2005 CHRYSLER CARAVAN location

HEADLAMP UNIT ADJUSTMENT
The low beam headlamp will project on the screen
upper edge of the beam (cut-off) at the horizontal
lamp centerline   50 mm (2 in.). Horizontal aim is
preset and can not be adjusted. The high beam pat-
tern should be correct when the low beams are
aligned properly (Fig. 12). To adjust headlamp verti-
cal alignment, rotate adjustment screw (Fig. 13) to
achieve the specified low beam cut-off location.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the three retaining screws (Fig. 14).
(3) Disconnect the wiring harness from the bulbs
(Fig. 15).(4) Remove wire harness retainer from back of
headlamp unit.
(5) Remove the headlamp unit.
INSTALLATION
(1) Reconnect wire harness to the bulbs.
(2) Install wire harness retainer to headlamp unit.
(3) Install the three retaining screws.
(4) Reconnect the battery negative cable.
HEADLAMP UNIT - EXPORT
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT - EXPORT
HEADLAMP UNIT ALIGNMENT PREPARATION
(1) Verify that the headlamp leveling switch is in
the ª0º position.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(6) Vehicles equipped with automatic load leveling
suspension should be driven normally for approxi-
mately 5 km (3 miles) before attempting a proper
headlamp unit alignment.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
Fig. 13 HEADLAMP UNIT ADJUSTMENT
1 - ADJUSTMENT LOCATION
2 - HEADLAMP UNIT
Fig. 14 HEADLAMP UNIT FASTENERS
1 - HEADLAMP UNIT RETAINING SCREW
2 - HEADLAMP UNIT
Fig. 15 HEADLAMP UNIT
1 - HEADLAMP UNIT
2 - HEADLAMP
3 - PARK/TURN SIGNAL LAMP
4 - WIRE HARNESS RETAINER
RSLAMPS/LIGHTING - EXTERIOR8L-15
HEADLAMP UNIT (Continued)

ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 10 meters (32.8 ft.) away from front
of headlamp lens (Fig. 16).
(2) If necessary, tape a line on the floor 10 meters
(32.8 ft.) away from and parallel to the wall.
(3) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(4) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(5) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
HEADLAMP UNIT ADJUSTMENT
The low beam headlamp will project on the screen
upper edge of the beam (cut-off) at the horizontal
lamp cut-off line   20 mm (0.75 in.). The high beam
pattern should be correct when the low beams are
aligned properly (Fig. 16). To adjust headlamp align-
ment, rotate adjustment screws (Fig. 17) to achieve
the specified low beam cut-off location.
Fig. 16 HEADLAMP UNIT ALIGNMENT SCREEN - EXPORT
1 - CENTER OF VEHICLE 5 - 10 METERS (32.8 FT.)
2 - CENTER OF HEADLAMPS 6 - HORIZONTAL CUT-OFF LINE
3 - 15É CUT-OFF LINE 7 - 100 mm (3.9 in.)
4 - FRONT OF HEADLAMP
Fig. 17 HEADLAMP UNIT ADJUSTMENT - EXPORT
1 - HEADLAMP ADJUSTMENT - HORIZONTAL
2 - HEADLAMP ADJUSTMENT - VERTICAL
8L - 16 LAMPS/LIGHTING - EXTERIORRS
HEADLAMP UNIT - EXPORT (Continued)

SELF-DIAGNOSTIC TEST
A self-diagnostic test is used to determine that the
electronics module is operating properly, and that all
the PCI data bus messages are being received for ini-
tial operation. Initiate the self-diagnostic test as fol-
lows:
(1) With the ignition switch in the Off position, on
Electronic Vehicle Information Center (EVIC) and
Compass Mini-Trip Computer (CMTC) equipped vehi-
cles simultaneously depress and hold theSTEPand
theRESETbuttons. On Compass Temperature Mod-
ule (CT) equipped vehicles depress theC/Tand the
US/Mpush buttons.
(2) Turn the ignition switch to the On position.
(3) Following completion of these tests, the elec-
tronics module will display one of the following mes-
sages:
a.Pass Self Test (EVIC only), PASS (CT,
CMTC)- The electronics module is working properly.
b.Failed Self Test (EVIC only), FAIL (CT,
CMTC)- The electronics module has an internal fail-
ure. The electronics module is faulty and must be
replaced.
NOTE: If the compass functions, but accuracy is
suspect, it may be necessary to perform a variation
adjustment. This procedure allows the compass
unit to accommodate variations in the earth's mag-
netic field strength, based on geographic location.
(Refer to 8 - ELECTRICAL/OVERHEAD CONSOLE -
STANDARD PROCEDURE - COMPASS VARIATION
ADJUSTMENT).
NOTE: If the compass reading display is blank and
only ªCALº appears in the display, demagnetizing
may be necessary to remove excessive residual
magnetic fields from the vehicle. (Refer to 8 - ELEC-
TRICAL/OVERHEAD CONSOLE - STANDARD PRO-
CEDURE - COMPASS DEMAGNETIZING).
STANDARD PROCEDURE
COMPASS CALIBRATION
CAUTION: Do not place any external magnets, such
as magnetic roof mount antennas, in the vicinity of
the compass. Do not use magnetic tools when ser-
vicing the overhead console.The electronic compass unit features a self-cali-
brating design, which simplifies the calibration pro-
cedure. This feature automatically updates the
compass calibration while the vehicle is being driven.
This allows the compass unit to compensate for small
changes in the residual magnetism the vehicle may
acquire during normal use. If the compass readings
appear to be erratic or out of calibration, perform the
following calibration procedure. Also, new service
replacement Electronic Modules (EVIC, CMTC, CT)
must have their compass calibrated using this proce-
dure. Do not attempt to calibrate the compass near
large metal objects such as other vehicles, large
buildings, or bridges; or, near overhead or under-
ground power lines.
NOTE: Whenever the compass is calibrated manu-
ally, the variance number must also be reset. (Refer
to 8 - ELECTRICAL/OVERHEAD CONSOLE - STAN-
DARD PROCEDURE - COMPASS VARIATION
ADJUSTMENT).
Calibrate the compass manually as follows:
(1) Turn the ignition switch to the On position. If
the compass/thermometer data is not currently being
displayed, momentarily depress and release the C/T
push button to reach the compass/thermometer dis-
play.
(2) On Electronic Vehicle Information Center
(EVIC) and Compass Mini-Trip Computer (CMTC)
equipped vehicles depress the Reset push button and
hold the button until ªCALº appears in the display.
This takes about ten seconds, and appears about five
seconds after ªVAR = XXº is displayed. On Compass
Temperature Module (CT) equipped vehicles depress
the C/T push button and US/M push button down
until ªCALº appears in the display. This takes about
ten seconds, and appears about five seconds after
ªVAR = XXº is displayed.
(3) Release the push button(s).
(4) Drive the vehicle on a level surface, away from
large metal objects and power lines, through three or
more complete circles at between five and eight kilo-
meters-per-hour (three and five miles-per-hour) for a
minimum of 48 seconds. The ªCALº message will dis-
appear from the display to indicate that the compass
is now calibrated.
NOTE: If the ªCALº message remains in the display,
either there is excessive magnetism near the com-
pass, or the unit is faulty. Repeat the calibration
procedure one more time.
8M - 4 OVERHEAD CONSOLERS
OVERHEAD CONSOLE (Continued)

NOTE: If the wrong direction is still indicated in the
compass display, the area selected for calibration
may be too close to a strong magnetic field. Repeat
the calibration procedure in another location.
COMPASS DEMAGNETIZING
A degaussing tool (Special Tool 6029) is used to
demagnetize, or degauss, the overhead console for-
ward mounting screw and the roof panel above the
overhead console. Equivalent units must be rated as
continuous duty for 110/115 volts and 60 Hz. They
must also have a field strength of over 350 gauss at 7
millimeters (0.25 inch) beyond the tip of the probe.
To demagnetize the roof panel and the overhead
console forward mounting screw, proceed as follows:
(1) Be certain that the ignition switch is in the Off
position, before you begin the demagnetizing proce-
dure.
(2) Connect the degaussing tool (Fig. 1) to an elec-
trical outlet, while keeping the tool at least 61 centi-
meters (2 feet) away from the compass unit.
(3) Slowly approach the head of the overhead con-
sole forward mounting screw with the degaussing
tool connected.
(4) Contact the head of the screw with the plastic
coated tip of the degaussing tool for about two sec-
onds.
(5) With the degaussing tool still energized, slowly
back it away from the screw. When the tip of the tool
is at least 61 centimeters (2 feet) from the screw
head, disconnect the tool.
(6) Place a piece of paper approximately 22 by 28
centimeters (8.5 by 11 inches), oriented on the vehicle
lengthwise from front to rear, on the center line of
the roof at the windshield header (Fig. 2). The pur-
pose of the paper is to protect the roof panel from
scratches, and to define the area to be demagnetized.
(7) Connect the degaussing tool to an electrical
outlet, while keeping the tool at least 61 centimeters
(2 feet) away from the compass unit.
(8) Slowly approach the center line of the roof
panel at the windshield header, with the degaussing
tool connected.(9) Contact the roof panel with the plastic coated
tip of the degaussing tool. Be sure that the template
is in place to avoid scratching the roof panel. Using a
slow, back-and-forth sweeping motion, and allowing
13 millimeters (0.50 inch) between passes, move the
tool at least 11 centimeters (4 inches) to each side of
the roof center line, and 28 centimeters (11 inches)
back from the windshield header.
(10) With the degaussing tool still energized,
slowly back it away from the roof panel. When the
tip of the tool is at least 61 centimeters (2 feet) from
the roof panel, disconnect the tool.
(11) Calibrate the compass and adjust the compass
variance (Refer to 8 - ELECTRICAL/OVERHEAD
CONSOLE - STANDARD PROCEDURE).
COMPASS VARIATION ADJUSTMENT
Compass variance, also known as magnetic decli-
nation, is the difference in angle between magnetic
north and true geographic north. In some geographic
locations, the difference between magnetic and geo-
graphic north is great enough to cause the compass
to give false readings. If this problem occurs, the
compass variance setting may need to be changed.
To set the compass variance:
Fig. 1 DEGAUSSING TOOL 6029
Fig. 2 ROOF DEMAGNETIZING PATTERN
RSOVERHEAD CONSOLE8M-5
OVERHEAD CONSOLE (Continued)

(1) Using the Variance Settings map, find your
geographic location and note the zone number (Fig.
3).
(2) Turn the ignition switch to the On position. If
the compass/thermometer data is not currently being
displayed, momentarily depress and release the C/T
push button to reach the compass/thermometer dis-
play.
(3) On Electronic Vehicle Information Center
(EVIC) and Compass Mini-Trip Computer (CMTC)
equipped vehicles depress the Reset push button and
hold the button down until ªVAR = XXº appears in
the display. This takes about five seconds. On Com-
pass Temperature Module (CT) equipped vehicles
depress the C/T push button and US/M push button
down until ªVAR = XXº appears in the display. This
takes about five seconds.
(4) Release the push button(s). ªVAR =XX º will
remain in the display. ªXXº equals the current vari-
ance zone setting.
(5) On Electronic Vehicle Information Center
(EVIC) and Compass Mini-Trip Computer (CMTC)
equipped vehicles momentarily depress and release
theSTEPbutton to step through the zone numbers,
until the zone number for your geographic location
appears in the display. On Compass Temperature
Module (CT) equipped vehicles depress theUS/M
push button to step through the zone numbers, until
the zone number for your geographic location
appears in the display.(6) On Electronic Vehicle Information Center
(EVIC) and Compass Mini-Trip Computer (CMTC)
equipped vehicles momentarily depress and release
theRESETpush button to enter the displayed zone
number into the EVIC/CMTC module memory. On
Compass Temperature Module (CT) equipped vehicles
depress theC/Tpush button to enter the displayed
zone number into the electronic module memory.
(7) Confirm that the correct directions are now
indicated by the compass.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the overhead console retaining screw,
located in the front of console.
(3) Grasp the sides of the overhead console and
pull straight down evenly to disengage the two snap
clips at the rear of the unit.
(4) Lower the overhead console far enough to
access the wire harness connectors.
(5) Disconnect the EVIC, CMTC or CT electronic
module and the reading/courtesy lamps electrical
connector.
(6) Remove the overhead console from the vehicle.
INSTALLATION
(1) Position the overhead console in the vehicle.
Fig. 3 Variance Settings
8M - 6 OVERHEAD CONSOLERS
OVERHEAD CONSOLE (Continued)

LIFTGATE SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
Liftgate opens unexpectedly Inoperative Power Liftgate Module or
Body Control Module (BCM)Disconnect then reconnect the battery
negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Inoperative latch assembly Check for blown fuse and loose wiring
connections
Check for Diagnostic Trouble Codes
(DTCs), replace latch as necessary
Inoperative open/close command
switchCheck for shorted or inoperative switch.
Replace switch as necessary
Liftgate will not open from
outside of vehicle manuallyInoperative key cylinder assembly Check for inoperative key cylinder
assembly. Replace key cylinder as
necessary
Check link rod connections at the latch and
key cylinder assembly
Check for binds or kinks in link rod
Check for foreign matter preventing the
operation of key cylinder assembly
Replace the components as necessary
Inoperative latch assembly Check for blown fuse and loose wiring
connections
Check for foreign matter preventing the
operation of latch assembly
Replace latch assembly as necessary
Binding or sticking of components Check for foreign matter preventing the
operation of door
Establish location of binding
Replace the components as necessary
Liftgate will not open/close
under powerInoperative Power Liftgate Module or
BCMDisconnect then reconnect the battery
negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Inoperative latch assembly Check for blown fuse and loose wiring
connections
Check for foreign matter preventing the
operation of latch assembly
Refer to the appropriate diagnostic
information. Replace latch assembly as
necessary
8N - 4 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Inoperative motor assembly Refer to the appropriate diagnostic
information.
Inoperative full open switch Refer to the appropriate diagnostic
information.
Binding or sticking of components Establish location of binding and replace
components as necessary
Power loss during Liftgate
operationLow battery voltage Charge battery
Inoperative Power Liftgate Module or
BCMDisconnect then reconnect the battery
negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Inoperative motor assembly Check for no drive condition
No power latching in
primary and/or secondary
positionsInoperative latch assembly Check for blown fuse and loose wiring
connections
Check for foreign matter preventing the
operation of latch assembly
Refer to the appropriate diagnostic
information. Replace latch assembly as
necessary
Binding or sticking of components Establish location of binding and replace
components as necessary
Inoperative Power Liftgate or BCM Disconnect then reconnect the battery
negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Door seal force too high Inspect seals for damage, mis-assembly,
foreign matter or other possible obstruction
Inoperative motor assembly Check for no drive condition
Latch will not fully release
from primary positionInoperative latch assembly Check for blown fuse and loose wiring
connections
Check for foreign matter or damaged
components preventing the operation of
latch assembly
Refer to the appropriate diagnostic
information. Replace latch assembly as
necessary
Inoperative outside handle switch Refer to the appropriate diagnostic
information. Replace switch as necessary
RSPOWER LIFTGATE SYSTEM8N-5
POWER LIFTGATE SYSTEM (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Inoperative Power Liftgate Module or
BCMDisconnect then reconnect the battery
negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Binding or sticking of components Establish location of binding and replace
components as necessary
Key fob, Outside Handle or
overhead console switches
do not power operate
liftgateBlown Fuse Check fuse and replace
Battery voltage low Charge or replace battery in key fob or
vehicle
Inoperative latch assembly Check for foreign matter preventing the
operation of latch assembly
Check wire connection
Pawl and/or ratchet switch inoperative.
Replace latch as necessary
Inoperative BCM Check electrical connections
Refer to the appropriate diagnostic
information for additional checks
Replace BCM as necessary
Inoperative key fob Verify inoperative key fob by trying other
key fob functions
Replace key fob battery
Reprogram key fob
Replace key fob as necessary
Inoperative Power Liftgate Module Disconnect then reconnect the battery
negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Inoperative liftgate motor assembly Check for foreign matter preventing the
operation of gear motor assembly
Check wire connections
Motor clutch does not engage. Replace
liftgate motor assembly
Full open switch inoperative, replace switch
as necessary
Liftgate does not stay open Inoperative liftgate prop rods Check for broken attachments. Replace
prop rods as necessary
High inside/outside opening
effortInoperative liftgate prop rods Check for broken attachments. Replace
prop rods as necessary
8N - 6 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)