2005 CHRYSLER CARAVAN light

(4) Remove wiring connector from bulb by sliding
red latch lock rearward and then depressing release
tab.
(5) Rotate headlamp bulb retaining ring counter-
clockwise.
INSTALLATION
DODGE
(1) Install headlamp bulb to the headlamp unit.
(2) Install headlamp bulb retaining ring.
(3) Connect wiring connector to bulb.
(4) Install the headlamp unit.
(5) Install headlamp unit retaining screws.
(6) Connect the battery negative cable.
CHRYSLER
(1) Install headlamp bulb to the headlamp unit.
(2) Rotate bulb clockwise to lock bulb in headlamp
unit.
(3) Connect wiring connector to bulb and slide red
latch lock forward.
(4) Install the headlamp unit.
(5) Install headlamp unit retaining screws.
(6) Connect the battery negative cable.
HEADLAMP SWITCH
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH
Using a Digital Multi-meter, perform the HEAD-
LAMP SWITCH CONTINUITY test and refer to (Fig.
11).
If the Headlamp Switch is not within specifications
replace the switch.
HEADLAMP SWITCH CONTINUITY
HEADLAMP
SWITCH
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
OFF 11 TO 6 3651 - 3729V
PARKING
LAMPS ON11 TO 6 1697 - 2517V
PARKING
LAMPS WITH
FRONT FOG
LAMPS ON11 TO 6 5765 - 5886V
HEADLAMPS
ON11 TO 6 788 - 809V
AUTO ON 11 TO 6 10056 - 10264V
HEADLAMPS
ON WITH
FRONT FOG
LAMPS11 TO 6 1171 - 1200V
AUTO ON WITH
FRONT FOG
LAMPS ON11 TO 6 24278 - 24773V
DIMMER
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
DOME 12 TO 6 15568 - 23357V
PARADE 12 TO 6 5168 - 7757V
DIM HIGH 12 TO 6 2288 - 3437V
DIM LOW 12 TO 6 688 - 1037V
OFF 12 TO 6 240 - 365V
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Removal.
(3) Reach up behind the left side of the instrument
panel and depress spring clip on top or bottom of
headlamp switch. Firmly push out on the headlamp
switch assembly.
(4) Disconnect the wiring connectors.
(5) Remove switch from vehicle.
INSTALLATION
(1) Connect the wiring connectors.
(2) Place headlamp switch assembly into position
and firmly snap into place.
(3) Install the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Installation.
(4) Connect the battery negative cable.
Fig. 11 HEADLAMP SWITCH CONNECTOR
RSLAMPS/LIGHTING - EXTERIOR8L-13
HEADLAMP (Continued)

HEADLAMP UNIT
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT
HEADLAMP UNIT ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(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.
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft.) away from front
of headlamp lens (Fig. 12).
(2) If necessary, tape a line on the floor 7.62
meters (25 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.
Fig. 12 HEADLAMP ALIGNMENT SCREEN
1 - CENTER OF HEADLAMPS 3 - FRONT OF HEADLAMP
2 - HEADLAMP BEAM 4 - 7.62 METERS (25 FT.)
8L - 14 LAMPS/LIGHTING - EXTERIORRS

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)

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the three retaining screws.
(3) Disconnect the central wiring harness connec-
tor from the headlamp unit.
(4) Remove the headlamp unit from the vehicle by
rotating the turn signal area out and towards the
center of the vehicle.
INSTALLATION
(1) Connect the wiring harness to the headlamp
unit's central connector.
(2) Place the headlamp unit in the headlamp unit
pocket in front end first by placing the inboard side
behind the fascia. Complete the installation by rotat-
ing the turn signal area of the headlamp into place.
(3) Place headlamp unit into headlamp unit pocket
in front end.
(4) Install the three retaining screws.
(5) Connect the battery negative cable.
(6) Verify vehicle and system operation.
LICENSE LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove two screws (Fig. 18).
(3) Twist bulb socket and remove (Fig. 19).
(4) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket.
(2) Install socket into lamp.
(3) Install two screws.
(4) Reconnect the battery negative cable.
MULTI-FUNCTION SWITCH
DESCRIPTION - TURN SIGNAL SYSTEM
The turn signals are actuated with a lever on
Multi-Function Switch, located on the left side of the
steering wheel. The signals are automatically turned
off by a canceling cam (two lobes molded to the clock
spring mechanism). The cam comes in contact with
the cancel actuator on the turn signal (multi-func-
tion) switch assembly. Either cam lobe, pushing on
the cancel actuator, returns the switch to the OFF
position. The multi-function switch is a resistive
MUX switch that feeds inputs to the BCM.
OPERATION - TURN SIGNAL SYSTEM
Lane change signaling is actuated by applying par-
tial turn signal stalk movement toward the direction
desired until the indicator lamps flashes in the
instrument cluster. When the switch stalk is released
the stalk will spring back into the neutral position
turning OFF the turn signal.
With the ignition switch ON and the turn signal
switch stalk actuated left or right, current flows
through the:
²Multi-function switch
²Body Control Module
²Integrated Power Module (IPM)
²Turn indicator lamp
²Front and rear turn signal bulbs.
A chime will sound after the vehicle has traveled a
distance of approximately 1.0 mile and a speed of 15
mph, with the turn signal ON.
Fig. 18 LICENSE PLATE LAMP UNITS
1 - SCREW
2 - LICENSE PLATE LAMP
Fig. 19 LICENSE PLATE LAMP - REMOVE/INSTALL
1 - LICENSE PLATE LAMP UNIT
2 - BULB
RSLAMPS/LIGHTING - EXTERIOR8L-17
HEADLAMP UNIT - EXPORT (Continued)

DIAGNOSIS AND TESTING - MULTI-FUNCTION
SWITCH
To test turn signal, headlamp beam select and opti-
cal horn portion of the multi-function switch:
(1) Remove the multi-function switch, refer to
Electrical, Lamps/Lighting - Exterior, Multi-Function
Switch, Removal, and Installation.
(2) Using an ohmmeter check the resistance read-
ings between multi-function switch pins. Refer to
Wiring Diagrams for proper pin numbers and the
MULTI-FUNCTION SWITCH RESISTANCE table.
MULTI-FUNCTION SWITCH RESISTANCE
SWITCH
POSITIONPIN NUMBER RESISTANCE
LEFT 2 AND 3 2.7V 5%
RIGHT 2 AND 3 1KV 5%
OPTICAL
HORN2 AND 4 1.7KV 5%
HI BEAM 2 AND 4 2.32KV 5%
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove upper and lower steering column
shrouds. Refer to Steering, Column, Shroud,
Removal.
(3) Disconnect wire connector from back of multi-
function switch.
(4) Remove screws holding multi-function switch to
steering column adapter collar.
(5) Remove the multi-function switch.
INSTALLATION
(1) Position the switch on to the steering column.
(2) Install the two retaining screws.
(3) Connect the wire harness connector.
(4) Install the upper and lower steering column
shrouds. Refer to Steering, Column, Shroud, Installa-
tion.
(5) Connect the battery negative cable.
PARK/TURN SIGNAL LAMP
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove headlamp retaining screws.
(3) Twist socket counter - clockwise and remove
(Fig. 20).
(4) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket.
(2) Twist socket into headlamp.
(3) Install headlamp retaining screws.
(4) Reconnect battery negative cable.
TAIL LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the tail lamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - REMOVAL).
(3) Squeeze the tabs on the bulb socket and
remove from tail lamp unit (Fig. 21).
(4) Pull bulb from lamp socket.
Fig. 20 PARK/TURN SIGNAL LAMP
1 - PARK/TURN SIGNAL LAMP
2 - LAMP SOCKET
Fig. 21 TAIL LAMP SOCKET
1 - LAMP SOCKET
2 - TAIL LAMP UNIT
8L - 18 LAMPS/LIGHTING - EXTERIORRS
MULTI-FUNCTION SWITCH (Continued)

INSTALLATION
(1) Push bulb into the lamp socket.
(2) Install bulb socket into the tail lamp unit.
Ensure that both retaining tabs engage with an audi-
ble click.
(3) Install the tail lamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - INSTALLATION).
(4) Reconnect the battery negative cable.
TAIL LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Raise the liftgate.
(3) Remove the two retaining fasteners by prying
under the head of the fastener with a flat bladed tool
(Fig. 22).(4) Rotate the lamp away from the vehicle body to
disengage hook from the rubber grommet in the
quarter panel opening.
(5) Disconnect wire harness connector from tail
lamp unit by sliding the red lock, then pressing
release tab.
INSTALLATION
(1) Reconnect wire harness connector to the tail
lamp. Slide red connector lock into position.
(2) Engage hook into rubber grommet in quarter
panel opening.
(3) Place lamp into position on quarter panel.
(4) Insert the two retaining fasteners by pressing
into position (insert into the hole first, followed by
the slot). Ensure that the head of the fastener is
open before inserting.
(5) Close the liftgate.
(6) Reconnect the battery negative cable.
Fig. 22 TAIL LAMP UNIT FASTENERS
1 - TAIL LAMP UNIT FASTENER
2 - TAIL LAMP UNIT
RSLAMPS/LIGHTING - EXTERIOR8L-19
TAIL LAMP (Continued)

LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS.....................20
CENTER CONSOLE LAMP
REMOVAL.............................21
INSTALLATION.........................21
CENTER CONSOLE LAMP SWITCH
REMOVAL.............................21
INSTALLATION.........................21
CLUSTER ILLUMINATION LAMPS
REMOVAL.............................21
INSTALLATION.........................21
COURTESY LAMP
REMOVAL.............................21
INSTALLATION.........................21DOME/CARGO LAMP
REMOVAL.............................22
INSTALLATION.........................22
GLOVE BOX LAMP SWITCH
REMOVAL.............................22
INSTALLATION.........................22
LIFTGATE LAMP
REMOVAL.............................22
INSTALLATION.........................22
READING LAMP
REMOVAL.............................22
INSTALLATION.........................23
VANITY LAMP
REMOVAL.............................24
INSTALLATION.........................24
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
ABS LED
AIRBAG LED
ALARM SET LED
BRAKE SYSTEM
WARNINGLED
CONSOLE 194
CRUISE INDICATOR VFD*
DOME/RAIL LAMPS 578
DOOR AJAR INDICATOR LED
DOOR COURTESY
LAMP578
FRONT DOOR
COURTESY567
GLOVE BOX 194
HIGH BEAM INDICATOR LED
CLUSTER
ILLUMINATIONPC74
LIFTGATE 578
LAMP BULB
LIFTGATE AJAR LED
LOW FUEL INDICATOR LED
LOW WASHER FLUID
INDICATORLED
MIL LED
OIL INDICATOR LED
OVERHEAD CONSOLE
READINGPC579
PRNDL INDICATOR
(BASE CLUSTER)LED
PRNDL INDICATOR VFD
READING 578
SEAT BELT INDICATOR LED
TEMPERATURE
INDICATORLED
TIRE PRESSURE
WARNINGLED
TRAC OFF INDICATOR VFD*
VISOR VANITY 6501966
VOLTAGE INDICATOR LED
* VFD = VACUUM FLUORESCENT DISPLAY
8L - 20 LAMPS/LIGHTING - INTERIORRS