light CHRYSLER CARAVAN 2005 Service Manual

8W-50 FRONT LIGHTING
Component Page
Body Control Module............. 8W-50-2, 4, 5
Front Control Module.... 8W-50-3, 4, 6, 7, 8, 9, 10
Front Fog Lamp Relay............... 8W-50-10
Fuse 1............................ 8W-50-10
Fuse 2.......................... 8W-50-4, 6
Fuse 3.......................... 8W-50-4, 6
G102......................... 8W-50-4, 6, 10
G200............................ 8W-50-2, 9
G300.............................. 8W-50-3
Headlamp Switch.................. 8W-50-2, 9
Integrated Power
Module........... 8W-50-3, 4, 5, 6, 7, 8, 9, 10
Left Fog Lamp..................... 8W-50-10
Left Front Park/Turn Signal Lamp....... 8W-50-4Component Page
Left Headlamp...................... 8W-50-3
Left Headlamp Leveling Motor........ 8W-50-6, 9
Left High Beam Lamp.............. 8W-50-6, 7
Left Low Beam Lamp................. 8W-50-7
Left Park Lamp................... 8W-50-6, 7
Multi-Function Switch................ 8W-50-5
Park Lamp Relay.................. 8W-50-4, 6
Right Fog Lamp.................... 8W-50-10
Right Front Park/Turn Signal Lamp..... 8W-50-4
Right Headlamp..................... 8W-50-3
Right Headlamp Leveling Motor...... 8W-50-6, 9
Right High Beam Lamp............. 8W-50-6, 8
Right Low Beam Lamp................ 8W-50-8
Right Park Lamp.................. 8W-50-6, 8
RS8W-50 FRONT LIGHTING8W-50-1

8W-51 REAR LIGHTING
Component Page
Back-Up Lamp Switch................ 8W-51-6
Battery............................ 8W-51-6
Body Control Module......... 8W-51-2, 3, 4, 5, 6
Brake Lamp Switch................ 8W-51-2, 5
Center High Mounted Stop Lamp....... 8W-51-7
Front Control Module............. 8W-51-2, 5, 6
Fuse 2.......................... 8W-51-2, 5
Fuse 3......................... 8W-51-2, 5, 6
Fuse 26.......................... 8W-51-2, 5Component Page
G101.............................. 8W-51-6
G302........................ 8W-51-3, 4, 5, 6
G303.............................. 8W-51-7
Integrated Power Module........ 8W-51-2, 3, 5, 6
Left Rear Lamp Assembly........ 8W-51-2, 4, 5, 6
License Lamp....................... 8W-51-7
Park Lamp Relay................ 8W-51-2, 5, 6
Right Rear Lamp Assembly...... 8W-51-2, 3, 5, 6
Trailer Tow Connector.............. 8W-51-3, 4
RS8W-51 REAR LIGHTING8W-51-1

Component Page
Evaporator Temperature Sensor........ 8W-80-70
Floor Console Lamp................. 8W-80-70
Floor Console Power Outlet (Export).... 8W-80-70
Front Blower Module C1 (ATC)........ 8W-80-71
Front Blower Module C2 (ATC)........ 8W-80-71
Front Cigar Lighter................. 8W-80-71
Front Control Module................ 8W-80-72
Front Intrusion Sensor (United
Kingdom)....................... 8W-80-73
Front Reading Lamps/Switch.......... 8W-80-73
Fuel Heater (Diesel)................. 8W-80-73
Fuel Injector No. 1 (2.4L/3.3L/3.8L)..... 8W-80-73
Fuel Injector No. 1 (Diesel)............ 8W-80-73
Fuel Injector No. 2 (2.4L/3.3L/3.8L)..... 8W-80-74
Fuel Injector No. 2 (Diesel)............ 8W-80-74
Fuel Injector No. 3 (2.4L/3.3L/3.8L)..... 8W-80-74
Fuel Injector No. 3 (Diesel)............ 8W-80-74
Fuel Injector No. 4 (2.4L/3.3L/3.8L)..... 8W-80-75
Fuel Injector No. 4 (Diesel)............ 8W-80-75
Fuel Injector No. 5 (3.3L/3.8L)......... 8W-80-75
Fuel Injector No. 6 (3.3L/3.8L)......... 8W-80-75
Fuel Pressure Sensor (Diesel).......... 8W-80-76
Fuel Pressure Solenoid (Diesel)........ 8W-80-76
Fuel Pump Module.................. 8W-80-76
Generator......................... 8W-80-76
Glow Plug Relay (Diesel)............. 8W-80-77
Hands Free Module C1............... 8W-80-77
Hands Free Module C2............... 8W-80-77
Hands Free Module C3............... 8W-80-78
Headlamp Switch................... 8W-80-78
Headlamp Washer Pump Motor (Export) . 8W-80-78
High Note Horn.................... 8W-80-79
Hood Ajar Switch (Export)............ 8W-80-79
Idle Air Control Motor (Gas)........... 8W-80-79
Ignition Coil (2.4L).................. 8W-80-79
Ignition Coil (3.3L/3.8L).............. 8W-80-80
Ignition Switch..................... 8W-80-80
Inlet Air Temperature Sensor.......... 8W-80-80
Input Speed Sensor................. 8W-80-80
Instrument Cluster.................. 8W-80-81
Instrument Panel Switch Bank
(Except Heated Seats)............. 8W-80-81
Instrument Panel Switch Bank
(Heated Seats)................... 8W-80-81
Integrated Power Module C1.......... 8W-80-82
Integrated Power Module C2.......... 8W-80-82
Integrated Power Module C3.......... 8W-80-83
Integrated Power Module C4.......... 8W-80-83
Integrated Power Module C5.......... 8W-80-84
Integrated Power Module C6.......... 8W-80-84
Integrated Power Module C7.......... 8W-80-84
Integrated Power Module C8.......... 8W-80-85
Integrated Power Module C9.......... 8W-80-85
Knock Sensor (Except Export)......... 8W-80-85Component Page
Left B-Pillar Switch (Power Sliding
Door).......................... 8W-80-86
Left Cinch/Release Motor (Power Sliding
Door).......................... 8W-80-86
Left Curtain Airbag Squib............ 8W-80-86
Left Cylinder Lock Switch (Export)..... 8W-80-86
Left Door Speaker.................. 8W-80-87
Left Fog Lamp..................... 8W-80-87
Left Front Door Ajar Switch (Base)..... 8W-80-87
Left Front Door Lock Motor/Ajar Switch
(Except Base).................... 8W-80-87
Left Front Impact Sensor (Export)...... 8W-80-87
Left Front Impact Sensor (Except
Export)......................... 8W-80-88
Left Front Park/Turn Signal Lamp...... 8W-80-88
Left Front Wheel Speed Sensor........ 8W-80-88
Left Full Open Switch (Power Sliding
Door).......................... 8W-80-88
Left Headlamp (Caravan/Voyager Except
Export)......................... 8W-80-89
Left Headlamp (Town And Country)..... 8W-80-89
Left Headlamp Leveling Motor (Export) . . 8W-80-89
Left High Beam Lamp (Export)........ 8W-80-89
Left Instrument Panel Speaker........ 8W-80-90
Left Liftgate Flood Lamp (Export)...... 8W-80-90
Left Low Beam Lamp (Export)......... 8W-80-90
Left Mid Reading Lamp (Premium/
Luxury)........................ 8W-80-90
Left Park Lamp (Export)............. 8W-80-91
Left Power Mirror................... 8W-80-91
Left Rear Lamp Assembly............ 8W-80-91
Left Rear Pillar Speaker (Highline
Audio).......................... 8W-80-92
Left Rear Reading Lamp (Luxury)...... 8W-80-92
Left Rear Speaker.................. 8W-80-92
Left Rear Vent Motor................ 8W-80-92
Left Rear Wheel Speed Sensor......... 8W-80-93
Left Remote Radio Switch............ 8W-80-93
Left Repeater Lamp (Export).......... 8W-80-93
Left Side Impact Sensor 1 (Export)..... 8W-80-93
Left Side Impact Sensor 1 (Except
Export)......................... 8W-80-94
Left Side Impact Sensor 2............ 8W-80-94
Left Side Impact Sensor 3............ 8W-80-94
Left Sliding Door Control Module C1
(Power Sliding Door).............. 8W-80-94
Left Sliding Door Control Module C2
(Power Sliding Door).............. 8W-80-95
Left Sliding Door Latch Sensing Switch
(Power Sliding Door).............. 8W-80-95
Left Sliding Door Lock Motor (Power Sliding
Door).......................... 8W-80-95
Left Sliding Door Lock Motor/Ajar Switch
(Manual Sliding Door)............. 8W-80-96
RS8W-80 CONNECTOR PIN-OUTS8W-80-3

C102 (GAS) - BLACK (POWERTRAIN SIDE)
CAV CIRCUIT
1 K11 16BR/YL (2.4L)
1 K342 16BR/WT (3.3L/3.8L)
2 K12 16BR/DB (2.4L)
2 K1 18VT/BR (3.3L/3.8L)
3 K13 16BR/LB (2.4L)
3 K11 16BR/YL (3.3L/3.8L)
4 K14 16BR/TN (2.4L)
4 K12 16BR/DB (3.3L/3.8L)
5 K342 16BR/WT (2.4L)
5 K13 16BR/LB (3.3L/3.8L)
6 K900 18DB/DG (2.4L)
6 K14 16BR/TN (3.3L/3.8L)
7 K2 18VT/OR (2.4L)
7 K900 18DB/DG (3.3L/3.8L)
8 K1 18VT/BR (2.4L)
8 K38 16BR/OR (3.3L/3.8L)
9 K58 16BR/VT (3.3L/3.8L)
10 F855 20PK/YL
C103 (DIESEL) - BLACK (FRONT END LIGHTING
SIDE)
CAV CIRCUIT
1 K342 16BR/WT
2 R80 18VT/LB
3 N122 20DB/YL
4 N210 18DB/DG
5 A201 12RD/LG
6 R82 18WT/LB
C103 (DIESEL) - BLACK (POWERTRAIN SIDE)
CAV CIRCUIT
1 K342 16BR/WT
2 R80 18VT/LB
3 N122 20DB/YL
4 N210 20DB/DG
5 A201 12RD/LG
6 R82 18WT/LB
C104 (EXCEPT EXPORT) - (ENGINE SIDE)
CAV CIRCUIT
1 Z166 18BK/WT
2 K107 20VT/WT
3 K106 20VT/LB
8W - 80 - 20 8W-80 CONNECTOR PIN-OUTSRS

C104 (EXCEPT EXPORT) - LT. GRAY (JUMPER
SIDE)
CAV CIRCUIT
1 Z166 18BK/WT
2 K107 18VT/WT
3 K106 18VT/GY
C106 (EXPORT) - BLACK (FRONT END LIGHT-
ING SIDE)
CAV CIRCUIT
1 L43 18WT/DB
2 L33 18WT/LG
3 L77 18WT/BR
4 L61 18WT/LB
5 Z343 18BK/LG
6 L13 20WT/YL
7 Z203 20BK/YL
8 Z377 18BK/BR
C106 (EXPORT) - BLACK/YELLOW (COMPONENT
SIDE)
CAV CIRCUIT
1 L43 16WT
2 L33 16GY
3 L77 16BK
4 L61 16YL
5 Z343 16BR
6 L13 16RD
7 Z203 16BR
8 Z377 18BK/BR
C107 (EXPORT) - BLACK (FRONT END LIGHT-
ING SIDE)
CAV CIRCUIT
1 L44 16WT/TN
2 L34 16WT/GY
3 L78 18WT/OR
4 L60 18WT/TN
5 Z344 16BK/TN
6 L13 20WT/YL
7 Z203 20BK/YL
8 Z378 18BK/TN
RS8W-80 CONNECTOR PIN-OUTS8W-80-21

C107 (EXPORT) - BLACK/YELLOW (COMPONENT
SIDE)
CAV CIRCUIT
1 L44 16WT
2 L34 16GY
3 L78 16BK
4 L60 16YL
5 Z344 16BR
6 L13 16RD
7 Z203 16BR
8 Z378 18BK/TN
C111 (EATX) - LT. GRAY (ENGINE SIDE)
CAV CIRCUIT
1 Z133 16BK/LG
2 T15 18YL/BR
3-
4 Z133 16BK/LG
5 T16 18YL/OR
6-
C111 (EATX) - LT. GRAY (TRANSMISSION SIDE)
CAV CIRCUIT
1 Z133 16BK/LG
2 T15 18YL/BR
3-
4 Z133 16BK/LG
5 T16 18YL/OR
6-
C112 (GAS) - BLACK (BODY SIDE)
CAV CIRCUIT
1 R80 20VT/LB
2 R82 20WT/LB
3 G31 18VT/LG (EXCEPT OCCUPANT
SENSING)
3 G31 18WT/LG (OCCUPANT SENSING)
4 K900 20DB/DG
C112 (GAS) - BLACK (FRONT END LIGHTING
SIDE)
CAV CIRCUIT
1 R80 18VT/LB
2 R82 18WT/LB
3 G31 18VT/LG
4 K900 18DB/DG
8W - 80 - 22 8W-80 CONNECTOR PIN-OUTSRS

FRONT BLOWER MODULE C1 (ATC) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1- -
2 Z134 12BK/OR GROUND
3 C56 20DB/LB BLOWER MOTOR CONTROL
4 C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT
FRONT BLOWER MODULE C2 (ATC) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 C7 12DB (EXCEPT EXPORT) HIGH SPEED BLOWER MOTOR
1 C7 12DG (EXPORT) HIGH SPEED BLOWER MOTOR
2 C70 12DB/YL (EXCEPT EXPORT) BLOWER MOTOR DRIVER
2 C70 12BK (EXPORT) BLOWER MOTOR DRIVER
FRONT CIGAR LIGHTER - RED/NATURAL 3 WAY
CAV CIRCUIT FUNCTION
1 F306 18DB/PK FUSED ACCESSORY RELAY OUTPUT
1 F306 18DB/PK FUSED ACCESSORY RELAY OUTPUT
2- -
3 Z736 18BK/YL GROUND
RS8W-80 CONNECTOR PIN-OUTS8W-80-71

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Engine Coolant Temp Sensor
(Gas)BK On Cylinder Block N/S
Engine Oil Pressure Sensor
(Diesel)BK Rear of Engine 16
Engine Coolant Temp Sensor
(Diesel)BL On Cylinder Block 15
Engine Oil Pressure Switch (Gas) LTGN On Cylinder Block 12, 18
Engine Starter Motor At Starter Motor 13, 15, 18
EVAP/Purge Solenoid (Gas) BK Right Motor Mount 10, 17
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Floor Console Lamp BK At Lamp N/S
Floor Console Power Outlet RD At Front Console N/S
Front Blower Module C1 (ATC) BK On HVAC N/S
Front Blower Module C2 (ATC) BK On HVAC N/S
Front Cigar Lighter RD/NAT Rear of Lighter 20, 23, 25
Front Control Module BK In Integrated Power Module N/S
Front Intrusion Sensor (United
Kingdom)BK At Sensor N/S
Front Reading Lamps/Switch BK At Switch N/S
Fuel Heater (Diesel) BK Left Rear Engine Compartment N/S
Fuel Injector No.1 (2.4L/3.3L/
3.8L)BK At Fuel Injector N/S
Fuel Injector No.1 (Diesel) BK At Fuel Injector 15
Fuel Injector No.2 (2.4L/3.3L/
3.8L)BK At Fuel Injector N/S
Fuel Injector No.2 (Diesel) BK At Fuel Injector 15
Fuel Injector No.3 (2.4L/3.3L/
3.8L)BK At Fuel Injector N/S
Fuel Injector No.3 (Diesel) BK At Fuel Injector 15
Fuel Injector No.4 (2.4L/3.3L/
3.8L)BK At Fuel Injector N/S
Fuel Injector No.4 (Diesel) BK At Fuel Injector 15
Fuel Injector No.5 (3.3L/3.8L) BK At Fuel Injector N/S
Fuel Injector No.6 (3.3L/3.8L) BK At Fuel Injector N/S
Fuel Pressure Sensor (Diesel) BK Top Left of Engine 15
Fuel Pressure Solenoid (Diesel) Right Front Engine 15
Fuel Pump Module LTGY Side of Fuel Tank 34
Generator BK Rear of Generator 11, 15, 17, 18
Glow Plug No.1 (Diesel) Top of Engine N/S
Glow Plug No.2 (Diesel) Top of Engine 15
Glow Plug No.3 (Diesel) Top of Engine 15
Glow Plug No.4 (Diesel) Top of Engine 15
Glow Plug Relay (Diesel) BK Near Transmission 15, 16
Hands Free Module C1 Instrument Panel N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE NUMBER LOCATION FIG.
S139 (Diesel) Between T/O for Engine Starter Motor and T/O for
Engine Control Module C115, 16
S141 (2.4L) Near T/O for Controller Anti-Lock Brake 11
S141 (3.3L/3.8L ABS Except
Export)Near T/O for G100 N/S
S141 (Diesel) Near T/O for G100 N/S
S141 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S
S142 (3.3L/3.8L) Near T/O for A/C Compressor Clutch 18
S144 (Diesel) Between T/O for Battery Temperature Sensor and T/O
for C103N/S
S148 (Diesel) Near T/O for Engine Starter Motor 5
S150 (Diesel) Near T/O for Controller Anti-Lock Brake N/S
S151 (Diesel) Near T/O for Radiator Fan Relays 2
S152 (Diesel) Near T/O for Radiator Fan No.1 N/S
S157 (Diesel) Near T/O for Glow Plug No.4 15
S177 In Right Headlamp Wiring Assembly N/S
S179 In Left Headlamp Wiring Assembly N/S
S187 (Diesel) In T/O for Engine Control Module C1 15
S188 (Diesel) Near T/O for Radiator Fan Relays 2
S189 (Diesel EATX) Near T/O for Battery (+) N/S
S190 (Diesel EATX) Near T/O for Transmission Control Module N/S
S191 (Diesel EATX) Near T/O for Transmission Control Module N/S
S192 (Diesel EATX) In T/O for Transmission Control Module N/S
S193 (Diesel EATX) In T/O for Transmission Control Module N/S
S201 In T/O to Instrument Panel Speaker 20, 26
S202 Near T/O for Instrument Panel Switch Bank 20, 26
S203 Near T/O for Instrument Panel Switch Bank 20, 26
S204 Near T/O to Instrument Panel Speaker 20, 26
S205 Near T/O for C201 N/S
S206 Near T/O for Instrument Cluster 20
S207 Near T/O for A/C Heater Control 20, 26
S208 (RHD) Between T/O for Antenna Connector and T/O for Front
Cigar Lighter26
S209 Near T/O for Evaporator Temperature Sensor N/S
S210 (RHD) Near T/O for C203 26
S211 In Steering Column Wiring Assembly N/S
S212 In Steering Column Wiring Assembly N/S
S222 Near T/O for C204 N/S
S223 Near T/O for Multi-Function Switch 20
S224 Near T/O for Siren N/S
S225 (Hands Free) Near T/O for Rear View Mirror N/S
S226 (Hands Free) In T/O for C207 N/S
S302 In Floor Pan Track Wiring 37
8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

(2) Check for battery voltage at the fused B(+) fuse
in the IPM. If OK, go to Step 3. If not OK, repair the
open fused B(+) circuit to the IPM fuse as required.
(3) Open the power outlet door. Check for continu-
ity between the inside circumference of the power
outlet receptacle and a good ground. There should be
continuity. If OK, go to Step 4. If not OK, go to Step
5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative
cable. Remove the appropriate bezel. Check for conti-
nuity between the ground circuit cavity of the power
outlet wire harness connector and a good ground.
There should be continuity. If OK, go to Step 6. If not
OK, repair the open ground circuit to ground as
required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the IPM fuse as
required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Note position of the retaining bosses (Fig. 4).
(3) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(4) Pull out the base through mounting ring by
gently rocking pliers.
(5) Disconnect the base wires.
(6) Remove light ring and disconnect wire.
INSTALLATION
(1) Position the mounting ring on the instrument
panel and feed the wires through the ring. Index thecap and the mounting ring with the index tab at the
9 o'clock position to the key in the instrument panel.
Install the ring.
(2) Connect the wires to the base. Orientate the
base alignment rib at the 11 o'clock position to mate
the groove in the mounting ring to the base.
(3) Push the base into the bezel until it locks in
place.
(4) Check operation of outlet or element and
install the outlet cap.
Fig. 4 POWER OUTLET
1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
3 - EXTERNAL SNAP-RING PLIERS
4 - PULL BASE OUT-THROUGH MOUNTING RING
8W - 97 - 4 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER OUTLET (Continued)