body CHRYSLER CARAVAN 2005 Service Manual

SPLICE NUMBER LOCATION FIG.
S303 In T/O to Data Link Connector 37, 41, 42
S304 (Export) In Floor Pan Track Wiring 38
S305 Near T/O for Memory Seat/Mirror Module - C2 N/S
S306 In Floor Pan Track Wiring 38
S307 Near T/O for Memory Power Seat Switch N/S
S309 In Floor Pan Track Wiring N/S
S310 Near T/O for C301 35, 36, 37
S311 In Floor Pan Track Wiring N/S
S312 Near T/O for C320 N/S
S313 Near T/O for Power Liftgate Module 47
S316 In Floor Pan Track Wiring 34
S317 Near T/O for Body Control Module 42
S318 Near T/O for Power Seat Circuit Breaker 34
S319 (Export) In Floor Pan Track Wiring 38
S321 Ner T/O for C301 35, 36, 37
S322 Near T/O for C301 37
S323 In Floor Pan Track Wiring 34
S324 In Floor Pan Track Wiring 34
S325 (Export) In Floor Pan Track Wiring 34
S326 Near T/O for C101 35, 36
S330 Near T/O for Power Liftgate Module 47
S331 Near T/O for Power Liftgate Motor 47
S332 In Floor Pan Track Wiring N/S
S333 (3 Zone MTC) In Floor Pan Track Wiring 37
S334 Near T/O to G301 34
S335 Near T/O for Left Rear Reading Lamp N/S
S336 Near T/O for Left Rear Reading Lamp N/S
S337 Near T/O for Right Mid Reading Lamp N/S
S338 Near T/O for Right Visor/Vanity Lamp N/S
S339 Near T/O for C312 N/S
S342 (LHD) Near T/O for Passenger Power Window Motor 44
S343 (LHD) Near T/O for Driver Power Window Motor 43
S344 In T/O to Right Sliding Door Control Module C2 45, 46
S345 Near T/O for Right Sliding Door Motor 45, 46
S346 Near T/O for Driver Power Window Switch 43
S347 Near T/O for Right Sliding Door Lock Motor 45, 46
S348 Near T/O for Left Sliding Door Lock Motor 46
S349 In T/O to Left Sliding Door Control Module - C2 46
S350 Near T/O for Left Sliding Door Motor 46
S352 Near T/O for Liftgate Cinch/Release Motor 49
S354 (Export) Near T/O for C301 36, 37
S354 (Except Export) Near T/O for C101 37
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-15
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE NUMBER LOCATION FIG.
S355 In T/O for C307 N/S
S356 (Export) In Floor Pan Track Wiring 37
S356 (Except Export) Near T/O for Passenger Heated Seat Back N/S
S359 Left Quarter Panel 47
S361 Near T/O for C304 N/S
S362 Near T/O for C304 N/S
S363 Near T/O for C331 N/S
S364 (RHD) Near T/O for Passenger Power Window Window 44
S365 (LHD) Near T/O for Driver Power Window Window N/S
S366 In Passenger Power Heated Seat Wiring Assembly N/S
S367 Near T/O for C301 37
S368 (Diesel) Near T/O for C101 35, 36
S370 (Except Export) In T/O for Integrated Power Module C6 7
S371 In T/O to Power Window Switch N/S
S372 Near T/O for Data Link Connector 41
S373 (Except Export In Floor Pan Track Wiring 37
S374 Near T/O for Body Control Module N/S
S376 (Highline Audio) In Floor Pan Track Wiring 34
S378 Near T/O for C301 35, 36, 37
S380 (Highline Audio) Right Quarter Panel 48
S381 (Highline Audio) Right Quarter Panel 48
S382 (Passenger Heated
Seat)Near T/O for Passenger Seat Weight Sensor N/S
S383 (Parktronics) Rear Fascia N/S
S384 (Parktronics) Rear Fascia N/S
8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 32 LEFT SIDE BODY LHD
8W - 91 - 44 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 33 RIGHT SIDE BODY RHD
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-45
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 34 BODY HARNESS SPLICES
8W - 91 - 46 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 35 BODY HARNESS SPLICES
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-47
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 37 LEFT FRONT BODY SPLICES
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-49
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 38 REAR BODY SPLICES
8W - 91 - 50 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 47 LEFT REAR BODY
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-57
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.
Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 2).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopart
Stud and Bearing Mount. Make certain the new plugis cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS
Damaged or worn threads (excluding spark plug
and camshaft bearing cap attaching threads) can be
repaired. Essentially, this repair consists of drilling
out worn or damaged threads, tapping the hole with
a special Heli-Coil Tap, (or equivalent) and installing
an insert into the tapped hole. This brings the hole
back to its original thread size.
CAUTION: Be sure that the tapped holes maintain
the original center line.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.)
(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
Fig. 2 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
9 - 10 ENGINE 2.4LRS
ENGINE 2.4L (Continued)