 Ð 23
Shroud Attaching Screws -
Lower/Upper2Ð17
SKIM Attaching Screw 4 Ð 30
Steering Column Coupling Pinch
Bolt28 Ð 250
Steering Column Mounting Nuts 12 Ð 105
Steering Wheel Retaining Bolt 61 45 Ð
IGNITION SWITCH
REMOVAL
The ignition switch attaches to the lock cylinder
housing on the end opposite the lock cylinder (Fig.
20). For ignition switch terminal and circuit identifi-
cation, refer to the appropriate wiring information.
The wiring information includes wiring diagrams,
proper wire and connector repair procedures, further
details on wire harness routing and retention, as well
as pin-out and location views for the various wire
harness connectors, splices and grounds.
(1) Disconnect negative cable from battery.
Fig. 20 Ignition SwitchÐViewed From Below
Column
1 - IGNITION SWITCH
2 - LOCK CYLINDER HOUSING
3 - RETAINING TABS
RSCOLUMN19-17
COLUMN (Continued)

(2) Remove the driver airbag mounting screws
(Fig. 40).
(3) Lift the airbag from its mount and disconnect
two airbag squib, speed control and horn connectors
(Fig. 41). Remove driver airbag. Properly store the
driver airbag out of the way. (Refer to 8 - ELECTRI-
CAL/RESTRAINTS - WARNING)(4) Remove the steering wheel retaining bolt (Fig.
42).
(5) Remove damper (Fig. 42).
(6) If equipped, disconnect the remote audio con-
trol switch wiring from the clockspring (Fig. 42).
CAUTION: Do not bump or hammer on steering col-
umn or steering column shaft when removing steer-
ing wheel from steering column shaft.
CAUTION: When installing steering wheel puller
bolts in steering wheel, do not thread bolt into
steering wheel more than a half inch. If the bolts
are threaded into the steering wheel more than a
half inch they will contact and damage the clock-
spring.
(7) While holding the steering wheel firmly in the
straight-aheadposition, remove the steering wheel
from steering column shaft using a steering wheel
puller (Fig. 43).
(8) Remove the puller from the steering wheel.
(9) If the remote audio switches need removed
from the steering wheel, (Refer to 8 - ELECTRICAL/
AUDIO/REMOTE SWITCHES - REMOVAL).
INSTALLATION
(1) If the remote radio switches need to be
installed on the steering wheel, (Refer to 8 - ELEC-
TRICAL/AUDIO/REMOTE SWITCHES - INSTALLA-
TION).
CAUTION: Do not force steering wheel onto steer-
ing column shaft by driving it on. Pull steering
wheel down onto shaft using only the steering
wheel retaining nut.
Fig. 41 Driver Airbag Wiring Connections
1 - DRIVER AIRBAG
2 - SQUIB CONNECTORS
3 - SPEED CONTROL/HORN WIRING CONNECTOR
4 - CLOCKSPRING
Fig. 42 Steering Wheel Mounting
1 - STEERING WHEEL
2 - REMOTE AUDIO CONTROL WIRING CONNECTOR (IF
EQUIPPED)
3 - RETAINING BOLT
4 - DAMPER
Fig. 43 Steering Wheel Removal
1 - STEERING WHEEL
2 - PULLER
19 - 24 COLUMNRS
STEERING WHEEL (Continued)

(2) Feed and route wiring from clockspring
through upper access hole in steering wheel.
(3) Align master serrations in steering wheel with
omitted spline on steering column shaft (at 12 o'clock
position). Slide the steering wheel onto the steering
column shaft by hand (Fig. 42). Use care not to pinch
any wiring.
NOTE: Before installing the damper on the steering
wheel, inspect the damper to ensure the rubber iso-
lator on the damper is not deteriorated or damaged.
If the damper is installed with a damaged isolator, a
buzz, squeak or rattle condition may develop.
(4) Install the damper on the steering wheel (Fig.
42).
(5) Install the steering wheel retaining bolt.
Tighten the steering wheel retaining bolt to 61 N´m
(45 ft. lbs.) torque.(6) If the steering wheel is equipped with remote
audio controls, connect the wiring connector to the
clockspring (Fig. 42).
(7) Connect the airbag squib wiring connectors to
the airbag and the horn and speed control switch
connector to the clockspring (Fig. 41).
(8) Install the driver airbag in the steering wheel
(Fig. 40). Install and tighten the airbag attaching
screws to 10 N´m (90 in. lbs.) torque.
(9) Connect the battery negative (ground) cable to
battery post following special Diagnosis And Testing
procedure. (Refer to 8 - ELECTRICAL/RESTRAINTS
- DIAGNOSIS AND TESTING)
(10) Check operation of all steering wheel mounted
components.
(11) Road test vehicle to ensure proper operation of
steering.
RSCOLUMN19-25
STEERING WHEEL (Continued)

(4) Place front door trim panel in position on door.
(5) Install trim panel into inner belt molding at
top of door.
(6) Install clips to attach door trim to door frame
around perimeter of panel.
(7) If equipped, install screw to attach door trim to
door panel behind inside latch release handle.
(8) If equipped, connect power switch into wire
connector.
(9) Place power accessary switch in position on
door trim.
(10) Connect wire connector into memory seat/mir-
ror switch and install switch into trim panel.
(11) Install screws to attach accessary switch
panel to door trim.
(12) Install screw cover into switch panel.
(13) If equipped, install window crank.
(14) If equipped, install screws to attach trim
panel to door inside map pocket.
(15) If equipped, install screw to attach door pull
cup to inner door panel.
(16) If equipped, install screws to attach door
assist handle to inner door panel.
(17) Connect wire connector into courtesy lamp.
(18) Install lamp in door trim.
(19) Install switch bezel.
WATERSHIELD
REMOVAL
(1) Remove door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(2) Remove the front door speaker. (Refer to 8 -
ELECTRICAL/AUDIO/SPEAKER - REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
INSTALLATION
(1) Insure that enough adhesive remains to
securely retain the water dam. Replace as necessary.
(2) Place the shield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(3) Install the front door speaker. (Refer to 8 -
ELECTRICAL/AUDIO/SPEAKER - INSTALLATION)
(4) Install door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
WINDOW CRANK
REMOVAL
(1) Using a window crank removal tool, disengage
clip attaching window crank to regulator shaft (Fig.
13).
NOTE: Wrap a shop towel around the window crank
to catch the clip when it springs out.
(2) Pull window crank from regulator shaft.
INSTALLATION
(1) Place the clip on to the window crank handle.
(2) Position window crank to regulator shaft.
(3) Push window crank onto regulator shaft to
engage retaining clip.
EXTERIOR HANDLE
REMOVAL
(1) Roll door glass up.
(2) Remove the watershield as necessary to gain
access to the outside door handle. (Refer to 23 -
BODY/DOOR - FRONT/WATERSHIELD -
REMOVAL)
(3) Through access hole at rear of inner door
panel, disconnect Vehicle Theft Security System
(VTSS) switch connector from door harness, if
equipped.
(4) Disengage push in fasteners attaching VTSS
switch harness to inner door reinforcement bar, if
equipped.
(5) Disengage clip holding door latch linkage to
door latch (Fig. 11).
(6) Remove latch linkage from latch.
Fig. 13 WINDOW CRANK - TYPICAL
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
RSDOOR - FRONT23-21
TRIM PANEL (Continued)

INSTRUMENT PANEL TOP PAD
ASSEMBLY
REMOVAL
(1)Remove the instrument cluster (Fig. 19). (Refer to 8
- ELECTRICAL/INSTRUMENT CLUSTER - REMOVAL)
(2) Remove the message center (Fig. 19). (Refer to
8 - ELECTRICAL/MESSAGE CENTER - REMOVAL)
(3) Remove the radio (Fig. 19). (Refer to 8 - ELEC-
TRICAL/AUDIO/RADIO - REMOVAL)
(4) Remove the headlamp switch (Fig. 19). (Refer
to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/HEADLAMP SWITCH - REMOVAL)
(5) Remove the lower console (Fig. 19). (Refer to 23
- BODY/INSTRUMENT PANEL/LOWER CONSOLE
- REMOVAL)
(6) Remove the lower panel. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER INSTRUMENT
PANEL TRIM - REMOVAL)
(7) Remove the instrument panel assembly. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL)
(8) Remove the instrument panel speakers.
(9) Remove the glove box light.
(10) Remove the two passenger air bag mounting
bolts (Fig. 20).
(11) Loosen the three passenger air bag support
bracket bolts to the hydro-form rail (Fig. 20).
(12) Remove the 16 screws along the upper edge of
the pad & panel assembly.(13) Remove the 19 screws along the lower edge of
the pad & panel assembly.
(14) Remove the pad and panel assembly (Fig. 19).
INSTALLATION
(1) Position the pan & panel assembly onto the
instrument panel support structure (Fig. 19).
(2) Install the 19 screws along the lower edge of
the pad & panel assembly (Fig. 19).
(3) Install the 16 screws along the upper edge of
the pad & panel assembly.
(4) Install and tighten the two passenger air bag
mounting screws (Fig. 20).
(5) Tighten the three passenger air bag support
bracket bolts to the hydro-form tube (Fig. 20).
(6) Install the glove box light.
(7) Install the instrument panel speakers.
(8) Install the instrument panel assembly. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION)
(9) Install the lower panel. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER INSTRUMENT
PANEL TRIM - INSTALLATION)
(10) Install the lower console. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER CONSOLE -
INSTALLATION)
(11) Install the headlamp switch. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP SWITCH - INSTALLATION)
(12) Install the radio. (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - INSTALLATION)
(13)
Install the message center. (Refer to 8 - ELEC-
TRICAL/MESSAGE CENTER - INSTALLATION)
(14) Install the instrument cluster. (Refer to 8 -
ELECTRICAL/INSTRUMENT CLUSTER - INSTAL-
LATION)
Fig. 19 INSTRUMENT PANEL ASSEMBLY
1 - INSTRUMENT CLUSTER
2 - TOP COVER
3 - PAD AND PANEL ASSEMBLY
4 - LOWER CONSOLE
5 - LOWER PANEL
6 - RADIO
7 - HEADLAMP SWITCH
Fig. 20 AIRBAG MOUNTING HARDWARE
1 - AIR BAG SCREWS (2)
2 - ELECTRICAL CONNECTOR
3 - AIR BAG SUPPORT BRACKET BOLTS (3)
4 - HYDRO-FORM INSTRUMENT PANEL SUPPORT RAIL
RSINSTRUMENT PANEL23-77

CONTROLS - REAR
TABLE OF CONTENTS
page page
A/C-HEATER CONTROL
DESCRIPTION.........................33
OPERATION...........................33
REMOVAL.............................33
INSTALLATION.........................34
BLEND DOOR ACTUATOR
DESCRIPTION.........................34
OPERATION...........................35
REMOVAL.............................35
INSTALLATION.........................35
BLOWER MOTOR RELAY
DESCRIPTION.........................36
OPERATION...........................36
REMOVAL.............................37
INSTALLATION.........................37
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION.........................37OPERATION...........................37
DIAGNOSIS AND TESTING
REAR BLOWER MOTOR RESISTOR
BLOCK.............................38
REMOVAL.............................38
INSTALLATION.........................39
MODE DOOR ACTUATOR - REAR
DESCRIPTION.........................39
OPERATION...........................39
REMOVAL.............................39
INSTALLATION.........................40
POWER MODULE - REAR BLOWER MOTOR
DESCRIPTION.........................40
OPERATION...........................40
REMOVAL.............................41
INSTALLATION.........................41
A/C-HEATER CONTROL
DESCRIPTION
The rear heating-A/C system is controlled by rota-
ry-type blower motor and temperature controls, cen-
trally mounted directly into the headliner, or if
equipped with the available DVD player, located in
the player housing. The rear A/C-heater control
allows selection of three blower motor speeds and an
Off position when the center knob on the front A/C-
heater control is set to the Rear position, otherwise
the front unit controls both front and rear heater-A/C
operation.
OPERATION
With the rear A/C-heater control active, tempera-
ture selection dictates the air distribution mode (floor
or overhead air) of the rear unit. A cool temperature
setting directs flow to the overhead outlets and a
warm temperature setting to the floor. Refer to Body
Diagnostic Procedures for further diagnostic informa-
tion.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) If the rear A/C-heater control is mounted in the
headliner, use a trim stick or another suitable wide
flat bladed tool and gently pry the top edge of the
control bezel away from the headliner far enough to
release the two snap clip retainers (Fig. 1).
(3) Pull the rear A/C-heater control and bezel
assembly rearward far enough to access the wire har-
ness connector on the back of the control.
(4) Disconnect the wire harness connector from the
rear A/C-heater control.
(5) Remove the rear A/C-heater control and bezel
assembly from the headliner.
(6) If the rear A/C-heater control is mounted in the
video screen housing, remove the housing from the
headliner (Refer to 8 - ELECTRICAL/AUDIO/VIDEO
SCREEN - REMOVAL).
(7) Remove the three screws that secure the rear
A/C-heater control to the bezel or video screen hous-
ing, depending on application and remove the control
(Fig. 2).
RSCONTROLS - REAR24-33

INSTALLATION
(1) Position the rear A/C-heater control onto the
bezel or video screen housing, depending on applica-
tion.
(2) Install the three screws that secure the rear
A/C-heater control to the bezel or video screen hous-
ing. Tighten the screws to 2 N´m (17 in. lbs.).(3) If the rear A/C-heater control is to be mounted
into the headliner, position the rear A/C-heater con-
trol near the headliner and connect the wire harness
connector to the rear of the control.
(4) Insert the locator tabs on the back of the rear
control bezel over the forward edge of the headliner
opening.
(5) Slide the rear A/C-heater control bezel forward
far enough to align the snap clips on the bezel with
the receptacles on the headliner and by using hand
pressure, press the top edge of the bezel upward
until the two snap clips fully seat into their recepta-
cles.
(6) If the rear A/C-heater control is mounted to the
video screen housing, install the video screen to the
headliner (Refer to 8 - ELECTRICAL/AUDIO/VIDEO
SCREEN - INSTALLATION).
(7) Reconnect the negative battery cable.
(8) Using the DRB-IIItscan tool, reset the Rear
Temperature Selector calibration values.
(9) Verify that the Actuator Calibration of the
Front Control has passed. If an Actuator Calibration
has not passed correct any errors before proceeding
further.
(10) Rotate the Rear Temperature Selector counter
clockwise to the Cold Position, allow the Selector to
remain in the Cold Position for 5 seconds.
(11) Rotate the Rear Temperature Selector Clock-
wise to the Hot Position, allow the Selector to remain
in the Cold Position for 5 seconds.
(12) Calibration is now complete.
BLEND DOOR ACTUATOR
DESCRIPTION
The rear blend door actuator is a reversible,
12-volt Direct Current (DC), servo motor. The single
blend door actuator is located on the outboard side of
the rear HVAC housing, below the mode door actua-
tor. The blend door actuator is mechanically con-
nected to the blend air door.
The rear blend door actuator is interchangeable
with the actuator for the mode door. Each actuator is
contained within an identical black molded plastic
housing with an integral wire connector receptacle.
Two integral mounting tabs allow the actuator to be
secured with two screws to the rear HVAC housing.
Each actuator also has an identical output shaft with
splines that connects it to the pivot or linkage of the
proper door. The rear blend door actuator does not
require mechanical indexing to the blend air door
pivot, as it is electronically calibrated by the front
heater-A/C control module.
Fig. 1 A/C-Heater Control - Rear
1 - TRIM STICK
2 - BEZEL
3 - REAR A/C-HEATER CONTROL
4 - HEADLINER
Fig. 2 Heater-A/C Control Bezel
1 - BEZEL/VIDEO SCREEN HOUSING (AS EQUIPPED)
2 - SNAP CLIP (2)
3 - REAR A/C-HEATER CONTROL
4 - SCREW (3)
5 - BEZEL LOCATOR TAB (2)
24 - 34 CONTROLS - REARRS
A/C-HEATER CONTROL (Continued)