DODGE CARAVAN 2005 4.G Workshop Manual

NOTE:These devices are not a substitute for proper seat
belt placement by the occupant. The seat belt still must be
worn snugly and positioned properly.
The pretensioners are triggered by the front airbag con-
trol module (see Front Airbag Section). Like the front
airbags, the pretensioners are single use items. After a
collision that is severe enough to deploy the front airbags
and pretensioners, both must be replaced.
Enhanced Driver Seat Belt Use Reminder System
(BeltAlert)
If the driver’s seat belt has not been buckled within 60
seconds of starting the vehicle and if the vehicle speed is
greater than 5 mph (8 km/h), the Enhanced Warning
System (BeltAlert) will alert the driver to buckle their seat
belt. The driver should also instruct all other occupants to
buckle their seat belts. Once the warning is triggered, the
Enhanced Warning System (BeltAlert) will continue tochime and flash the Seat Belt Warning Light for 96
seconds or until the driver’s seat belt is buckled.
The Enhanced Warning System (BeltAlert) will be reacti-
vated if the driver’s seat belt is unbuckled for more than
10 seconds and the vehicle speed is greater than 5 mph (8
km/h).
The Enhanced Warning System (BeltAlert) can be en-
abled or disabled by your authorized dealer or by
following these steps:
NOTE:The following steps must occur within the first
60 seconds of the ignition switch being turned to the ON
or RUN position. DaimlerChrysler does not recommend
deactivating the Enhanced Warning System (BeltAlert).
1. Turn the ignition switch to the OFF position, and
buckle the driver’s seat belt.
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 51
2

2. Turn the ignition key to the RUN position (engine
does not need to be running), and wait for the Seat Belt
Warning Light to turn off.
3. Within 60 seconds, unbuckle and then re-buckle the
driver’s seat belt at least three times, ending with the seat
belt buckled.
4. Turn the ignition key to the OFF position. A single
chime will sound to signify that you have successfully
completed the programming.
The Enhanced Warning System (BeltAlert) can be reacti-
vated by repeating this procedure.
NOTE:Although the Enhanced Warning System
(BeltAlert) has been deactivated, the Seat Belt Warning
Light will continue to illuminate while the driver’s seat
belt remains unfastened.Seat Belts and Pregnant Women
We recommend that pregnant women use the seat belts
throughout their pregnancies. Keeping the mother safe is
the best way to keep the baby safe.
Pregnant women should wear the lap part of the belt
across the thighs and as snug across the hips as possible.
Keep the belt low so that it does not come across the
abdomen. That way the strong bones of the hips will take
the force if there is a collision.
Seat Belt Extender
If a seat belt is too short, even when fully extended and
when the adjustable upper shoulder belt anchorage (if
equipped) is in its lowest position, your dealer can
provide you with a seat belt extender. This extender
should be used only if the existing belt is not long
enough. When it is not required, remove the extender
and stow it.
52 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

WARNING!
Using a seat belt extender when not needed can
increase the risk of injury in a collision. Only use
when the lap belt is not long enough when it is worn
low and snug, and in the recommended seating
positions. Remove and store the extender when not
needed.
Driver And Front Passenger Supplemental
Restraint Systems (SRS)—Airbags
This vehicle has airbags for both the driver and front
passenger as a supplement to the seat belt restraint
systems. The driver’s front airbag is mounted in the
center of the steering wheel. The passenger’s front airbag
is mounted in the instrument panel, above the glove
compartment. The words SRS AIRBAG are embossed on
the airbag covers.NOTE:The front airbags are certified to the Federal
regulations that allow less forceful deployment in low
speed collisions.
The front airbags have a multi stage inflator design. This
may allow the airbag to have different rates of inflation
that are based on collision severity and occupant size.Front Airbag Components
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 53
2

Also, the front passenger airbag is certified to the Federal
regulations that define Occupant Classification (Refer to
“Occupant Classification System”in this section).
This vehicle may also be equipped with a driver inflat-
able knee blocker located on the instrument panel below
the steering column.
This vehicle may also be equipped with window bags to
protect the driver, front, and rear passengers sitting next
to a window. If the vehicle is equipped with window
bags, they are located above the side windows. Their
covers are also labeled SRS AIRBAG.
NOTE:Airbag covers may not be obvious in the interior
trim; but they will open to allow airbag deployment.
Window Bags
54 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

WARNING!
•Do not put anything on or around the airbag covers
or attempt to manually open them. You may dam-
age the airbags and you could be injured because
the airbags are not there to protect you. These
protective covers for the airbag cushions are de-
signed to open only when the airbags are inflating.
•If your vehicle is equipped with window bags, do
not stack luggage or other cargo up high enough to
block the location of the window bag. The area
where the window bag is located should remain
free from any obstructions.
•If your vehicle is equipped with window bags, do
not have any accessory items installed which will
alter the roof, including adding a sunroof to your
vehicle. Do not add roof racks that require perma-
nent attachments (bolts or screws) for installation
on the vehicle roof. Do not drill into the roof of the
vehicle for any reason.
Along with the seat belts, front airbags work with the
instrument panel knee bolsters to provide improved
protection for the driver and front passenger. Window
bags also work with seat belts to improve occupant
protection.
The seat belts are designed to protect you in many types
of collisions. The front airbags deploy in moderate to
severe frontal collisions.
NOTE:The passenger front airbag may not deploy even
when the driver front airbag has if the Occupant Classi-
fication System (refer to“Occupant Classification Sys-
tem”in this section) has determined the seat is empty or
is occupied by a child.
If your vehicle is equipped, the window bag on the crash
side of the vehicle is triggered in moderate to severe side
collisions. But even in collisions where the airbags inflate,
you need the seat belts to keep you in the right position
for the airbags to protect you properly.
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 55
2

Here are some simple steps you can take to minimize the
risk of harm from a deploying airbag.
1.Children 12 years old and under should always ride
buckled up in a rear seat.
Infants in rear facing child restraints shouldNEVERride
in the front seat of a vehicle with a passenger front airbag.
An airbag deployment can cause severe injury or death to
infants in that position.
Children that are not big enough to properly wear the
vehicle seat belt (refer to section on Child Restraint)
should be secured in the rear seat, in a child restraint or
belt-positioning booster seat. Older children who do not
use child restraints or belt-positioning booster seats
should ride properly buckled up in the rear seat, and in
the outboard seat if possible. Never allow children to
slide the shoulder belt behind them or under their arm.If a child from 1 to 12 years old must ride in the front
passenger seat because the vehicle is crowded, move the
seat as far back as possible, and use the proper child
restraint. See the section on Child Restraint.
You should read the instructions provided with your
child restraint to make sure that you are using it properly.
2.All occupants should wear their lap and shoulder
belts properly.
3.The driver and front passenger seats should be
moved back as far as practical to allow the front airbags
room to inflate.
4.If your vehicle has window bags, do not lean against
the door, airbags will inflate forcefully into the space
between you and the door.
56 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

WARNING!
•Relying on the airbags alone could lead to more
severe injuries in a collision. The airbags work
with your seat belt to restrain you properly. In
some collisions the airbags won’t deploy at all.
Always wear your seat belts even though you
have airbags.
•Being too close to the steering wheel or instru-
ment panel during front airbag deployment could
cause serious injury. Airbags need room to inflate.
Sit back, comfortably extending your arms to
reach the steering wheel or instrument panel.
•If the vehicle has window bags, they also need
room to inflate. Do not lean against the door or
window. Sit upright in the center of the seat.
The Airbag System consists of the following:
•Occupant Restraint Controller (ORC)
•AIRBAG Readiness Light
•Driver Airbag
•Front Passenger Airbag
•Window Bags above Side Windows (If Equipped)
•Front Impact Sensors
•Side Impact Sensors (If Equipped)
•Steering Wheel and Column
•Instrument Panel
•Seat Belt Readiness Light
•Front Seat Belt Pretensioners
•Interconnecting Wiring
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 57
2

•Knee Impact Bolster
•Driver Inflatable Knee Blocker
•Front Passenger Seat Occupant Classification System
(OCS)—If Equipped
Occupant Classification Module
Passenger Airbag Disabled (PAD) Indicator Light
Interconnecting Wiring
Bladder Assembly
Belt Tension Sensor
How The Airbag System Works
•
TheOccupant Restraint Controller (ORC)determines
if a frontal collision is severe enough to require the
airbags to inflate. Based on the level of collision
severity, the front control module determines theproper rate of inflation. The front airbag inflators are
designed to provide different rates of airbag inflation.
•The ORC may modify the rate of inflation based on the
occupant size provided by the Occupant Classification
Module.
•The ORC will not detect side, roll over, or rear impacts.
•The ORC monitors the readiness of the electronic parts
of the system whenever the ignition switch is in the
START or RUN positions. These include all of the
items listed above except the steering wheel and
column, instrument panel and passenger knee bol-
sters. If the key is in the OFF position, in the ACC
position, or not in the ignition, the airbags are not on
and will not inflate.
•Also, the ORC turns on the AIRBAG warn-
ing light and PAD indicator light in the
center of the instrument panel for 6 to 8
seconds for a self-check when the ignition is
58 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

first turned on. After the self-check, the AIRBAG
warning light will turn off. The PAD indicator light
will function normally (Refer to“Passenger Airbag
Disable (PAD) Indicator Light”in this section). If the
ORC detects a malfunction in any part of the system, it
turns on the AIRBAG warning light either momen-
tarily or continuously. A single chime will sound if the
light comes on again after initial start up.
WARNING!
Ignoring the AIRBAG warning light in your instru-
ment panel could mean you won’t have the airbags
to protect you in a collision. If the light does not
come on, stays on after you start the vehicle, or if it
comes on as you drive, have the airbag system
checked right away.
•TheDriver and Passenger Airbag/Inflator Unitsare
located in the center of the steering wheel and the right
side of the instrument panel. When the ORC and
impact sensors detects a collision requiring the air-
bags, it signals the inflator units. A large quantity of
nontoxic gas is generated to inflate the front airbags.
Different airbag inflation rates may be possible based
on collision severity and occupant size. The steering
wheel hub trim cover and the upper right side of the
instrument panel separate and fold out of the way as
the airbags inflate to their full size. The airbags fully
inflate in about 50–70 milliseconds. This is about half
of the time it takes to blink your eyes. The airbags then
quickly deflate while helping to restrain the driver and
front passenger.
The driver’s and passenger’s front airbag gas is vented
through the airbag material towards the instrument
panel. In this way the airbags do not interfere with
your control of the vehicle.
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 59
2

•TheSide Impact SRS Window Bagsare designed to
activate only in certain side collisions. When the ORC
and the side impact sensors (with side impact option)
detects a collision requiring the window bags to
inflate, it signals the inflators on the crash side of the
vehicle. A quantity of nontoxic gas is generated to
inflate the window bag. The inflating window bag
pushes the outside edge of the headliner out of the
way and covers the window. The airbag inflates in
about 30 milliseconds (about one quarter of the time it
takes to blink your eyes) with enough force to injure
you if you are not belted and seated properly, or if
items are positioned in the area where the window bag
inflates. This especially applies to children. The win-
dow bag is only about 3
12inches (9 cm) thick when it
is inflated.
•When the ORC and the side impact sensors (with side
impact option) detects a collision requiring theDriver
Inflatable Knee Blocker, it signals the inflator unit. A
quantity of nontoxic gas is generated to inflate the
Driver Inflatable Knee Blocker. The Driver Inflatable
Knee Blocker inflates rearward towards the driver’s
knees to help protect the knees and position you for
the best interaction with the front airbag. The Driver
Inflatable Knee Blocker fully inflates in about 50
milliseconds, this is only about half of the time it takes
you to blink your eyes. It then quickly deflates while
helping to protect the driver’s knees.
•TheKnee Impact Bolstershelp protect the knees, and
position everyone for the best interaction with the
front airbag.
60 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE