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Chrysler / Dodge Minivan Service Manual 2008-2010 Model Year Main: Local: Fax: (800) 956-6668 (952) 890-7851 (952) 808-2775 Your Life. Your Ride. 6591 W. Hwy 13 Savage, MN 55378 www.rollxvans.com TM Chrysler / Dodge Minivan 2008-2010 Model Year Service Manual #08028-011 September 2012 Table of Contents Important Item Locations....................................................................................................................... 1 Important Information............................................................................................................................ 4 Battery Information - General................................................................................................................ 5 Battery Information - Draw Test Procedure........................................................................................... 7 Rollx Vans Power Door (Not OEM) Troubleshooting............................................................................11 Rollx Vans Power Door (Not OEM) Replacement Parts...................................................................... 12 OEM Power Door Troubleshooting...................................................................................................... 13 Door Modifications............................................................................................................................... 14 Exhaust System.................................................................................................................................. 16 Ground Effects / Van Dimensions........................................................................................................ 18 Fuel System........................................................................................................................................ 19 Interior................................................................................................................................................. 25 Kneeler Troubleshooting..................................................................................................................... 27 Kneeler Replacement Parts................................................................................................................ 28 One Touch System Troubleshooting.................................................................................................... 29 One Touch System Overview.............................................................................................................. 30 One Touch System - v8.0 Basic Interface........................................................................................... 32 One Touch System - v8.0 Advanced Interface - Setup........................................................................ 33 One Touch System - v8.0 Advanced Interface - Debugger................................................................. 34 One Touch System - v8.0 Error Codes................................................................................................ 36 One Touch System - Relay Board Troubleshooting............................................................................ 42 In The Floor (Metal Springs) Troubleshooting..................................................................................... 43 In The Floor (Metal Springs) Replacement Parts................................................................................ 44 Folding Ramp Troubleshooting........................................................................................................... 45 Folding Ramp Replacement Parts...................................................................................................... 46 Folding Ramp Motor Install / Removal and Adjustment...................................................................... 49 Rear Heat & Air................................................................................................................................... 51 Table of Contents Remote System SECO (BEFORE 9/19/2011) . .................................................................................. 53 Remote System COMPUSTAR (AFTER 9/19/2011)........................................................................... 54 OTC System - v8.0.............................................................................................................................. 55 Right Sliding Door Extensions............................................................................................................. 59 2008-2010 Power Seats - Seat Detector............................................................................................. 62 2010 Power Seats - Driver w/ Power Only.......................................................................................... 63 2010 Power Seats - Driver w/ Power, Heat & Memory........................................................................ 67 2010 Power Seats - Passenger w/ Power & Heat............................................................................... 71 2008-2009 Power Seats - Driver w/ Power Only................................................................................. 73 2008-2009 Power Seats - Driver w/ Power & Heat............................................................................. 75 2008-2009 Power Seats - Driver w/ Power, Heat & Memory.............................................................. 77 2008-2009 Power Seats - Passenger w/ Power & Heat...................................................................... 81 Power Seats (Pre-Seat Detector) - Resistors...................................................................................... 83 Power Seats (Pre-Seat Detector) Manual or Driver Power Only......................................................... 84 Power Seats (Pre-Seat Detector) - Driver w/ Power and Heat............................................................ 85 Power Seats (Pre-Seat Detector) - Dr. w/ Memory, Pwr and Heat...................................................... 87 Power Seats (Pre-Seat Detector) - Ps. w/ Pwr and Heat.................................................................... 91 Power Seats (Pre Seat Detector) - Dr Memory Seat Shunt Plug........................................................ 92 Rollx Vans Power Door System (MOTOR BAR)................................................................................. 93 Rollx Vans Power Door System REMOTE WIRING (before Jan 2011)...............................................97 Rollx Vans Power Door System REMOTE WIRING (after Jan. 2011).................................................98 Maintenance Information..................................................................................................................... 99 Warranty.......................................................................................................................................... ..100 Important Item Locations Rollx Vans Main Wire Harness (Ceiling Along Passenger’s Side) OEM Main Wire Harness (Floor Along Driver’s Side) OTC Remote Receiver (Before 1/8/09) Main Fuse ITF Ramp Access Panel Power Seat Connector Rollx Vans Seat Detector OTC Relay Panel OTC Remote Receiver (After 1/8/09) One Touch Controller (OTC) Board OTC Fuse Panel (Under Glove Box) Kneeler Passenger Sliding Door Open Switch Rear Heat Rear AC Page Important Item Locations Main Fuse (Engine Compartment) OTC Remote Receiver (Before 1/8/2009) (Center Dash) OTC Remote Receiver (After 1/8/2009) (Rear Passenger Quarter Panel) 6way Seat Fuse (40 Amp) (If Equipped) Main OTC Fuse (40 Amp) OEM Wire Harness Rollx Vans Main Wire Harness Passenger Sliding Door Open Switch OTC Fuse Panel (Under Glove Box - Must Pull Back Fabric) Rollx Vans Remote Power Tie Down (If Equipped) Vans Built after 5/28/2009 are equipped with a Ignition Hot and Neutral Safety Panel to allow for quick connection. See OTC Wiring for more information. Page 6way Seat Controller (If Equipped) Important Item Locations ITF Ramp Access Plate OTC Relay Board (Behind Rear Passenger Quarter Panel) Rear AC (Behind Rear Right Tire) Rear Heat (Front of Rear Right Tire) Kneeler and One Touch Controller Board Power Seat Connector OTC Board Kneeler Page Important Information Ignition Hot For Vans Built Before 5/28/2009 Due to constraints on Chrysler’s OEM Ignition Hot circuit, Rollx Vans installs the Rollx Vans Ignition Hot Box #IGNITION HOT if certain high current accessories are to be added such as a Dual Rollx Vans Ignition Hot Relay Board Wiring Battery System. Power Tiedown can use the OEM Ignition Hot as long as the one below is used. 2008 Chrysler Minivans The Ignition Hot Circuit is located near the Rollx Vans Fuse Panel under the glove box. (Installed if van has multiple accessories or a dual battery) RED (12V CONSTANT) FUSE PK / YL (OEM IGNITION HOT) 40A FUSE BLOCK (UNDER GLOVE BOX) PK / WT (12V IGNITION HOT) RED (12V CONSTANT) MUST TAP INTO OEM IGNITION HOT (PK/YL WIRE) THAT IS LOCATED BEHIND THE CENTER BEZEL GOING INTO THE RADIO YELLOW 20 10A TO ALL ACCESSORIES THAT REQUIRE IGNITION HOT Ignition Hot For Vans Built After 5/28/2009 Ignition Hot and Neutral Safety Panel were added to the OTC Fuse Panel located behind the glove box for all 2008-2009 Chrysler Vans. This is now where Accessories and OTC Board will get required signals. Power Folding Rear Sofa If the van is equipped with a Power Folding Rear Sofa, Rollx Vans disables the FOLD/TAILGATE SWITCH MUX that would allow the seat to be stowed into the floor. Rollx Vans cuts the LG/TN Wire at the switch. Page Battery Information - General Measuring current draw from a battery means we are going to measure the number of Electrons flowing out of the Negative Terminal of the battery and returning to the Positive Terminal. (Yes, it’s true, electrons flow from the negative to positive terminal of a battery.) Electron Flow is known as Current and is measured in Amperes often referred to as Amp(s). One Amp is 18.628 x 1018 electrons. We will use the term Amp(s) and Milli-amps in this procedure. One Milli-amp is a thousandth of an Amp. As an example 125 Milli-amps is .125 of an Amp. The Vans we use have the Negative Terminal of the Battery attached to the frame. Current is “Drawn” from the battery by one or more loads. The Radio is a load. Each Microcomputer in the Van is a load. The OTC Controller is a load. The Ramp Motor is a load. A 6-Way Seat is a load. A Power Tie Down is a load. The Dome-light is a load, etc. Each load draws some amount of current determined by its design. The total current taken from the battery is the sum of all the loads currently running. If as an example, you turn the radio on, you add its current load to what ever is the draw currently being taken from the battery. The current flows out the Negative Terminal, splits up in to branches as it flows through each load, and then merges back together and flows back into the Positive Terminal. The total current flowing back into the Positive Terminal always equals the total current flowing out of the Negative Terminal. You can measure the total draw (current flow) at either terminal of the battery. Always use the Negative Terminal, its safer! The Electronic System found in Chrysler Vans is made up of a number of small Microcontrollers, each monitoring and controlling one or more functions in the vehicle. The Rollx Vans OTC Microcontroller is similar. One characteristic they share is the ability to put themselves into a “Sleep Mode”. While in sleep mode the load they take from the battery is greatly reduced. The Rollx Vans OTC goes to sleep in about ten seconds of non-use. When a Van is shutdown, the engine turned off, the key removed and the doors shut, the Chrysler Microcontrollers start to shut themselves down. They go to sleep in stages. You can see this happen by placing a meter capable of measuring current “in series” with the Negative (Black) Terminal of the battery. Over the course of several minutes the current will drop in stages from a number of Amps to a few Milli-amps. Chrysler spec’s the current draw for a Van in “Sleep Mode” as between 40 and 70 Milli-amps (.040 - .070 Amps) depending on version and features. The Rollx Vans OTC Microcontroller is spec at 8 to 10 Milli-amps (.008-.010 Amps). The Rollx Vans Remote Keyless Entry (RKE) Receiver draws 10-12 Milli-amps (.010-.012 Amps). Add the min and max numbers of each together and you should expect a Van to draw from 58 to 92 Milli-amps (.058-.092 Amps) normally. Note: This is with no other Rollx Vans options installed. As you add options you add their load to the total. To help you better understand battery draw here are common definition of terms used to rate batteries: Amp-Hour Rating: AHR (or A/H) is a commonly used rating of a battery capacity to supply current over a period of time. The Amp-hour rating of battery capacity is calculated by multiplying the current (in amperes) by discharge time (in hours). Amp-hour battery rating is commonly used when describing sealed lead acid batteries. For example: a battery which delivers 2 amperes for 20 hours would have a 40 amp-hour battery rating (2 * 20= 40). A 40 AHR battery can supply 40 amps for 1 hour, 1 amp for 40 hours or any mathematical factor of load and time. Cold Cranking Amperage rating: CCA is the short-term discharge load in amps which a battery can sustain for 30 seconds at 0 degrees F. and not fall below 1.2 volts per cell (7.2V on 12V battery). This rating measures a burst of current that a car needs to start on a cold morning. This rating is used mainly for rating batteries for engine starting capacity. Page Battery Information - General Reserve Capacity rating: RC is the number of minutes a new, fully charged battery at 80 degrees F. will sustain a discharge load of 25 amps to a cut-off voltage of 1.75 volts per cell (10.5V on 12V battery). This rating measures a continuous load on the battery. Note: As the charge of a battery is used up the battery voltage drops. Generally speaking, at 10.5 volts a battery is considered discharged. CCA and RC ratings aren’t meaningful for determining the maximum current draw a battery can sustain over a period of time. The AHR is best used for this. In the vehicle world, CCA is the most common rating found for a battery, and the AHR is often not readily available. The Electronic Department is currently running a series of tests to determine the AHR and max load (for Sleep Mode), for a standard Van battery as well as a high capacity, deep discharge battery (for use with Vans with a large number of accessories). When these tests are complete we will publish the results and get them to you. Some notes on extending battery life: The Van must be “put to sleep” when not in use. This means the user must shut off all accessories and close all the windows and doors. If the doors are not completely shut, the Van will stay awake. The Rollx Vans Ramp and Kneel system should not be deployed! When it is, both the Chrysler Computer System and the Rollx Vans OTC System are awake and drawing high current. This will run the battery down very rapidly. The Van should be started and run for at least fifteen minutes daily to allow the battery to be charged. Page Battery Information - Draw Test Procedure The following procedure should be used to test the current draw from any battery used in our Vans. 1) Insure the battery is fully charged. 2) Remove the key from the ignition switch. 3) Close all the doors including the Sliding doors and the Rear Tailgate. 4) Close all the windows including the Rear Vent Windows. 5) Remove the Negative (Black) cable from the battery and move it to a safe location away from both the Positive (Red) and Negative Terminals of the battery. 6) Acquire a Digital Multimeter with a 20 Amp current range function. NOTE: A standard Van can draw between 15 and 17 amps of current when it is first powered up (When the battery is reconnected). You must use a Multimeter with a 20-amp range. Using a Multimeter with a lower current range function will damage the meter if it does not have an internal fuse. If it has an internal fuse, it will be blown. NOTE: DO NOT RUN THE ROLLX VANS OTC OR TRY TO START THE VAN WHEN YOU HAVE THE METER CONNECTED! YOU WILL DAMAGE THE METER! 7) Place the Function switch of the Multimeter in the 20 Amp Current Measurement position. 8) Connect the Negative (Black) Probe (wire lead) to the Black Jack on the Multimeter. 9) Most Multimeters have more then one Red Jack for the Positive (Red) Probe. They usually have one Jack for measuring AC & DC Voltage and Resistance, along with a second Jack for measuring AC & DC Current. Some Multimeters have more then one Red Jack for measuring current (three Red Jacks total). As an example a meter might have two Red Jacks, one rated for 200 Milli-amps and a second for 20 amps. You should use the 20-amp plug (or the one with the largest rating). 10)Acquire two Test Jumpers with Alligator Clips (Radio Shack # 278-002). Attach one Jumper to the Positive (Red) Probe and the other to the Negative (Black) Probe. 11)Turn the Multimeter on. 12)Attach the other end of the Jumper clipped on the Positive (Red) meter probe to the disconnected Battery cable. NOTE: Polarity does not matter much when measuring current. A positive current is the same as negative current. Disregard the polarity indicator on the Multimeter during these tests. 13)Attach the Jumper on the Negative (Black) meter probe to the Negative Terminal of the battery. NOTE: YOU MAY GET A SPARK WHEN YOU ATTACH THE JUMPER. THIS IS NORMAL. ALL THE CURRENT BEING USED BY THE VAN IS NOW RUNNING THROUGH THE METER. AS MUCH AS 15-17 AMPS). Page Battery Information - Draw Test Procedure 14)The Multimeter should now show a reading. Keep you eye on the meter and watch the draw. A typical Van can have from 18 to 28 Computer modules in it. They are all woke up when power was applied to the Van by attaching your meter probes. As you watch the current reading you will note that it will start to fall. This happens as the computers in the Van decide they are not needed and put themselves to sleep. Chrysler says it can take up to thirty minutes for everything to go into Sleep Mode. The current should drop in stages similar to the sequence below: a. The reading will start as high as 15-17 amps for a short period of time. b. It then falls to 6-8 amps for a short time. c. Then 1 to 1.5 amps for a period of time. d. It will then settle on around .800 amps (800 Milli-amps) for a while. e. Then it may drop to .100 to .200 amps (100 to 200 Milli-amps) for period of time. f. Finally it will drop all the way into Sleep mode, .040 to .100 amps (40 to 100 Milli-amps) and will stay there until the van is woke up. g. Note: The values you will see will vary from Van to Van, from Van type to type and by the number and type of accessories installed on the Van. The important thing is that it drops to a value less the 100 Milli-amps (.100 Amps) for a standard Van when it goes into Sleep Mode. 15)You can wake the van simply by opening the Drivers Side Door for a few seconds, then closing it. 16)Watch the meter again to see the Van go into sleep mode again. You should repeat this test until you are satisfied the Van’s “Sleep Mode” is functioning correctly. Continued on next page. Page Battery Information - Draw Test Procedure This picture shows a complete setup for a Draw Test: Note the Black Probe attached to the Negative Terminal and the Red Probe attached to the Negative Battery Cable. This picture shows a typical Multimeter. Note the Current Range Switch settings and current Probe Jack markings are all in yellow for uA (Micro-Amps), mA (Milli-amps and A (Amps). Also note that the meter has two Jacks for current measurement, “20A” and “uA/mA”. On this meter, for our Draw Test, we would place the Function Switch in the “A” (for Amps) position and plug the Red Probe into the “20A” Jack. The Black Probe always goes in the Black Jack. Page This Page was intentionally left blank Page 10 Rollx Vans Power Door (Not OEM) Troubleshooting Symptom Door does not operate. Possible Cause Front passenger door is locked. Remedy Unlock front passenger door. Make sure all user switches are not Switch is stuck. stuck. Replace 30 or 15 amp blade fuse Blown fuse. located underneath hood near battery. Turn handle all the way counterManual release handle is not engaged. clockwise. Door will open, but ramp will not deploy. Door open limit switch needs adjustment. Adjust the door open limit swtich (#7 on next page). The switch can be accessed by the passenger side rear speaker area (remove the speaker first). Door will open, but not close or door will “jump” closed. Ramp up limit switch is not engaged. Adjust the cam for up limit. Door “ratchets” when operating (make sure kneeler is off). Gear on motor is stripped. Replace motor. Gear on bar is stripped. Replace gear rack (bar). Page 11 Item Qty. 1 1 1 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 Page 12 1 2 8 11 17 4 10 Description DOOR BAR ASM (INCLUDES THE 3 FOLLOWING) MTR BAR DOOR OPENER (RACK AND ASSEMBLY) WIRE HARNESS 5.5" FOR MTR 12V 10NM 10MM DOUBLE GEAR RACK (ONLY RACK) 3/8 X 1 STRIP ARM BAR (FOR MOTOR BAR) - MODIFIED VERSION OF 2005 PART WIRE HARNESS 5.5" FOR MOTOR ONLY W/GEAR ASM (INCLUDES WIRE HARNESS AND SHIMS) BRKT MTR BAR LIMIT SWITCH, 2008 SWITCH DPDT (CHERRY) 15 Part # 10026ASM 10026 310-1059 210-1011 10026-4 1126318 10026-22-08 310-1059 10026-15ASM MB1006-08 E19-50H 5 Item Qty. 8 1 9 1 10 1 11 N/A 12 3 13 2 14 1 15 1 16 1 17 2 18 1 16 18 9 13 6 Description HANDLE CHROME INSIDE SEATBELT MOUNT BRACKET, 2008 DOOR ARM PLATE, 2008 MANUAL RELEASE TENSION ADJUSTMENT 1/4-20 YZ NE NYLOCK 6-32 NYLOCK NM Z HCS 1/4-20X1 1/4 YZ8QP HCS 3/8-16 X 1YZ8 QPA (ADJUSTMENT) SHIM KIT FOR DOOR OPENERS (INCLUDES ALL 3 - VARYING SIZES) #10-32X2 HEX HEAD (5/32) PARTIALLY THREADED SCREW #10-32X2-1/2 HEX HEAD (5/32) PARTIALLY THREADED SCREW (NUT ON BACK) 12 14 7 Part # 6022 MB08001 MB08002 NA 1137183 1137010 0115007 0115105 10026-12 SHOP SUPPLY SHOP SUPPLY 12 COM NC NO NC NO 3 COM Rollx Vans Power Door For 2008 Chrysler Exploded View Rollx Vans Power Door (Not OEM) Replacement Parts OEM Power Door Troubleshooting Note: In order to disable the OEM door from closing when the ramp is out, Rollx Vans interupts Chrysler’s CAN BUS to prevent the door from getting any signal to close. The StarScan Tool will record a “No Communication with Right Rear Door Module” everytime the Rollx Vans system deploys the ramp and simply overwrite itself each cycle thereafter. This is a normal trouble code and is to be expected. Symptom Passenger sliding door does NOT OPEN with interior Rollx Vans user button. Ramp sliding door does NOT OPEN with interior OEM push buttons after pressing OTC reset button. Ramp sliding door does NOT attempt to CLOSE after ramp stows. Ramp sliding door attempts to close (door motor runs) after ramp stows, but door does not move. Possible Cause Remedy Van is NOT in park. Overhead on/off switch is turned to the OFF position. OTC program failure. Place van into park. Turn switch to ON position. OTC reads low voltage. Start van's engine and press OTC reset button. If door still does not open review OTC board display and contact customer service. Bad OTC board. Press the OTC reset button and while in Idle Mode press a user button and watch the LED. Notice if OTC appears to be working properly. Review error codes stored and call customer service. Main OTC fuse (40 amp) is blown. Replace fuse under hood by battery. OEM overhead ON / OFF switch is OFF. Turn switch to ON position. This switch enables / disables the OEM buttons located on the B pillars that Rollx Vans uses to trigger the sliding door to open or close. Defective OEM door opener. Operate door manually and contact customer service. Ramp up limit switch is not being activated properly. Close door manually, press OTC reset button, and press Rollx Vans user button to operate system again. If door still does not attempt to close after ramp is stowed, review OTC board display and contact customer service. Defective door open bracket. Adjust the bracket and contact customer service. Defective OEM door opener. Ramp sliding door kicks back when opening or closing. Obstruction. Ramp needs adjustment (Foldout only). OEM door sensitivity set low. Ramp sliding door opens and van kneels, but when door is all the way open, van unkneels and cycle ends. OEM Door Ajar Pin Switch (Rollx Vans Door Close signal) is never deactivated when door begins to open. Ramp sliding door does not seal when almost closed. Ramp sliding door does NOT OPEN manually. Ramp sliding door does NOT OPEN manually from interior handle, but does from exterior handle. Ramp sliding door closes half way and then moves back and forth. Ramp sliding door will NOT CLOSE manually. 10/2/2012 Ramp needs adjustment (Foldout only). Defective OEM cinch motor. Door is locked. Press OTC reset button. Press OTC reset button, press interior OEM push button to see if door will close automatically. If door still does not respond, review OTC board display and contact customer service. Check door track for any debris and remove. Adjust folding ramp to stow more. Contact local Chrysler Dealership. If the OTC thinks the door is open and closed it will end the cycle. Examine switch / wiring. Adjust folding ramp to stow more. Operate door manually and contact customer service. Unlock door. When pulling door handle, pull handle out and then slide door to open. Child safety lock is activated. See OEM owner manual to deactivate child safety lock. Stuck door open limit switch. Adjust swtich located in rear of lower door track. Door handle is not releasing. Obstruction. 2008 Trouble Shooting.xls Page 13 Pull handle to disengage latch and slide to close. Check door track for any debris and remove. Page 1 Door Modifications Door extension kits part numbers and descriptions Inner Door Skin (Extension) Driver Side - #B08180-D5 Passenger Side - #B08180-P5 B08180-D5-KIT-ITF -Door skin svc kit itf dr B08180-d5-kit-fo -door skin svc kit fo dr B08180-p5-kit-itf -Door skin svs kit itf pass B08180-p5-kit-fo -Door skin svs kit fo pass #10277 - Rivets (9 per Door) Current #B08180-DP6 - L BRKT DOOR SKIN DR/PASS 08 Before 10/20/2008 #10503 - 1”X 1” 14GA ROLLED ANGLE #B08033 ‘08 LOWER DOOR ARM (Spaceship bracket) Outer Sliding Door #10277 - Rivets (6 per Door) OEM BOLT (3) #6505 480AA CABLE POWER DOOR 2008 #AR-2008 OEM LOWER DOOR ROLLER ARM Passenger Side - #5020 920AB Driver Side - #5020 921AB DOOR TRACK EXT BKT UPPR 08 #B08030ASM Needs to be painted to match van Page 14 BOLT (3) - #0115007 WASHER (3) - #1133004 Door Modifications DOOR OPEN SWITCH ASSEMBLY - #05089-003 FHSCS 1/4-20X1/2 ZB #94222 M+ ZOO FHSCS 1/4-20X1/2 ZB #94222 DOOR TRACK EXT BKT LOWR 08 #B08032 (#B08032-1 Vans Started after 7/21/2010) DOOR TRACK EXT BKT LOWR 08 ASM #B08032ASM (#B08032-1ASM Vans Started after 7/21/2010) (Includes Switch, Wire Harness, and Bracket) SNAKE CONNECT BLOCK SLIDE ARM #B08050 (Not Shown) Door track kits and descriptionsincludes oem track and door open switch bracket B08059asm-dr - Door track asm 08-09 dr B08059asm-dr-2010 - Door track asm 10-12 dr B08059asm-ps - Door track asm 08-09 ps B08059asm-ps-2010 - Door track asm 10-12 ps Passenger Sliding Door Middle Track BUMPER, MIDDLE TRACK #9306K14 Page 15 Exhaust System OEM Catalytic Converter / O2 Sensor Rollx Vans Exhaust #B08200 On 4.0L Vans #B08202 Rollx Vans Weld OEM Hanger Rollx Vans begins their exhaust from the OEM Catalytic Converter (Rollx Vans does not modify the OEM Catalytic Converter or OEM 02 Sensor). Rollx Vans Exhaust is welded to the OEM Catalytic Converter and runs down the passenger side of the van. Rollx Vans reuses the OEM Hangers to support the exhaust. Rollx Vans Exhaust pipe is 2-1/4 inch diameter aluminized tubing and replaces the OEM 2-1/2 inch tubing. Rollx Vans Exhaust #B08201-SS Rollx Vans Weld Page 16 Exhaust System Rollx Vans Exhaust #B08201-SS Rollx Vans Weld OEM Muffler and Tailpipe Rollx Vans Exhaust continues over the rear axle and is welded to the OEM Muffler and Tailpipe. Rollx Vans eliminates the OEM Resonator. Page 17 Ground Effects & Van Dimensions #B08180-P =�Passenger�Side #B08180-D�=�Driver�Side (Chrysler�Vans�Only) #B08180-P4 #B08180-D4 (Dodge�Vans�Only) #B08180-P4D #B08180-D4D (Before�12/2/08) #B08180-P3 #B08180-D3 (Before�12/2/08) #B08180-P2 #B08180-D2 (After�12/2/08) #B08180-P3.2 #B08180-D3.2 (After�12/2/08) #B08180-P2.2 #B08180-D2.2 #B08180-P1 #B08180-D1 When�replacing�either�of�these�ground�effects�on�a�2008�Chrysler�van�built�before�12/2/08.�order as�follows: � D3�or�P3�=�it�is�necessary�to�replace�both�the�D2�and�D3�with�the�new�D2.2�and�D3.2 (same�for�passenger�side). � D2�or�P2�=�we�have�about�20�in�stock�of�each�so�just�replace�that�required�piece�until out�of�stock,�then�follow�above�rule. 2008�Chrysler�/�Dodge�Minivan�Dimension�Sheet 3 1 A 2 4 5 8 6 6 7 Rollx�Vans�Chrysler/Dodge In�The�Floor�Ramp 11�Inch�Drop 1 Floor�to�Ceiling�Height 58 2 Passenger�Sliding�Door�Opening�Height 54.5 3 Floor�to�Overhead�Console 57 4 Passenger�Sliding�Door�Opening�Width 31.5 5 Cargo Area�Length�(Rear�"z"�to�Firewall Along�Floor) 84 6 Ground�Clearance�-�Ground�Effect 7 7 Ramp�Length 50 8 Ramp�Width�(Inside�Wall�to�Inside�Wall) 30 Cargo Area�Width�When�Closed�(Door�to�Door�/�Door�to�Ramp) 66.5 Ground�Clearance�-�Lowest�Point�(Exhaust) 5.5 Cargo Area�Length�(Rear�Sofa�to�Clip-in�Base) 54.5 * All�measurements�are�subject�to�change�depending�on�various�van�configurations�and�should�be�used�as�approximations. Measurement Description Page 18 Rollx�Vans�Chrysler/Dodge Folding�Ramp 11�Inch�Drop 58 54 57 31.5 84 7 55.5 29 61.5 5.5 54.5 Fuel System 2008-2009 Chrysler Town & Country / Dodge Grand Caravan (3.3L, 3.8L & 4.0L) Rollx Vans Fuel / Emission System Overview (V5) OEM Fuel Quick Disconnect (5/16, 0°) To Engine OEM EGR Valve OEM Plastic Line OEM Quick Disconnect (3/8, 45°) Rollx Vans Main Fuel Metal Line (5/16) Pre-modified OEM Setup OEM Filler Neck Top (Gas Cap) Rollx Vans Charcoal Canister Vent Metal Line (3/8) OEM Charcoal Canister Vent Line Rollx Vans Filler Neck Metal Tube OEM Fuel Fill Vent Line Rollx Vans Fuel Fill Vent Hose (5/16) OEM Fuel Tank OEM Charcoal Canister Rollx Vans Charcoal Canister Vent Hose (5/8) OEM Fuel Pump / OEM Fuel Filter Page 19 Rollx Vans Main Fuel Hose (3/8) Page 20 0° OET 15 Rollx Vans Charcoal Canister Vent Hose (5/8) #10929-00834 (FUEL LINE 5/8-R7) 53 inches OEM Quick Disconnect (5/8) OEM Charcoal Canister Rollx Vans Fuel Fill Vent Hose (5/16) #H-211 (5/16 HIGH PRESSURE HOSE-R9) 37 inches OEM Quick Disconnect (5/16) OEM Fuel Fill Vent Metal Line OEM Filler Neck Top (Gas Cap) Rollx Vans Main Fuel Metal Line (5/16) #126299 (5/16X028/X13' FUSION) 45° OET 17 90° OET 15 OEM Fuel Tank 90° Clamp #10 OEM Fuel Pump / OEM Fuel Filter 45° Clamp #10 90° 90° OET 17 OEM Charcoal Canister Vent Line OEM Quick Disconnect (3/8, 90°)) OEM Quick Disconnect (3/8) Rollx Vans Main Fuel Hose (3/8) #H-212 3/8 HIGH PRESSURE HOSE-R9) 40 inches OEM Quick Disconnect (5/8) Rollx Vans Filler Neck #B08103ASM (FILLER NECK 2008 ASM) Rollx Vans Charcoal Canister Vent Metal Line (3/8) #101865 (3/8X028X13' FUSION WELD) Fuel System Fuel System OEM Fuel Filler Neck (Gas Cap) OEM Fuel Fill Neck OEM Fuel Fill Vent Line Rollx Vans Fill Neck Extension #B08103 (Aluminized Steel Tubing) Rollx Vans Fuel Fill Neck Assembly #B08103ASM OEM Quick Disconnect with Rollx Vans Clamp #OET 1315 (5/16) Rollx Vans Fuel Fill Vent Hose #H-211 (5/16 Fuel Injection Hose,SAE 30R9, Goodyear) Rollx Vans welds a Fill Neck Extension onto OEM Fuel Fill Neck to extend the OEM Fuel Fill Neck to the OEM Fill Neck Hose that attaches to the tank. The completed assembly is #B08103ASM that includes the OEM Fuel Fill Neck welded to the Rollx Vans Fill Neck Extension. The modified filler neck Is smoke tested for possible pin hole leaks. Rollx Vans attaches a Fuel Fill Vent Hose that begins at the gas tank to the OEM Fuel Fill Vent Line with a 9/16 clamp. This hose and the filler neck tube are routed underneath the frame. Page 21 Fuel System Rollx Vans Main Fuel Hose #H-212 (3/8 Fuel Injection Hose,SAE 30R9,180 PSI,WP, CARB #c-u-06-002, Gates Corp.) OEM Quick Disconnet with Rollx Vans Clamp #OET 1317 (3/8) Rollx Vans Charcoal Canister Vent Hose #10929-00834 (5/8 Fuel/Emissions Hose, SAE 30R7, Goodyear) OEM Quick Disconnect with #10 Hose Clamp Rollx Vans Fuel Fill Vent Hose #H-211 (5/16 Fuel Injection Hose,SAE 30R9, Goodyear) OEM Quick Disconnect with Rollx Vans Clamp #OET 1315 (5/16) Rollx Vans reuses the OEM Gas Tank. Rollx Vans replaces OEM Fuel Fill Vent Hose with Rollx Vans Fuel Fill Vent Hose that runs to OEM Fuel Vent Line near Filler Neck top (Gas Cap). Rollx Vans replaces OEM Charcoal Canister Vent Hose with Rollx Vans Charcoal Canister Vent Hose that runs to OEM Charcoal Canister. Rollx Vans does not modify the OEM Charcoal Canister or its mounting. Rollx Vans replaces OEM Main Fuel Hose with Rollx Vans Main Fuel Hose that runs to Rollx Vans Main Fuel Metal Line where it is attached to the flared metal line with the OEM Quick Disconnect. OEM Charcoal Canister (OEM mounting) Rollx Vans Fuel Fill Vent Hose OEM Quick Disconnect with #10 Hose Clamp Rollx Vans Charcoal Canister Vent Hose #10929-00834 (5/8 Fuel/Emissions Hose, SAE 30R7, Goodyear) OEM Fuel Fill Hose at Tank OEM Clamp Page 22 Rollx Vans Fill Neck Extension #B08103ASM (Aluminized Steel Tubing) Fuel System A) Rollx Vans runs the Rollx Vans Main Fuel Metal Line (5/16) under the driver side of the van using P-Clamps to secure. B) The Rollx Vans Main Fuel Metal Line (5/16) is routed up the rear z, flared and attached to OEM Quick Disconnect. C) The Rollx Vans Main Fuel Metal Line (5/16) is routed up under the engine compartment, flared and attached to OEM Quick Disconnect. B OEM Fuel Quick Disconnect (5/16) C OEM Fuel Quick Disconnect (5/16, 0°) Rollx Vans Main Fuel Metal Line (5/16) #126299 (5/16X028/X13' FUSION) Rollx Vans Main Fuel Metal Line (5/16) #126299 (5/16X028/X13' FUSION) Engine Compartment A Rollx Vans Main Fuel Metal Line (5/16) #126299 (5/16X028/X13' FUSION) Page 23 Fuel System A) Rollx Vans runs the Rollx Vans Canister Vent Metal Line (3/8) under the passenger side of the van using P-Clamps to secure. B) The Rollx Vans Canister Vent Metal Line (3/8) is routed up under the engine compartment, flared and attached to OEM Quick Disconnect. C) The Rollx Vans Canister Vent Metal Line (3/8) is routed up the rear z, flared and attached to OEM Quick Disconnect. OEM EGR Valve OEM Quick Disconnect (3/8, 45°) B C Rollx Vans Charcoal Canister Vent Metal Line (3/8) #101865 (3/8X028X13' FUSION WELD) OEM Plastic Line Engine Compartment Rollx Vans Charcoal Canister Vent Metal Line (3/8) #101865 (3/8X028X13' FUSION WELD) OEM Quick Disconnect (3/8, 90°)) A Rollx Vans Charcoal Canister Vent Metal Line (3/8) #101865 (3/8X028X13' FUSION WELD) Page 24 Interior FOLDOUT RAMP ROLLER ASM (NOT SHOWN, FOLDOUT RAMP ONLY) BRACKET STABALIZER, 2008 - #F08018 ROLLERS CUSHIONED - #22875T11 B PILLAR PASS INTERIOR #B8801-1 DOOR PANEL PASS INTERIOR #B8803-1 L TRACK 5 HOLE - #10006 L TRACK 6 HOLE - #10007 (#10007 NOT SHOWN, IN FRONT OF SOFA) 8" SECTION W/ 4 COUNTER #Fe200763 B PILLAR DR INTERIOR #B8800-1 DOOR PANEL DR INTERIOR #B8802-1 Interior Wire Cover #B8806-1 (may need to be painted to match) END CAP FOR SERIES L #8663 END CAP Page 25 Interior CLIP IN FOOTREST11 IN.,DR #4003-11INCH-D-FOOTREST #4003-11INCH-P-FOOTREST CLIP IN COVER FLAP (NOT SHOWN FLAP TO ACCESS SEAT CONNECTORS) #B08070 SEAT BELTS QUARTZ #HS66MD5 CLIP IN BASE,11 #4003-11-ASM-DR #4003-11-ASM-PS (INCLUDES FOOTREST) SEAT BELT MOUNT BRKT "Z" #STBLT1 SEATBELT EXT L TRACK #5086227AA-L (seat belt 2008 unmodified) #5086227AA SEATBELT EXT 2008 12"FEM/MALE NOT SHOWN - MAKES SHOULDER HARNESS LONGER) #5086227AA-EXT COVER, DOGBONE #B2205-1 TIRE COVER 2008 ASM #B08060ASM KNEEL ACCESS COVER (NO PART NUMBER) RATCHET, REVERSIBLE - #800-0072 SOCKET 3/8" - #4PW71 Page 26 Kneeler Troubleshooting Symptom Van does NOT LOWER to ground while door is opening after Rollx Vans user button is pressed. Possible Cause Kneel on / off switch is turned OFF. Remedy Turn kneel switch to the ON position. Kneel motor. Review display board. Turn kneel switch to the OFF position and press OTC reset button. Temporarily operate sytem without kneel option enabled. Contact customer service. Kneel chain is broken. After van is lowered to ground the kneeler makes a loud ratcheting sound. Van will NOT RAISE when ramp is stowed. Kneel down limit switch was not activated. Adjust kneel down limit switch. Replace if broken. Contact customer service. Kneel on / off switch is turned OFF. Turn kneel switch to the ON position. Kneel motor. Review display board. Manually un-kneel van, turn kneel switch to the OFF position and press OTC reset button. Contact customer service. Kneel up limit switch is activated incorrectly. Van raises and while door closing the kneeler ratchets. 12/6/2012 Kneel up limit switch is not activated. P 27 ageShooting.xls 2008 Trouble Adjust kneel up limit switch. Replace if broken. Contact customer service. Once door is closed and van is at normal height, turn kneeling switch to the OFF position and contact customer service. Page 1 Qty. 1 2 1 1.5 1 1 2 1 1 1 2 3 4 4 1 1 1 1 1 Item 1 2 3 3A 4 5 6 7 8 9 10 11 12 13 14 15 Description ACTUATOR KNEELING ASM 50 CONN LINK KNEEL CHAIN ASM 2008 CHAIN 50 ROLLER KNEEL CHAIN SWIVEL COTTER PIN FLANGE BRG SPRING TORSION ASM SPROCKET FOR #50 CHAIN KNEEL LIMIT SWITCH ASM SWITCH TANG BZ-2RW80-A2 HCS 3/8-16 X 1YZ8 QPA PPH MS 6-32 X 1 1/2Z 10-32 NYLOCK NMZ ACTUATOR GUIDE ASM Parts on Van KNEEL AXLE MOUNT RATCHET REVERSIBLE SOCKET 3/8" BOOT BLK "2005" KNEELACT 1 Page 28 B08022 800-0072* 4PW71* 152303* * Not Shown Part # K2XG20-12V-08RX-ASM N0511-C 6261K534ASM-02 2008 6261K534 K05012 98338A220 10FDU06 LTR-075M-6-5ASM 6280K249 03220-003 6X284 0115105 1128838 1137015 K05006ASM 13 11 11 2 9 7 10 12 3 6 3A 15 8 6 5 2 4 #KNEEL 2008 SNG OT-01 - KNEEL 2008 OTC SNG COMPLETE ASM 14 Kneeler Replacement Parts One Touch System Troubleshooting Important: If OTC Board is removed, the OEM System will not operate normally unless the CAN Bus Shunt is installed. The shunt is attached to the wire harness behind the OTC board. See OTC Wiring Diagram for more information. Symptom Remedy Check that OTC ON/OFF switch is on. The power toggle switch is on the actual OTC board itself. No power to One Touch Controller (OTC). Ensure the connections on the back of the OTC board are tight. Check the OTC main fuse (40 amp) located near the vehicles main battery. Reset the OTC.The reset is located on the dash by the drivers left knee and on the OTC board (red button). Check battery voltage. Battery is low. Turn off the OTC and charge battery. Note: The alarm will sound when the battery voltage is below 11.4 VDC. OTC beeps 4 times when the user tries to This is to prevent the OTC system from draining the battery far run a normal open/close cycle. enough as to prevent the vehicle from starting. This level is adjustable in the boards setup menu. The van's battery is dead. The OTC display is garbled Van has been sitting for an extended period of time. Charge the battery. Check the current draw by placing an ampeter in series with the negative terminal on the battery with all doors closed and engine off. The draw varies, but awake, the system should be less than .850 amps and when sleeping, less than .050 amps. Additional equipment installed will also vary these numbers. See Battery section for more information. Reset the OTC. The reset is located on the dash by the drivers left knee and on the OTC board (red button). Page 29 One Touch System Overview The Rollx Vans One Touch Controller, known as the OTC, is a Single Board Computer specifically designed for the Rollx Vans system. The OTC system was designed to be independent to the operation of the Chrysler computer system. When power is removed from the OTC, it has no effect on the operation of the Chrysler system as long as the OTC Shunt Plug is installed into the OTC Main Harness on all 2008 Chrysler Vans due to the CAN BUS system (see OTC Wiring Diagram for more information). The OTC is a low power system. When the OTC is in Sleep Mode with the Display disabled, it typically draws less then 10ma of current from the battery. When awake in Idle Mode (not running a cycle) with the Display enabled, it typically draws less than 200ma of current from the battery. The current state of the OTC can be determined by viewing the Display. During open or close operation the progress of the system can be tracked by watching the Display. 8 OTC V8.0 Sequence of Operation Open Cycle 1) The OTC is activated by any Rollx Vans User Switch or Remote being pressed. 2) Door unlock command sent (1 sec.) To Front Passenger Door Control Module to unlock all doors. 3) Door open command sent to OEM B-Pillar Door Open/Close Button to open the passenger sliding door. 4) Door starts to open. 5) Kneeler motor is turned on and starts to lower van. *If door fails to open within 2 seconds of User Switch being pressed, cycle stops (van unkneels and cycle is ended) 6) Door reaches open position and activates Rollx Vans Door Open Limit Switch. 7) Passenger sliding door is disabled by OTC interrupting the CAN Bus signal with built in relay. 8) Ramp motor is turned on and starts to deploy. 9) Kneeler stops lowering when Kneel Down Limit Switch is activated. 10) Ramp stops deploying when Ramp Down Limit Switch is activated. 11) OTC enters Idle Mode. 12) OTC enters Sleep Mode. Close Cycle 1) The OTC is activated by any Rollx Vans User Switch or Remote being pressed. 2) Ramp motor is turned on and starts to stow. 3) After a few seconds (ramp is off the ground and begun to slide into van) kneeler motor is turned on and starts to raise the van. 4) Kneeler stops raising when Kneel Up Limit Switch is activated. 5) Ramp stops stowing when Ramp Up Limit Switch is activated. 6) Passenger sliding door is enabled by OTC reconnecting the CAN Bus signal with built in relay. 7) Door close command sent to OEM B-Pillar Door Open/Close Button to close the passenger sliding door. 8) OTC receives signal from OEM Door Ajar Pin Switch that door is closed. 9) OTC enters Idle Mode. 10) OTC enters Sleep Mode. Note: There are “Watch Dogs” programmed in the OTC software that act as timers to end a function if the function does not complete within a certain amount of expected and very reasonable time. Page 30 One Touch System Overview INPUTS KNEEL DISABLE SWITCH (Violet wire) Allows the user to enable (the “I” position) or disable (the “O” position) the kneeling system. There is no display for this input. USER SWITCH INPUT (Blue wire) Active while any Rollx Vans user button or Rollx Vans remote is pressed. IGNITION INPUT (Pink/White wire) Indicates the status of the van ignition switch. When active, it indicates the ignition switch is off and the OTC will go into sleep mode when not in use. When not active it indicates the van ignition switch is on and the OTC will not go into sleep mode. NEUTRAL INPUT (Green wire) Indicates the status of the gear shifter. When active, the van is either in neutral or park. The OTC system will not run a operational cycle unless the van is in neutral or park. DOOR CLOSE LIMIT INPUT (Violet/Yellow wire) Active when the right side sliding door is fully shut. DOOR OPEN LIMIT INPUT (Orange/Red wire) Active when the right side sliding door is fully open. RAMP DOWN LIMIT INPUT (Red/White wire) Active when the ramp is in the down position. RAMP UP LIMIT INPUT (Red/Green wire) Active when the ramp in the up position. KNEEL DOWN LIMIT INPUT (Yellow/Green wire) Active when the kneeler is in the down position. KNEEL UP LIMIT INPUT (Yellow/White wire) Active when the kneeler is in the up position. OUTPUTS System Status: Indicates if the system is ready to except a command. It is off when the OTC is in sleep mode. V6.0 & V8.0 Display will show Rollx Vans: Idle. RAMP DOWN MOTOR OUTPUT (Red wire) Active when the OTC is driving the ramp down (V6.0 & V8.0 OTC boards have obstacle detection monitoring this output). RAMP UP MOTOR OUTPUT (Red/Black wire) Active when the OTC is driving the ramp up (V6.0 & V8.0 OTC boards have obstacle detection monitoring this output). RAMP DISABLE OUTPUT (Red/Blue wire) Active anytime when the OTC is driving the ramp up or down. It indicates the ramp manual mode is disabled. KNEEL UP MOTOR OUTPUT (Yellow/Red wire) Active when the OTC is driving the kneeler up. KNEEL DOWN MOTOR OUTPUT (Yellow/Black wire) Active when the OTC is driving the kneeler up. DOOR DISABLE OUTPUT (Orange/Blue) Used by the OTC to disable the Chrysler right side door controller anytime it wants to open the ramp. This prevents the right side door controller from banging the right side sliding door against the ramp. DOOR CONTROL OUTPUT (Orange) OTC sends a command to the Chrysler system to open or close the right side sliding door. DOOR UNLOCK OUTPUT (Yellow/Brown) OTC sends a command to the Chrysler system to unlock the doors at the beginning of an open cycle. Page 31 ESC ESC Page 32 DOWN ENTER Scrolls Last Error Kneel Down ESC UP ENTER START Rollx Vans Idle Hardware Version V-X.XX ESC DOWN ENTER ENTER UP Serial # XXXXX DOWN UP Manual Kneeler Kneel Up DOWN UP Rollx Vans Service 800-956-6668 Software Version Mod X DOWN ENTER ESC ESC ENTER Password Required DOWN UP ENTER Data Logger Setup DOWN UP #02 0000:00:00 Status: Err# XX ESC UP #03 0000:00:00 Status: Err# XX (Move to next Log Entry) DOWN ENTER #01 0000:00:00 Scrolls Error Info To get into setup a password is required. Setup options include Cycle Tester, Battery Alarm Level, Debugger, Cycle Counter, Ramp Type, Kneeler Mode, and Obstacle Detection Level. For more info on Debugger see next page. Also see OTC 6.0 User Interface Flowchart for more in depth information. ESC UP #01 0000:00:00 Status: Err# XX (Move to previous Log Entry) #02 0000:00:00 Scrolls Error Info #03 0000:00:00 Scrolls Error Info One Touch Controller Basic Operation 1) How to manually kneel van 2) How to check software and hardware versions 3) How to review error codes in Data Logger One Touch System - v8.0 Basic Interface One Touch System - v8.0 Advanced Interface - Setup Options within Setup Setup View Data Log START Password Good View the past 30 errors recorded. Hit enter to view Error Details. UP ENTER ESC DOWN Setup Data Logger Mode Select “Log All Mode” or “Log Error Only Mode” to decide which type of errors to record. Default is “Log Error Only Mode”. Setup Engineering Setup Cycle Counters Setup Kneeler Displays the number of Open and Close cycles. Select if Kneel System installed or not. Default is “Yes”. Setup Battery Alarm Select the Battery Alarm Trip Point between 10.9 vdc and 12.4 vdc. If OTC reads vdc below Trip Point, OTC will not operate. Default is “11.5 vdc). Setup Cycle Tester Select the number of cycles between 10 and 99 you want the system to run automatically in order to test. Hit Esc to stop. Setup Serial Number Setup Debug Setup Hobbs Meter Setup OB Detect Level Select between “Input Test Mode” and “Output Test Mode” to test OTC System operation. THIS IS VERY USEFUL. For more information see How To Use Debugger on next page. Displays current Clock Time. Select the sensativity of the ramp’s obsticle detection between 0 and 9. “0” is the weakest and “9” is the strongest (ramp is very hard to stop at “9”). Default is “5”. Page 33 One Touch System - v8.0 Advanced Interface - Debugger How to Use Debugger (Output Test Mode) START Use extreme caution when using the Output Test Mode. The Output Test Modes sends the signal directly to the OTC Relay Board which results in power going to the called motor. No safeties are in place (ie. The Ramp Down will operate the ramp regardless if the door is open or closed. Output Test Mode UP ENTER ESC Output Test Mode Ramp Down Relay should click and ramp should go out. Output Test Mode Door Unlock All OEM Doors should unlock. Output Test Mode Door Close Closes the passenger sliding door. Output Test Mode Door Open Opens the passenger sliding door. Output Test Mode Kneel Down Press and hold to operate the kneeler and lower the van. Relay should click. Output Test Mode Kneel Up Press and hold to operate the kneeler and raise the van. Relay should click. DOWN Output Test Mode Ramp Enable Relay should click. Output Test Mode Ramp Up Relay should click and ramp should go out. Page 34 One Touch System - v8.0 Advanced Interface - Debugger How to Use Debugger (Input Test Mode) START Input Test Mode UP ENTER ESC The Input Test mode is very useful for testing the various limit switches the systems requires. To operate: 1) Select a Limit Switch (Input) you would like to test from the list below. 2) Notice if the Switch is “On” or “Off” when it is suppose to be. The audible beeps let you test the switch by hand without looking at the OTC Board. - On (activated) = Double Beeps - Off (not activated) = Single Beeps Input Test Mode Ramp Up ON when ramp is all the way in. Input Test Mode Neutral ON when van is in Park or Neutral. Input Test Mode Door Close ON when passenger sliding door is closed. Input Test Mode Door Open ON when passenger sliding door is all the way open. Input Test Mode Kneel Sw ON when Dash Kneel On/Off switch is on. Input Test Mode Kneel Down ON when kneeler is all the way down (knelt). DOWN Input Test Mode Kneel Up ON when kneeler is all the way up (normal). Input Test Mode Ramp Down ON when ramp is all the way out. Page 35 One Touch System - v8.0 Error Codes For information about OTC Interface and how to use the Debugger, please refer to 'One Touch System - v8.0 Advanced Interace' section. Remember, in Input Test Mode, double beeps indicate the switch is on or activated and single beeps indicate that it is not. Also refer to the 'One Touch System - Relay Board Troubleshooting' for more information about the Relay Board, its Overide Switches and LED Indicator Lights. Code Description - What Caused the Code Everytime before the OTC cycles, it checks the Main Battery's voltage. If reading is below the value set in the OTC Setup, the OTC will continue to operate, but will indicate a low battery warning. The default value is 11.5 volts. Diagnostic Tests More Information Rollx Vans recommends starting your van every 4-5 days, Perform a Draw Test allow it to run 15-20 minutes to keep the battery at a Follow instuctions in 'Battery Information - Draw Test Procedure' sufficient state of charge. Section A timer is included on the OTC that will shut it off after 5 minutes UNLESS in Setup Mode. Update OTC if needed. Error 1 - Battery Low Error Page 36 One Touch System - v8.0 Error Codes Code Description - What Caused the Code Door Control Output failure (The OTC did not successfully control the door to open or close). The OTC did not receive the signal that the door came off the OEM Door Ajar Switch when opening or did not receive the signal that the door came off the Rollx Vans Door Open Switch when closing. Once the OTC sends the signal to open the door, it waits about 2 seconds to see if the Door Ajar Switch is not activated. If the Door Ajar Switch is still active, this message will appear. More Information Error 11 - Door Control Error Diagnostic Tests Output Test Place OTC in Debug - Output Test Mode to verify OTC operates the door correctly by sending signal to OEM B-Pillar Switch and/or OEM Front Passenger Door Unlock Switch. 1) Check Door Open. 2) Check Door Close. 3) Check Door Unlock. 4) Check Ramp Enable. This closes a relay on the OTC Relay Board that enables the ramp to run (prevents the ramp from running if the door is not open, door open enables ramp enable). OEM B-Pillar Switch / Door On/Off If off, the OEM Overhead Power Sliding Door On/Off Switch will prevent the door from operating from the OEM B-Pillar Switch. The OTC uses this switch to open or close the door. When off, the OTC can not control the door. Make sure the switch is on and try hitting the OEM B-Pillar switch. If the door still does not work, likely an OEM issue. If OEM function works, but OTC does not check wiring. Door Unlock Switch Door must be unlocked to open. First try OEM Unlock Switch in Passenger Front Door. The OTC uses this switch to unlock all the doors before an Door Open Command is sent. If OEM Switch does not unlock doors, likely an OEM issue. If OEM functions, but OTC does not check wiring. Input Test Place OTC in Debug - Input Test Mode to verify limits operate correctly. 1) Check Door Open (Rollx Vans Door Open Switch), by opening door all the way in Door Open. 2) Check Door Close (OEM Door Ajar Switch), by close door all the way in Door Close. Rollx Vans taps into OEM Door Ajar Door Ajar Switch Switch in Lower B-Pillar (See OTC Wiring for more If the OEM Door Ajar Switch is not deactivated within 2 information). seconds of the start of the cycle, Door Control Error will be returned. Page 37 One Touch System - v8.0 Error Codes Code Error 18 - Ramp Obstacle Detection Error Diagnostic Tests Check Error Log for multiple Obstactle Detection Errors. If there are many, raise the level in Setup. Input Test Place OTC in Debug - Input Test Mode to verify limits operate correctly. 1) Check Ramp Up [Limit Switch] by operating the ramp with Power Overide Switch (ITF Ramp) or manually raising (Folding Ramp). 2) Check Ramp Down [Limit Switch] by operating the ramp with Power Overide Switch (ITF Ramp) or manually raising (Folding Ramp). Code Error 23 - Neutral Status Error Description - What Caused the Code OTC detected that the ramp may have hit an obstruction on the in or out cycle. The OTC detects an obstruction by measuring the current generated from the ramp motor. The obstruction could be something in the way or a Ramp Limit is not recognized. If this current exceeds the set limit in the OTC Setup (default is 5, scale is 1-10 with 1 being the most sensative) More Information Setup - OB Detect Level (default is 5, scale is 1-10 with 1 being the most sensative) If a Ramp Limit Switch fails, the Obstacle Detection should activate and cause an error. If the Obstacle Detection does not activate, the Ramp Watchdog Timer should. This will also cause an error (Error 27) and end the cycle. Description - What Caused the Code Everytime before the OTC cycles, it checks to make sure the van is in Park. This is for safety and can not be changed. More Information Diagnostic Tests Input Test Place OTC in Debug - Input Test Mode to verify OTC recognizes Refer to Important Item Information or OTC Wiring if the van is in Park correctly Diagram for more information about where Rollx Vans gets 1) Check Neutral by placing the van in and out of Park and this signal. listening for the double beeps from the debugger. Code Error 25 - Emergency Stop Error Diagnostic Tests Operate User Button to verify working correctly. Description - What Caused the Code Anytime a Rollx Vans User or Remote Button is pressed during an open or close cycle, the system will stop immediately. If a Hard Wired User Button is held down long enough, the OTC will think it has been pressed twice and thus, cause an error. More Information This is a safety feature and can not be changed. Page 38 One Touch System - v8.0 Error Codes Code Description - What Caused the Code Error 27 - Ramp Watchdog Error Once the OTC sends the signal to start running the ramp motor in or out, a timer starts. If enough time passes before the proper limit switch is activated at the end of the cycle, the OTC will return this error. This is a safety feature to limit power to the motor in case of mulitple failures. Diagnostic Tests More Information Operate the In-The-Floor ramp with Power Overide to help Not available on Folding Ramps. determine if motor and ramp are functioning correctly. Output Test Place OTC in Debug - Output Test Mode to verify OTC operates the ramp motor correctly. 1) Check Ramp Open. 2) Check Ramp Close. Input Test Place OTC in Debug - Input Test Mode to verify limits operate correctly. 1) Check Ramp Up [Limit Switch] by operating the ramp with Power Overide Switch (ITF Ramp) or manually raising (Folding Ramp). 2) Check Ramp Down [Limit Switch] by operating the ramp with Power Overide Switch (ITF Ramp) or manually raising (Folding Ramp). Several factors such as low battery, cold weather or debris can prevent the motor from operating correctly. If low battery, very cold or a bad motor, the motor may run too slow causing this watchdog to activate. Debris can also prevent the motor or ramp operating at correct speed, also causing this error. If a Ramp Limit Switch fails, the Obstacle Detection should activate and cause an error (Error 18). If the Obstacle Detection does not activate, the Ramp Watchdog Timer should. This will also cause an error. If OTC Debug Output Test does not activate the motor being tested, try the overides located on the OTC Relay Board. This will inidicate a communication problem between the One Touch Controller and One Touch Relay Board. Page 39 One Touch System - v8.0 Error Codes Code Error 28 - Door Watchdog Error Diagnostic Tests Operate the OEM Door with the OEM B-Pillar Switch to determine of OEM Door is functioning properly. Description - What Caused the Code Once the OTC sends the signal to operate the OEM Door, a timer starts. If enough time passes before the proper limit switch is activated at the end of the cycle, the OTC will return this error. More Information If OEM B-Pillar Switch is not working, try the OEM Overhead Door Switch and make sure the OEM Overhead Door On/Off Switch is on. Input Test Place OTC in Debug - Input Test Mode to verify limits operate correctly. If Door Limits function correctly and door cycles open and close 1) Check Door Open (Rollx Vans Door Open Switch), by okay, the issue is with the door taking too long to open or close. opening door all the way in Door Open. 2) Check Door Close (OEM Door Ajar Switch), by close door Check alignment or motor. all the way in Door Close. Rollx Vans taps into OEM Door Ajar Switch in Lower B-Pillar (See OTC Wiring for more information). Output Test Place OTC in Debug - Output Test Mode to verify OTC operates the door correctly by sending signal to OEM B-Pillar Switch If an Output is an issue, the Door Control Error (Error 11) and/or OEM Front Passenger Door Unlock Switch. will likely display. 1) Check Door Open. 2) Check Door Close. Code Error 29 - Kneeler Watchdog Error Description - What Caused the Code Once the OTC sends the signal to operate the Kneeler, a timer starts. If enough time passes before the proper limit switch is activated at the end of the cycle, the OTC will return this error. More Information Diagnostic Tests Operate the Kneeler with Power Overide to help determine Reset - Esc - Kneel Up/Kneel Down if motor is functioning correctly. Input Test Place OTC in Debug - Input Test Mode to verify limits operate correctly. 1) Check Kneel Up [Limit Switch], by raising Kneeler until switch is activated or activate switch by hand. 2) Check Kneel Down [Limit Switch], by Lowering Kneeler until switch is activated or activate switch by hand. Testing with Power Overide is preferreed since it will incidicate if Limit Switch is being properly activated by Actuator's Guide. When Kneel Actuator reaches its run limit, it will begin to ratchet making a terrible sound. This is simply the motor's clutch mechanism, is not damaging but should try and be minimized. If OTC Debug Output Test does not activate the motor being tested, try the overides located on the OTC Relay Output Test Board. This will inidicate a communication problem Place OTC in Debug - Output Test Mode to verify OTC operates between the One Touch Controller and One Touch Relay the Kneeler correctly. Board. 1) Check Kneel Up. 2) Check Kneel Down. Also a low battery, bad motor or cold weather causing the motor to run very slowly can return this error. Page 40 One Touch System - v8.0 Error Codes Code Description - What Caused the Code The OTC will not run a Cycle if the door is Ajar (Not fully opened or closed). If Ramp deployed, open door fully. If ramp stowed, fully close and latch door. More Information If OEM B-Pillar Switch is not working, try the OEM Overhead Door Switch and make sure the OEM Overhead Door On/Off Switch is on. Error 33 - Door Ajar Error Diagnostic Tests Operate the OEM Door with the OEM B-Pillar Switch to determine of OEM Door is functioning properly. Input Test Place OTC in Debug - Input Test Mode to verify limits operate correctly. 1) Check Door Open (Rollx Vans Door Open Switch), by opening door all the way in Door Open. 2) Check Door Close (OEM Door Ajar Switch), by close door all the way in Door Close. Rollx Vans taps into OEM Door Ajar Switch in Lower B-Pillar (See OTC Wiring for more information). Page 41 One Touch System - Relay Board Troubleshooting RELAY BD OTC VERSION 2 P.N. 08044-003 ORDER #OTCV8 RELAY BD OUTPUTS Run to the Kneeler and Ramp Motors INPUTS Run from the OTC Control Board LED Indicator Lights Manual push button test switches *Pressing the switches should operate each function as shown on the board as long as the board is working properly. Remember, to run the ramp, the Ramp Enable must also be pressed at the same time. Pressing a switch is the same as sending a ground to the terminal. Page 42 In The Floor (Metal Springs) Troubleshooting Symptom Possible Cause Remedy Door open limit switch is not being activated. When a Open Cycle starts, the OTC will send a command to the Chrysler System to unlock the doors. It then sends a second command to the Chrysler System to open the Right Side Sliding Door. The OTC Computer then waits two seconds and checks the Door Closed Limit Switch. If it finds it still indicates the door is closed, it assumes that a person (or and obstacle) stopped the door opening sequence. It then ends the open cycle and goes back into Idle Mode. After ten to fifteen seconds it goes back into Sleep Mode. This is the sequence of events you will see if the Door Closed Limit Switch malfunctions (sticks closed). This switch is located towards the rear of the lower door track. Ramp motor not engaged. Engage ramp motor. Refer to the "Manual Operation" section of this manual. Ramp down limit switch needs adjustment to deactivate. Press Rollx Vans user button again to unkneel van and close door. Review display on OTC board and contact customer service. Ramp will NOT DEPLOY after door opens automatically. Ramp motor. OTC program failure. Ramp will NOT STOW automatically. Ramp motor not engaged. Ramp motor. Low voltage from the battery. Ramp will deploy before door is all the way open. Door open limit switch is shorted to ground or malfuctioning. Ramp will STOP AND REVERSE mid-cycle. Obstacle is detected. Ramp will start to deploy or stow then stop functioning. Pressure on cover plate. 10/16/2012 2008 Trouble Shooting.xls Page 43 Review display on OTC board and contact customer service. Press OTC reset button. Engage ramp motor. Refer to the "Manual Operation" section of this manual. Review display on OTC board and contact customer service. Start vehicle. Press OTC reset button and press Rollx Vans user button again. Examine door open limit switch, connections, and wiring. Clear obstruction and press Rollx Vans user button. Review display on OTC board and contact customer service. Ensure that there are no objects on top of cover plate. Page 1 17 18 19 20 21 21a 22 23 24 26 27 28 30 31 32 33 34 35 36 37 2 2 4 8 4 1 2 1 1 1 1 1 2 1 1 1 4 4 2 4 2 1 1 1 1 2 Page 44 37 20 32 34 N05021G-F NO5021G-B 115111 1126331 1136406 1107632 N1-N1DXLA N005001ASM 1173912 N05017ASM N05016ASM B08032ASM 05089-002 92510A351 2483K18 N05003ASM CHRLCL035 24412 10929-02112 1133004 N05049 97517A130 N05048 21a 33 21 26 30 3 28 1 HCS 3/8-16X2 YZ8 QPACK 5/16-18 x 1 SLDR 3/8 3/8-16 FHNyz8 3/8 NYLON FLAT WASHER ROLLER, ITF RAMP PLATE RAMP ITF ASM 5/16-18X2 S/S FHSCS TRACK FLOOR PLATE FRONT ASM TRACK FLOOR PLATE REAR ASM TRACK TRACK EXT.BKT, LOWER 08,ASM DOOR OPEN SWITCH ASSEMBLY ALUMINUM UNTHREADED (ACTIVATOR) PRECISION MINATURE IDLER ROLLER PLATE 2008, CHYSLER CONN LINK #35 CARBON LOCKING HOLE & VENT SS TORX BHCS 1/4-20 1/4 USS F/W Z TEFLON BLOCK FOR ITF RAMP RIVETS SPACER ROLLER CUSHIONED SEE PAGE 15 SEE PAGE 15 CARPET TRIM FRONT CARPET TRIM BACK 27 18 23 35 5 3 17 31 30 22 14 12 8 19 4 16 6 7 13 36 15 9 Item Qty. 1 1 2 1 1 3 6 4 10 5 1 6 2 7 8 8 1 3 3 3 3 9 7 10 2 12 2 13 1 14 4 15 2 10 24 Description ITF ACCESS PLATE MOTOR GEAR BOX ITF 2008 ASM MOTOR WITH GEAR ONLY 1/4-20 YZ NE NYLOCK CHAIN ROLLER SS #35 TENSIONER/SPROCKET ASM ITF ROLLERS CUSHIONED SS TORX BHCS 1/4-20 FLAP ASM ITF RAMP PRECISION MINATURE IDLER* 5/16" x 1/16" NYLN WSHR HCS 1/4-20X1 1/4 YZ8QP* 1/4-20 YZ NE NYLOCK* SS TORX BHCS 1/4-20 HCS1/4-20X1YZ8 QPACK HCS 1/4-20 X 3/4 YZ8 QPA CHAIN ANCHOR FPH MS 10-32X3/8 Z K RAMP SPRING 1137183 35 10005 22875T11 10929-02112 N05014ASM 2483K18 76002 0115007 1137183 10929-02112 0115005 0115003 N05033 29504 N05044 N08111-MTR/GEAR ASM Part # N05019 N08111ASM In The Floor (Metal Springs) Replacement Parts Folding Ramp Troubleshooting Symptom Ramp will NOT DEPLOY after door opens automatically. Ramp will NOT STOW automatically. Possible Cause Remedy Ramp fuse or circuit breaker is blown. Press Rollx Vans user button again to unkneel van and close door. Reset circuit breaker or check ramp fuse and replace if needed with 15 amp glass fuse located in glove box. Door open limit switch is not being activated. When a Open Cycle starts, the OTC will send a command to the Chrysler System to unlock the doors. It then sends a second command to the Chrysler System to open the Right Side Sliding Door. The OTC Computer then waits two seconds and checks the Door Closed Limit Switch. If it finds it still indicates the door is closed, it assumes that a person (or and obstacle) stopped the door opening sequence. It then ends the open cycle and goes back into Idle Mode. After ten to fifteen seconds it goes back into Sleep Mode. This is the sequence of events you will see if the Door Closed Limit Switch malfunctions (sticks closed). This switch is located in the Right Side Sliding Door Latch Assembly. Ramp down limit switch needs adjustment to deactivate. Press Rollx Vans user button again to unkneel van and close door. Review display on OTC board and contact customer service. Ramp motor. Press Rollx Vans user button again to unkneel van and close door. Review display on OTC board and contact customer service. OTC program failure. Press OTC reset button. Ramp fuse or circuit breaker is blown. Press Rollx Vans user button again to unkneel van and close door. Reset circuit breaker or check ramp fuse and replace if needed with 15 amp glass fuse located in glove box. Ramp motor. Ramp will deploy before door is all the way open. Door open limit switch is shorted to ground or malfuctioning. Ramp will STOP AND REVERSE mid-cycle. Obstacle is detected. 10/12/2012 2008 Trouble Shooting.xls Page 45 Review display on OTC board and contact customer service. Examine door open limit switch, connections, and wiring. Clear obstruction and press Rollx Vans user button. Review display on OTC board and contact customer service. Page 1 Page 46 Item 1 2 3 4 5 6 7 8 9 10 11 12 11 2 3 8 10 9 Description MOTOR RAMP (Does not include connector (OTC only) CAM FOR PICK UP ARM ALUM #8-32X1/4 CUP POINT SET SCREW ROLLER CROWNED YOKE 5/16-18 X 1-1/4 BHSCS 5/16-18 X 1-1/4 FHSC BEARING/BUSHING RAMP LIMIT SWITCH ASM SWITCH MINI SNAP ACTING SWITCH SPACER STD RAMP S/S PPHMS 4-40X1 1/2 #4 sae 5/16od z f/w 12 Qty. 1 2 2 1 1 4 1 1 2 1 2 2 1 19 18 Part # K01325A350 RLXRP00CAM-ALUM N/A CY36L 1124072 1124257 SF-2432-8 03220-004 7779K62 RLXRPOO-14 72498 1133066 6 Item 13 14 15 16 17 18 19 19A 19B 20 21 21A 22 22 23 Qty. 2 1 1 1 3 1 2 2 2 1 1 1 1 1 1 20 5 13 4 16 21 Description 4-40 S/S NYLOK NUT RAMP CABLE W/BALL SHANK, BHSCS 5/16-18 X 7/8 5/16-18HX JAM Z 5/16-18 FLAT NYLON WASHERS CB 10AMP RESETTABLE HCS 3/8-24 X 1 YZ8 3/8 HI-ALLOY L/W YZ 3/8 USS F/W Z WOODRUFF KEY, 3/16X3/4 FLAT BOTTOM PICK UP ARM (RAMP) 1/4-20X3/8 CUP POINT SET SCREW 5/16-18X1 3/4 FHSCS 5/16-18X1 3/4 FHSCS* 5/16-18HX JAM Z COVER RAMP NEW GENERATION 7 21A 14 17 15 Part # 1170854 RLXR1100 24070 1137023 76062 CB-PM3-10 18834 1133893 1133008 N/A RLXR2005 (INCLUDES SET SCREW) N/A 1124259 1124259 1136204 10068 * For motor bar ramps only 22 RLXR1000-04-OTC / RLXR1000-04-MB / RLXR1000-04-NARROW-MB Folding Ramp Replacement Parts 9 Page 47 Item Qty. 1 1 2 1 3 3 4 3 5 3 6 3 7 6 8 2 9 2 10 2 3 Description RAMP STANDARD (RAMP NARROW) RAMP CABLE W/BALL SHANK, CLAMP INSULATED 3/8" 1/4-20 X 1/2 BHSCS 1/4-20 NTE JAM NYLOK 10-32 X 3/4 BHSCS #10 SAE F/W Z 1/4 HI-ALLOY L/W YZ 3/8 USS F/W Z 3/8-16 YZ8 NE NYLOCK 4 2 RAMP SIDE OF HINGE VAN SIDE OF HINGE 10 14 12 5 7 18 6 Part # RLXR4000 (RLXR4000N) RLXR1100 8863T13 1124049 1137020 1124042 1133074 1133891 1133008 1137185 19 8 Item Qty. 11 1 12 12 13 1 14 1 15 4 15 4 15 1 16 0.4 17 1 18 12 19 1 RLXR1000-05-OTC / RLXR1000-05-MB / RLXR1000-05-NARROW-MB 11 RAMP BASE 1/4-20x5/8 BOLT (#12) 15 Description HCS 1/4-20X1/2 YZ8 QPA 1/4-20X5/8 SS BUTTON HEAD CAP SCREW HINGE, RAMP FOLDING W BOLTS CABLE GUIDE (ROUND DISC) RIVETS* #4 sae 5/16od z f/w RUBBER BULB SEAL BACK FOAM* ANTI-RATTLE RUBBER URETH FOR (Motor Bar Only)* HINGE UPPER RAMP FO PAINTED 1/4-20 KEPS NUT Ramp Base Weldment Assembly 13 1 HINGE (#13) Part # 0115001 10929-02786 RLRX4006 RLXR1025 97517A130 1133066 NX504B1 27036 RLXR1007 1137410 RLXR4003 * Not Shown 16 17 KEPS NUT (#19) RAMP RAMP HINGE AREA CROSS SECTION 1/4-20 KEPS NUT (#18) 9 10 Folding Ramp Replacement Parts This Page was intentionally left blank Page 48 Folding Ramp Motor Install / Removal and Adjustment Folding Ramp Motor Install (steps 1-19) Ramp Removal Instructions (steps 1-4 + 15-19) 1. Remove carpeted motor panel. This is held on by two Phillip head screws. 2. Disconnect wires going to limit switches and motor. 3. Unbolt ramp. There are two bolts (3/8) that go into the side of the van above ramp motor and two nuts (3/8) on the floor of the van-one nut is by the motor and one nut is by b-pillar. 4. Remove ramp from van. 5. Extend ramp so it is laying flat. 6. Remove roller from pick up arm. Also, remove cable bolt. 7. Remove set screw from pick up arm. Then insert 5/16 bolt into pick up arm to pull pick up arm off of motor shaft. If this does not work, cut motor shaft with a saw and punch out scrap piece from pick up arm. 8. Remove limit switches off of ramp. 9. Take out the four Allen head bolts (3/16) holding ramp motor. Remove motor. 10. Insert new motor. Reinstall the four Allen head screws with lock tight. 11. Reinstall limit switches. 12. Remove cams off of old motor and install on the new ramp motor. You will need to adjust these cams at step 16. 13. Reinstall pick up arm. Line up pick up arm and key way. Ensure Woodruff key is all the way inserted into the pick up arm. 14. Reinstall set screw (3/16) with lock tight. 15. Reinstall ramp in the van. Secure ramp with original hardware. 16. Install wiring for limit switches and motor. 17. Adjust ramp cams. Refer to Ramp Adjustment Instructions. 18. Test ramp for proper limit switch adjustment. 19. Reinstall carpeted motor cover. Folding Ramp Adjustment Process 1. Bring folding ramp into the stow position so it resting in the van where you want it. 2. Remove carpeted motor panel. This is held on by two Phillip head screws. 3. Locate Adjustment Cam Set Screws and loosen. 4. Rotate the Up Limit Cam until it activates the Up Limit Switch and tighten set screw. 5. Push ramp out slowly and rest on something that is 6 inches off the ground as shown below. 6. Rotate Down Limit Cam until it activates the Down Limit Switch and tighten set screw. 7. Test ramp for proper limit switch adjustment and reinstall carpeted motor cover. 6 Inches Page 49 Folding Ramp Motor Install / Removal and Adjustment Resettable Circuit Breaker 3/8 Nut Pick Up Arm Roller Phillips Head Screws 3/8 Bolt Cable Bolt Adjustment Cam Set Screw Down Adjustment Cams Set Screw Backstop Adjustment Bolt Up Adjustment Cams Limit Switches Page 50 3/8 Nut Rear Heat & Air OEM Lines O-RINGS FOR H-BLOCK Front of Van #B2100 - REAR HEAT LINE 5/8 (2 PER) #B08101-rasm - REAR AC LINE 5/8 #MT0258 - O RING #10 AC after market (2) Rear AC (Behind Rear Right Tire) Rollx Vans Hose and Clamps Front of Van OEM Lines Rear Heat (Front of Rear Right Tire) Model Year 08 - 11 #B08100-rasm - REAR AC LINE 3/8 includes o-rings Model Year 12 #B01200-rasm - Rear AC Line 3/8 includes o-rings #MT0250 - O'RING #8 AC after market (2) Rollx VansHose and Clamps HIGH PRESSURE #5136091AA - O RING 3/8” (1) LOW PRESSURE #4882136 - O RING AC 5/8" (1) OEM Lines Front of Van Page 51 Remote System Troubleshooting * If remote does not work first try to operate door and ramp from any interior Rollx Vans user button. If interior Rollx Vans user button operates normally, see below for remote system troubleshooting Symptom Possible Cause Remedy Receiver out of range. Try remote within 10 feet of van. Overhead on/off switch is turned to the OFF Turn switch to ON position. position. Door does not open when One Remove case by loosening screw on back and Touch remote is pressed. prying open. Replace batteries with battery type Remote batteries are dead. CR2016. Use second remote or Rollx Vans user button. Locate fuse box under glove box and check / Blown fuse. replace fuse. Neither One Touch remote works. Review display on OTC board and contact Receiver malfunction. customer service. Page 52 OTC Remote System (Before 9/19/2011) OTC Remote Receiver (Before 1/8/2009) OTC Remote Receiver (Rear View) OTC Remote Transmitter Opened Red LED Indicator Light OTC Remote Receiver (After 1/8/2009) A23 Battery Each Rollx Vans Transmitter has a unique code. These codes are applied to the transmitter either by a trace cutting method or a DIP switch programming method. This is done at the Rollx Vans Factory. In order to program the transmitter(s) to the receiver the following process must be done! Learning a New Button Code (channel 1) 1. Press mode switch #1 for three seconds. The green LED will start to flash quickly. If no green LED lights, ensure power is getting to the unit through the 1 Amp fuse in the Rollx Vans Fuse Panel. 2. While the green LED is flashing quickly, press a button on a compatible transmitter. The green LED will flash once and then turn off to show that button was learned. 3. Repeat steps 1 and 2 to learn more buttons into channel 1. NOTE — The green LED will flash a maximum of 15 seconds. If no transmitter button is pressed during this time, the receiver will exit the code-learning mode, and the green LED will turn off. Note Regarding Code Learning 1. The receiver will only learn the code of a particular button once. Once a button’s code is learned, if you try to code-learn that button again, whether it is for the same channel or not, the receiver will exit code learning mode. 2. Each channel can learn the codes of a maximum of 15 transmitter buttons. If you attempt to learn a sixteenth button, the earliest code learned will be deleted. 3. To clear all codes — Press the appropriate mode switch (#1 or #2) for three seconds. When the LED starts flashing, press that switch again for three seconds. The LED flashes twice to indicate that all codes associated with that channel are now deleted. *From SECO-LARM Manual Page 53 OTC Remote System (After 9/19/2011) OTC Remote Receiver (Behind Rear Passenger Quarter Panel Above Rear Heat Unit) OTC Remote Transmitter OTC Remote Receiver (Rear View) BLUE LED Indicator Light ANTENNA To PROGRAMING SWITCH POWER To USER SWITCH CR2016 Batteries (X 2) 1BAMR-ASM ASM #03295-003 FUSE PANEL (BEHIND GLOVE BOX) 1 AMP REMOTE Version 8 1 AMP DOOR DETECTOR 1 AMP CONTROLLER PWR Nuetral Safety To Rollx Vans user switches Ignition Hot BK (8 GA.) 40A FUSE RD (8 GA.) + - CM6200 Programming switch BK RD (14 GA.) DB ASM #03220-005 DB (20 GA.) BK (20 GA.) PROGRAMING SWITCH ASM #03295-003 ANTENNA RUNS UP PASSENGER “D” PILLAR Programming the Rollx Vans OTC Remote *Activate the programming mode by pushing the button on the left side of the OTC controller (PROGRAMMING SWITCH) 5 times within 7 seconds. * Within 2 seconds after pushing the button 5 times, press the single remote button for .5 Seconds. Wait 30 seconds and press the remote to operate the system. *Repeat the sequence if programming an additional remote. Page 54 OTC System - v8.0 ROLLX VANS ONE TOUCH OTC VERSION 8.00 (20 PRODUCTION START DATE: 5/28/2009 R KNEEL DISABLE (ON / OFF) SWITCH (ASM #03220-001) 4 1 BLACK 16 N/C RIGHT PASSENGER DOOR CONTROL MODULE BK DB / YL (20 GA.) BK (20 GA. X 3) DOOR DISABLE CONTROL TAP TO OEM LG / WT BK (20 GA.) VT (20 GA.) DB / YL (20 GA.) FROM T.I.P.M. ROLLX VANS INTERRUPTS THE OEM DOOR COMMUNICATION BY BREAKING THE I-CAN BUS AT THE B PILLAR WT / OR FLOOR AREA ON PS. SIDE N/C WT / OR BACK SIDE SHUNT, 2008 CAN BUS #WM4814-ND ASM DOOR DISABLE 16 N/C VT LG / WT (20 GA.) DOWN A PILLAR BACK SIDE AUX I/O If the OTC Board is ever removed from the van, in order for the OEM System to operate normally a Shunt Plug must be inserted into the OTC Wire Harness’s Door Disable Control Plug as shown above. The Shunt will reconnect the OEM CAN Bus System. The Shunt is attached to the OTC Wire Harness directly behind the OTC Board. TO DOOR CONTROL MODULE VIA DOOR SNAKE WT / GY WT / GY TO PASSENGER DOOR COMPUTER MODULE 2 1=OFF 2=UNLOCK 3=LOCK 2 13K 3 1 2K 3 3.3K PASSENGER DOOR LOCK SWITCH WT / RD (20 GA.) WT / RD (20 GA.) DB (20 GA.) 1 BLACK BLACK N/C INPUTS BACK SIDE 14 1 DG VT / YL (20 GA.) RD / DG (20 GA.) RD / WT (20 GA.) YL / DG (20 GA.) N/C YL / WT (20 GA.) RD (20 GA.) RD / BK (20 GA.) 12 BACK SIDE OUTPUTS (20 GA.) OR / RD (20 GA.) N/C N/C BLACK YL / BK (20 GA.) YL / RD (20 GA.) N/C OR N/C (20 GA.) RD / DB (20 GA.) 1 R LG / WT (20 GA. HF) BK (10 GA) BLACK TAP TO OEM VT / YL BK BK BLACK RD (12 GA.) BK OR YL (12 GA.) 07303-003 REVISION: V-8.00 CHRYSLER DRAWN BY: CME / WRW CHECKED BY: Rollx Vans, Inc. 6591 West Highway 13 Savage, MN 55378 952.890.7851 Jason Hodgkins COPYRIGHT 2008 REVISION HISTORY: 08330-001 INITIAL RELEASE. 11/25/2008. UPDATED 10/17/2012 UP LIMIT YL / WT BK KNEEL SYSTEM* BK NC NO COM DRAWING #: NONE NC NO COM SCALE: BK GY (-) (+) KNEEL LIMIT SWITCHES (#6X284) YL / DG Italic Font = OEM Wire (BK 20 GA.) * = For pictures of location see Important Information and Location Section in Service Manual OEM B-PILLAR DOOR OPERATION SWITCH (ROLLX VANS USES TO OPERATE DOOR) YL / WT RAMP MOTOR 1 DOWN LIMIT YL / DG RD (12 GA.) YL (12 GA.) OTC System - v8.0 CONTROLLER WIRING DIAGRAM 008- 2010 Chyrsler Model Year) ROLLX VANS USER / RESET SWITCHES (ASM #03220-005) D-PILLAR DASH RESET SWITCH (8/21/06) DB BK DB DB DASH C-PILLAR BK POWER OVERRIDE SWITCH IN THE FLOOR RAMP ONLY (BEFORE 6/4/08 - FRONT PASSENGER DOOR JAM) (AFTER 6/4/08 - DRIVER SIDE B-PILLAR) (# 05175-001) BK DB BK OUT DB (20 GA.) BK (20 GA.) DB (20 GA.) BK (20 GA.) BK (20 GA.) IN * DG / TN (20 GA.) FUSE PANEL (BEHIND GLOVE BOX) BK (20 GA. X 3) BK (20 GA.) WT / RD (20 GA.) X 3 1N4007 DIODES 1 AMP REMOTE 1 AMP CONTROLLER PWR ADDED GY / LB (20 GA.) NEUTRAL SAFETY OUT IGN. HOT OUT WT / RD (20 GA.) WT / RD (20 GA.) DG / WT (20 GA.) 6/1/09 BK (8 GA.) 40A RD (20 GA.) FUSE RD (8 GA.) DG (20 GA.) OR / RD (20 GA.) BK * ITF RAMP LIMIT SWITCHES #6X284 FOLDING RAMP LIMIT SWITCH ASM #03220-004 RD (10 GA.) ITF RAMP RD (-) YL (+) J2 PK/LG 2 C200 BLACK BODY SIDE TO 20 A FUSE M15 ANTENNA ROLLX VANS REMOTE RECEIVER #SK-910R * BK * RELAY BOARD #OTCV8 RELAY BD J1 D DB (20 GA.) BK (20 GA.) RD (20 GA.) #310-1059 N OEM NEUTRAL SAFETY TAP TO OEM DG / DB (OEM NEUTRAL SAFETY) YL/RD RD/DB R P PWR OVERRIDES BK (12 GA.) RD (12 GA.) OUTPUTS BK (10 GA.) DG / TN (20 GA.) DG / WT (20 GA.) INPUTS BK (20 GA.) ROLLX VANS OTC REMOTE RECEIVER (BEFORE 1/8/08 - CENTER DASH) (AFTER 1/8/08 - REAR RIGHT QUARTER PANEL) C PILLAR FLOOR AREA A B A B BK OR / RD OEM DOOR SNAKE (UNMODIFIED) ROLLX VANS VT / YL (ROLLX VANS DOOR CLOSE) TAP INTO OEM VT / YL (OEM DOOR AJAR) AT B PILLAR FLOOR AREA NO COM GY / LB (20 GA.) RAMP ENABLE BK (20 GA.) KNL UP OR / RD KNL DN BK (12 GA.) RAMP UP VT / YL YL (12 GA.) RAMP DN ROLLX VANS DOOR OPEN LIMIT SWITCH LOCATED NEAR REAR SIDE OF LOWER PASSENGER DOOR TRACK (#05089-003) POWER OVERRIDE BUS RD / BK YL / BK PK/LG (20 GA.) DG / DB RD UP LIMIT DG (20 GA.) DOWN LIMIT NC NO COM RD / WT (20 GA.) NC NO COM RD / DG (20 GA.) ROLLX VANS TAPS INTO OEM IGNITION HOTTO INSTRUMENT ON THE INSTRUMENT PANEL SIDE OF PANEL CONNECTOR C200, CAV. 22 (UNDER DRIVER DASH) VT / YL (20 GA.) OTC System (After 3/6/2012) - v8.0 ROLLX VANS ONE TOUCH OTC VERSION 8.00 (20 PRODUCTION START DATE: 3/6/2012 R KNEEL DISABLE (ON / OFF) SWITCH (ASM #03220-001) 4 1 BLACK 16 N/C RIGHT PASSENGER DOOR CONTROL MODULE BK DB / YL (20 GA.) BK (20 GA. X 3) DOOR DISABLE CONTROL TAP TO OEM LG / WT BK (20 GA.) VT (20 GA.) DB / YL (20 GA.) FROM T.I.P.M. ROLLX VANS INTERRUPTS THE OEM DOOR COMMUNICATION BY BREAKING THE I-CAN BUS AT THE B PILLAR WT / OR FLOOR AREA ON PS. SIDE N/C WT / OR BACK SIDE SHUNT, 2008 CAN BUS #WM4814-ND ASM DOOR DISABLE 16 N/C VT LG / WT (20 GA.) DOWN A PILLAR BACK SIDE AUX I/O If the OTC Board is ever removed from the van, in order for the OEM System to operate normally a Shunt Plug must be inserted into the OTC Wire Harness’s Door Disable Control Plug as shown above. The Shunt will reconnect the OEM CAN Bus System. The Shunt is attached to the OTC Wire Harness directly behind the OTC Board. TO DOOR CONTROL MODULE VIA DOOR SNAKE WT / GY WT / GY TO PASSENGER DOOR COMPUTER MODULE 2 1=OFF 2=UNLOCK 3=LOCK 2 13K 3 1 2K 3 3.3K PASSENGER DOOR LOCK SWITCH WT / RD (20 GA.) WT / RD (20 GA.) DB (20 GA.) 1 BLACK BLACK N/C INPUTS BACK SIDE 14 1 DG VT / YL (20 GA.) RD / DG (20 GA.) RD / WT (20 GA.) YL / DG (20 GA.) N/C YL / WT (20 GA.) RD (20 GA.) RD / BK (20 GA.) 12 BACK SIDE OUTPUTS (20 GA.) OR / RD (20 GA.) N/C N/C BLACK YL / BK (20 GA.) YL / RD (20 GA.) N/C OR N/C (20 GA.) RD / DB (20 GA.) 1 R LG / WT (20 GA. HF) BK (10 GA) BLACK TAP TO OEM VT / YL BK BK BLACK RD (12 GA.) BK OR YL (12 GA.) 07303-003 REVISION: V-8.00 CHRYSLER DRAWN BY: CME / WRW CHECKED BY: Rollx Vans, Inc. 6591 West Highway 13 Savage, MN 55378 952.890.7851 Jason Hodgkins COPYRIGHT 2008 REVISION HISTORY: 08330-001 INITIAL RELEASE. 11/25/2008. UPDATED 10/17/2012 UP LIMIT YL / WT BK KNEEL SYSTEM* BK NC NO COM DRAWING #: NONE NC NO COM SCALE: BK GY (-) (+) KNEEL LIMIT SWITCHES (#6X284) YL / DG Italic Font = OEM Wire (BK 20 GA.) * = For pictures of location see Important Information and Location Section in Service Manual OEM B-PILLAR DOOR OPERATION SWITCH (ROLLX VANS USES TO OPERATE DOOR) YL / WT RAMP MOTOR 1 DOWN LIMIT YL / DG RD (12 GA.) YL (12 GA.) OTC System (After 3/6/2012) - v8.0 CONTROLLER WIRING DIAGRAM 008-2010 Chyrsler Model Year) Compustar Remote Effective Start Date of 9/19/2011 ROLLX VANS USER / RESET SWITCHES (ASM #03220-005) D-PILLAR DASH RESET SWITCH (8/21/06) DB DB BK DB DASH C-PILLAR BK DB POWER OVERRIDE SWITCH IN THE FLOOR RAMP ONLY (BEFORE 6/4/08 - FRONT PASSENGER DOOR JAM) (AFTER 6/4/08 - DRIVER SIDE B-PILLAR) (#05175-001) BK BK OUT DB (20 GA.) BK (20 GA.) DB (20 GA.) BK (20 GA.) BK (20 GA.) IN * DG / TN (20 GA.) FUSE PANEL (BEHIND GLOVE BOX) BK (20 GA. X 3) BK (20 GA.) WT / RD (20 GA.) X 3 1N4007 DIODES 1 AMP REMOTE 1 AMP CONTROLLER PWR ADDED GY / LB (20 GA.) NEUTRAL SAFETY OUT IGN. HOT OUT WT / RD (20 GA.) WT / RD (20 GA.) DG / WT (20 GA.) 6/1/09 BK (8 GA.) 40A RD (20 GA.) FUSE RD (8 GA.) DG (20 GA.) OR / RD (20 GA.) RD (-) YL (+) * GN/WT (24 GA.) RELAY BOARD #OTCV8 RELAY BD J1 J2 RD (12 GA.) BK (10 GA.) DG / TN (20 GA.) DG / WT (20 GA.) BK (12 GA.) OUTPUTS BK (20 GA.) OR / RD PK/LG GN (24 GA.) Compustar Remote ASM #03295-003 C PILLAR FLOOR AREA A B A B BK OR / RD OEM DOOR SNAKE (UNMODIFIED) ROLLX VANS VT / YL (ROLLX VANS DOOR CLOSE) TAP INTO OEM VT / YL (OEM DOOR AJAR) AT B PILLAR FLOOR AREA NO COM GY / LB (20 GA.) RAMP ENABLE BK (12 GA.) KNL DN KNL UP PWR OVERRIDES RD (14 GA.) BK (24 GA.) VT / YL YL (12 GA.) RAMP UP BODY SIDE TO 20 A FUSE M15 BK Programming switch RD (14 GA.) RAMP DN INPUTS DB C200 BLACK CM6200 RD (10 GA.) ITF RAMP DB (20 GA.) BK (20 GA.) RD (20 GA.) #310-1059 ANTENNA RUNS UP PASSENGER “D” PILLAR ROLLX VANS DOOR OPEN LIMIT SWITCH LOCATED NEAR REAR SIDE OF LOWER PASSENGER DOOR TRACK (#05089-003) POWER OVERRIDE BUS TAP TO OEM DG / DB (OEM NEUTRAL SAFETY) YL/RD RD/DB 2 OEM NEUTRAL SAFETY DG / DB * ITF RAMP LIMIT SWITCHES #6X284 FOLDING RAMP LIMIT SWITCH ASM #03220-004 D BK (20 GA.) BK N R P BL (20 GA.) RD / BK YL / BK PK/LG (20 GA.) ASM #03220-005 RD 1N4007 DIODE UP LIMIT DG (20 GA.) DOWN LIMIT NC NO COM RD / WT (20 GA.) NC NO COM RD / DG (20 GA.) ROLLX VANS TAPS INTO OEM TO INSTRUMENT IGNITION HOT PANEL ON THE INSTRUMENT PANEL SIDE OF CONNECTOR C200, VT / YL (20 GA.) Right Sliding Door Extensions C382 BK (12 GA.) RD (12 GA.) Door Side Wire WT/GY (20 GA.) WT/OR (20 GA.) = SOLDER AND DOUBLE WALL HEAT SHRINK Extension wire is same color as OEM wire C382 POWER SLIDING DOOR EXTENSION OEM CAV COLOR PART # EXT. (FT.) FUNCTION 1 WT/OR (20 GA.) TWISTED 10 CAN INTERIOR BUS (-) 2 WT/GY (20 GA.) 3036 10 CAN INTERIOR BUS (+) 3 RD (12 GA.) 3012 10 FUSED B(+) 4 BK (12 GA.) 3006 10 GROUND Rollx Vans extends OEM wires from Driver A Pillar to Passenger B Pillar as shown C309 Rollx Vans extends OEM wires from Driver A Pillar to Passenger B Pillar as shown Page 59 C382 Right Sliding Door Extensions C309 WT/RD (12 GA.) WT/OR (20 GA.) WT/GRY (20 GA.) TN/DB (16 GA.) VT/YL (20 GA.) Body Side BK (12 GA.) LB (20 GA.) WT/LG (20 GA.) TN/LB (16 GA.) TN/OR (16 GA.) = SOLDER AND DOUBLE WALL HEAT SHRINK Extension wire is same color as OEM wire OEM CAV COLOR 1 WT/RD (12 GA) 2 WHT/ORG (20 GA) 10 WHT/GRY (20 GA) 3 TN/DB (16 GA) 4 VT/YL (20 GA) 5 BK (12 GA) 7 LB (20 GA) 8 WT/LG (20 GA) 9 TN/LB (16 GA) C309 POWER SIDIING DOOR EXTENSION PART # EXT. (FT.) FUNCTION 2005 10 FUSED B(+) TWISTED CAN INTERIOR BUS (-) 10 3036 CAN INTERIOR BUS (+) 2071 10 RIGHT REAR DOOR LOCK DRIVER 2040 10 RIGHT SLIDING DOOR AJAR SWITCH SENSE 3006 10 GROUND TWISTED RIGHT SIDE IMPACT SENSOR 2 SIGNAL 10 3040 RIGHT SIDE IMPACT SENSOR 2 GROUND 2069 10 RIGHT REAR DOOR UNLOCK DRIVER Rollx Vans extends OEM wires from Driver A Pillar to C309 Rollx Vans extends OEM wires from Driver A Pillar to Page 60 C382 2008-2010 Power Seats - Seat Detector The Rollx Vans Seat Detector eliminates the need for resistors on OEM Seat Functionality (Seat Position for Airbags and Seatbelt Switch for Seatbelt Light). It also eliminates the need for a Seat Shunt being installed if seat with memory was ever removed. The seat detector started being installed 8/6/2008. #08134-001ASM - SEAT DETECTOR 2008 ASM Seat Detector is located under dash behind driver’s knee bolster as shown. It is attached to the OEM main wire harness bundle with electrical tape. Page 62 Page 63 2 1 8 14 7 16 11 C A V C AV 8 15 16 17 21 12 11 O E M L G /G B K L B /W L B /V R D B K /R P K /W Y (2 0 (1 2 G T (2 0 T (2 0 (1 2 G D (2 0 T (2 0 G A .) A .) G A .) G A .) A .) G A .) G A ,) C O L O R Y L /G N (2 0 G A .) Y L (2 0 G A ) R D (2 0 G A .) B K (2 0 G A .) L G /G Y (1 8 G A .) L B /W T (2 0 G A .) L B /V T (2 0 G A .) P K /W T (2 0 G A ) B K /R D (2 0 G A ) P K /B L (2 0 G A ) B K /W T (2 0 G A ) YL/GN YL RD BK LG/GY LB/WT LB/VT PK/WT BK/RD PK/BL BK/WT #08134-001ASM Body Side Wire SeatDetector # # TW # # # # 20 30 IS 30 30 30 30 2 0 T 3 1 4 1 2 6 E D 7 2 8 8 P A R T # #3027 #2047 #3013 #2009 #2022 T W IS T E D # 3037 #3018 #3048 #3085 #2016 25 A OR/RD S E A T B E L T S W IT C H S E N S E G R O U N D D R IV E R S S E A T P O S IT IO N S E N S O R D A T A D R IV E R S S E A T P O S IT IO N S E N S O R V O L T A G E F U S E D B (+ ) H E A D R E S T O U T H E A D R E S T IN D R IV E R S C 3 7 6 D riv e r P o w e r O n ly - B o d y S id e E X T . (F T .) F U N C T IO N 3 .5 G R O U N D F O R D E T E C T I N G D R I V E R 'S S E A T 3 .5 G R O U N D F O R D E T E C T I N G P A S S E N G E R 'S S E A T 3 .5 P O W E R 3 .5 G R O U N D 3 .5 T A P S T O D R IV E R S S E A T B E L T S W IT C H S E N S E 3 .5 T A P S T O D R IV E R S S E A T P O S IT IO N S E N S O R D A T A 3 .5 T A P S T O D R IV E R S S E A T P O S IT IO N S E N S O R V O L T A G E 3 .5 D R IV E R H E A D R E S T IN 3 .5 D R IV E R H E A D R E S T O U T 3 .5 P A S S E N G E R H E A D R E S T IN 3 .5 P A S S E N G E R H E A D R E S T O U T TO PASSENGERS SIDE SEAT PLUG 4 8 2 5 TOP 1 9 3 610 10/30/2012 BODY SIDE CONNECTOR # A16030-ND 13 14 11 12 16 15 7 A 1 6 4 8 -N D A 2 5 0 3 2 -N D A 1 6 4 8 -N D A 1 6 4 8 -N D A 2 5 0 3 2 -N D A 1 6 4 8 -N D A 1 6 4 8 -N D P IN P A R T # A 1 6 4 8 -N D TO PASSENGER SEAT (PASSENGER SEAT SHARES POWER FROM DRIVERS SEAT) RD (12 GA.) - CAV 7 OR/RD (12 GA.) LB/VT (20 GA.) - CAV 14 LB/WT (20 GA.) - CAV 8 BK (12 GA.) - CAV 1 LG/GY (20 GA.) - CAV 2 PK/WT (20 GA.) - CAV 11 BK/RD (20 GA.) - CAV 16 RELOCATED OEM CIRCUIT BREAKER RD (12 GA.) PK/YL (12 GA.) TO PASSENGERS SIDE SEAT PLUG YL/GN (20 GA.) - CAV 9 YL (20 GA) 2010 Chrysler Minivan C376 Driver Seat with Power Only - With Seat Detector Body Side 2010 Power Seats - Driver w/ Power Only 9 5 1 8 2 47 Page 64 CAV 2 1 8 14 7 1/9 16 11 12 11 8 15 16 17 21 OEM CAV SEAT SIDE CONNECTOR # A16036-ND 11 16 13 12 14 15 10 6 3 TOP BK (20 GA.) - CAV 1/9 A1661-ND A1661-ND A1661-ND / A25033-ND SOCKET PART # A1661-ND A25033-ND A1661-ND A1661-ND A25033-ND OEM CONNECTOR C376 Driver Power Only - Seat Side #10010-000-SD (C376 OEM CONNECTOR NOT INCLUDED) COLOR PART # EXT. (FT.) FUNCTION LG/GY (20 GA.) 2022 9 DRIVERS SEAT BELT SWITCH SENSE BK (12 GA.) 3006 9 GROUND LB/WT (20 GA.) TWISTED DRIVERS SEAT POSITION SENSOR DATA 9 LB/VT (20 GA.) # 3037 DRIVERS SEAT POSITION SENSOR VOLTAGE RD (12 GA.) 3012 9 FUSED B (+) BK (20 GA.) 2009 0.25 GROUND FOR DETECTING SEAT BK/RD (20 GA.) 3048 9 GROUND PK/WT (20 GA,) 3018 9 SEAT BELT PRETENSIONER IR (-) PASS RD (12 GA.) - CAV 7 LB/VT (20 GA.) - CAV 14 LB/WT (20 GA.) - CAV 8 LG/GY (20 GA.) - CAV 2 BK (12 GA.) - CAV 1 PK/WT (20 GA.) - CAV 11 BK/RD (20 GA.) - CAV 16 2010 Chrysler Minivan C376 Driver Seat with Power Only - With Seat Detector Seat Side 2010 Power Seats - Driver w/ Power Only Page 65 1 3 7 1 6 1 1 3 5 2 1 6 8 1 4 C A V C A V 1 7 8 1 5 2 3 1 6 1 7 4 1 9 2 2 1 1 2 1 1 O E M L G /W T (2 0 W T /D G (2 0 L G /G Y (2 0 B K (1 2 G L G /V T (2 0 L B /W T (2 0 L B /V T (2 0 L G /G Y (1 8 L G /G Y (1 8 P K /Y L (2 0 R D (1 2 G B K R D (2 0 P K /W T (2 0 G G G A G G G G G G A G G A .) A .) A .) .) A .) A .) A .) A .) A .) A .) .) A .) A ,) C O L O R Y L /G N (2 0 G A .) Y L (2 0 G A .) R D (2 0 G A .) B K (2 0 G A .) L G /G Y (2 0 G A .) L B /W T (2 0 G A .) L B /V T (2 0 G A .) P K /W T (2 0 G A ) B K /R D (2 0 G A ) P K /B L (2 0 G A ) B K /W T (2 0 G A ) YL/GN YL RD BK LG/GY LB/WT LB/VT PK/WT BK/RD PK/BL BK/WT #08134-001ASM Body Side Wire Seat Detector e d 7 2 8 8 s 7 1 4 1 u 0 0 0 0 N o # # # # t 2 3 3 3 7 5 4 2 2 2 0 6 7 6 T E D IR # 2 0 # 2 0 # 2 0 # 3 0 # 2 0 T W IS P A P A R T # # 3 0 2 7 # 2 0 4 7 # 3 0 1 3 # 2 0 0 9 # 2 0 2 2 T W IS T E D # 3 0 3 7 # 3 0 1 8 # 3 0 4 8 # 3 0 8 5 # 2 0 1 6 LG/GY (20 GA.) - CAV 2 25 A OR/RD PK/YL (20 GA.) - CAV 13 3 3 3 3 . . . . 3 C 3 7 6 D r iv E X T . 3 . 3 . 3 . 3 . 3 . R U N R E A L Y O U T P U T L IN B U S S E A T B E L T S W IT C H S E N S E G R O U N D R IG H T S E A T H E A T E R B ( + ) D R IV E R D R IV E R S S E A T P O S IT IO N S E N S O R D A T A D R IV E R S S E A T P O S IT IO N S E N S O R V O L T A G E L E F T R E A R H E A T E R B ( + ) D R IV E R R IG H T R E A R H E A T E R B ( + ) D R IV E R F U S E D R U N R E L A Y O U T P U T F U S E D B (+ ) G R O U N D S E A T B E L T P R E T E N S IO N E R IR ( - ) P A S S D R IV E R S F U S E D e r P o w e r a n d H e a t - B o d y S id e (F T .) F U N C T IO N 5 G R O U N D F O R D E T E C T I N G D R I V E R 'S S E A T 5 G R O U N D F O R D E T E C T I N G P A S S E N G E R 'S S E A T 5 P O W E R 5 G R O U N D 5 T A P S T O D R IV E R S S E A T B E L T S W IT C H S E N S E T A P S T O D R IV E R S S E A T P O S IT IO N S E N S O R D A T A T A P S T O D R IV E R S S E A T P O S IT IO N S E N S O R V O L T A G E 5 D R IV E R H E A D R E S T IN 5 D R IV E R H E A D R E S T O U T 5 P A S S E N G E R H E A D R E S T IN 5 P A S S E N G E R H E A D R E S T O U T TO PASSENGER’S SIDE SEAT PLUG 4 8 2 5 TOP 1 9 BODY SIDE CONNECTOR # A16030-ND 13 14 11 12 16 15 7 A 1 6 4 8 -N D A 1 6 4 8 -N D A 1 6 4 8 -N D A 2 5 0 3 2 -N D A 1 6 4 8 -N D A 1 6 4 8 -N D A 1 6 4 8 -N D S O L D E R T O G E T H E R A 1 6 4 8 -N D A 2 5 0 3 2 -N D A 1 6 4 8 -N D A 1 6 4 8 -N D P IN P A R T # A 1 6 4 8 -N D TO PASSENGER SEAT (PASSENGER SEAT SHARES POWER FROM DRIVERS SEAT) RD (12 GA.) - CAV 7 OR/RD (12 GA.) LB/VT (20 GA.) - CAV 14 LB/WT (20 GA.) - CAV 8 WT/DG (20 GA.) - CAV 5 LG/VT (20 GA.) - CAV 6 LG/WT (20 GA.) - CAV 3 BK (12 GA.) - CAV 1 RELOCATED OEM CIRCUIT BREAKER RD (12 GA.) PK/YL (12 GA.) GN/GY (20 GA.) GN/GY (20 GA.) TO PASSENGERS SIDE SEAT PLUG BK/RD (20 GA.) - CAV 16 PK/WT (20 GA.) - CAV 11 YL/GN (20 GA.) - CAV 9 YL (20 GA) 3 610 10/30/2012 2010 Chrysler Minivan C376 Driver Seat with Power and Heat - With Seat Detector Body Side 2010 Power Seats - Driver w/ Power & Heat 9 5 1 8 Page 66 13 7 1/9 16 11 CAV 3 5 2 1 6 8 14 12 11 1 7 8 15 23 16 17 4 19 2 21 OEM CAV SEAT SIDE CONNECTOR # A16036-ND COLOR LG/WT (20 GA.) WT/DG (20 GA.) LG/GY (20 GA.) BK (12 GA.) LG/VT (18 GA.) LB/WT (20 GA.) LB/VT (20 GA.) LG/GY(18 GA.) LG/GY (18 GA.) PK/YL (16 GA.) RD (12 GA.) BK (20 GA.) BKRD (20 GA.) PK/WT (20 GA,) 2 47 11 16 13 12 14 15 10 6 3 TOP BK (20 GA.) - CAV 1/9 PART # 2075 2042 2022 3006 2076 TWISTED # 3037 NOT USED 2077 3012 2009 3048 3018 9 9 0.25 9 9 9 EXT. (FT.) 9 9 9 9 9 RD (12 GA.) - CAV 7 PK/YL (20 GA.) - CAV 13 LB/VT (20 GA.) - CAV 14 LG/GY (20 GA.) - CAV 2 BK (12 GA.) - CAV 1 LG/VT (20 GA.) - 6 BKRD (20 GA.) - CAV 16 PK/WT (20 GA.) - CAV 11 LB/WT (20 GA.) - CAV 8 WT/DG (20 GA.) - CAV 5 LG/WT (20 GA.)- CAV 3 FUNCTION FUSED RUN REALY OUTPUT LIN BUS DRIVERS SEAT BELT SWITCH SENSE GROUND RIGHT SEAT HEATER B(+) DRIVER DRIVERS SEAT POSITION SENSOR DATA DRIVERS SEAT POSITION SENSOR VOLTAGE LEFT REAR HEATER B(+) DRIVER RIGHT REAR HEATER B(+) DRIVER FUSED RUN RELAY OUTPUT FUSED B (+) GROUND FOR DETECTING SEAT GROUND SEAT BELT PRETENSIONER IR (-) PASS A1661-ND A1661-ND A1661-ND / A25033-ND A1341-ND A25033-ND SOCKET PART # A1661-ND A1661-ND A1661-ND A25033-ND A1341-ND A1661-ND A1661-ND OEM CONNECTOR 2010 Chrysler Minivan C376 Driver Seat with Power and Heat - With Seat Detector Seat Side 2010 Power Seats - Driver w/ Power & Heat Page 67 CAV O E M C AV YL/GN YL RD BK LG/GY LB/WT LB/VT PK/WT BK/RD PK/BL BK/WT #08134-001ASM Body Side Wire 13 7 4 12 16 11 3 5 2 1 6 8 14 1 7 8 15 23 16 17 4 19 2 21 9 6 12 11 Seat Detector #08134-001ASM L G / W T (2 0 G A . ) W T/ D G (2 0 G A . ) L G / G Y (2 0 G A . ) B K (1 2 G A . ) L G / V T (2 0 G A . ) L B / W T (2 0 G A . ) L B / V T (2 0 G A . ) L G / G Y (1 8 G A . ) L G / G Y (1 8 G A . ) P K / Y L (2 0 G A . ) R D (1 2 G A . ) O R G / L G (2 0 G A . ) O R G / L B (2 0 G A . ) B K / R D (2 0 G A . ) P K / W T (2 0 G A , ) COLOR Y L / G N (2 0 G A . ) R D (2 0 G A . ) B K (2 0 G A . ) L B / W T (2 0 G A . ) L B / V T (2 0 G A . ) L G / G Y (1 8 G A . ) OR/RD RELOCATED OEM CIRCUIT BREAKER 25 A PK/YL (20 GA.) - CAV 13 OR/RD (12 GA.) #2077 #3012 #2079 #2078 #3048 #3018 #2075 #2042 #2022 #3006 2076 TW IS TE D P A IR F U S E D R U N R E A L Y O U TP U T L IN B U S D R IV E R S S E A T B E L T S W ITC H S E N S E GROUND R IG H T S E A T H E A TE R B (+ ) D R IV E R D R IV E R S S E A T P O S ITIO N S E N S O R D A TA D R IV E R S S E A T P O S ITIO N S E N S O R V O L TA G E L E F T R E A R H E A TE R B (+ ) D R IV E R R IG H T R E A R H E A TE R B (+ ) D R IV E R F U S E D R U N R E L A Y O U TP U T F U S E D B (+ ) A D JU S TA B L E P E D A L S S W ITC H R E A R W A R D A D JU S TA B L E P E D A L S S W ITC H F O R W A R D GROUND S E A T B E L T P R E TE N S IO N E R IR (-) P A S S 4 1 9 13 3 610 11 12 16 15 8 5 TOP 10/30/2012 TO PASSENGER SEAT (PASSENGER SEAT SHARES POWER FROM DRIVERS SEAT) BODY SIDE CONNECTOR # A16030-ND 14 7 2 A 1 6 4 8 -N D A 1 6 4 8 -N D A 1 6 4 8 -N D A 2 5 0 3 2 -N D A 1 6 4 8 -N D A 1 6 4 8 -N D A 1 6 4 8 -N D S O LDE R TO G E TH E R A 1 6 4 8 -N D A 2 5 0 3 2 -N D A 1 6 4 8 -N D A 1 6 4 8 -N D A 1 6 4 8 -N D A 1 6 4 8 -N D P IN P A R T # A 1 6 4 8 -N D RD (12 GA.) - CAV 7 C 3 7 6 D ri v e r P o w e r, H e a t a n d M e m o ry - B o d y S i d e P ART # EX T . (F T . ) F U N C T IO N #3027 3.5 G R O U N D F O R D E TE C TIN G S E A T #3013 3.5 POW ER #2009 3.5 GROUND TW IS TE D TA P S TO D R IV E R S S E A T P O S ITIO N S E N S O R D A TA 3 #3037 TA P S TO D R IV E R S S E A T P O S ITIO N S E N S O R V O L TA G E #2022 3.5 TA P S TO D R IV E R S S E A T B E L T S W ITC H S E N S E TO PASS RD (12 GA.) SIDE SEAT PLUG PK/YL (12 GA.) LG/GY (18 GA.) LG/GY(18 GA.) LB/VT (20 GA.) - CAV 14 LB/WT (20 GA.) - CAV 8 LG/VT (20 GA.) - 6 OR/LG (20 GA.) - 4 OR/LB (20 GA.) - 12 BK (12 GA.) - CAV 1 LG/GY (20 GA.) - CAV 2 WT/DG (20 GA.) - CAV 5 PK/WT (20 GA.) - CAV 11 LG/WT (20 GA.)- CAV 3 YL/GN (20 GA.) - CAV 9 BKRD (20 GA.) - CAV 16 2010 Chrysler Minivan C376 Driver Seat with Power, Heat and Memory - With Seat Detector Body Side YL (20 GA. TO PASSENGER’S SIDE SEAT PLUG) 2010 Power Seats - Driver w/ Power, Heat & Memory Page 68 CAV 1 3 4 5 3 6 2 7 8 1 2 5 7 8 9 10 12 14 OEM CAV Body Side Wire COLOR LG / WT (20 GA.) LG/LB (20 GA.) WT/OR (20 GA.) WT/GRY (20 GA.) ORG/RED (14 GA.) VT/LB (20 GA.) BK/ORG (14 GA.) VT/GRY (20 GA.) VT /DB (20 GA.) FROM DRIVER POWER AND HEAT HARNESS (C376) PART # #2075 #2023 TWISTED #3037 #2063 #2070 #10609 #2073 #2072 C1 Driver Memory Seat - Body Side EXT. (FT.) FUNCTION ADJUSTABLE PEDALS MOTOR FORWARD ADJUSTABLE PEDALS MOTOR READWARD CAN INTERIOR BUS (-) CAN INTERIOR BUS (+) FUSED B (+) ADJUSTABLE PEDALS SENSOR SUPPLY GROUND ADJUSTABLE PEDALSSENSOR RETURN ADJUSTABLE PEDALS SENSOR SIGNAL VT/DB (20 GA.) VT/GRY (20 GA.) BK/ORG (14 GA.) VT/LB (20 GA.) LG/WT (20 GA.) WT/GRY (20 GA.) LG/LB (20 GA.) WT/OR (20 GA.) ORG/RD (12 GA.) Body Side - Memory Plug 10 6 9 2 5 8 1 4 SOCKET PART # A1661-ND A1661-ND A1661-ND A1661-ND A25069-ND A1661-ND A25069-ND A1661-ND A1661-ND BODY SIDE CONNECTOR # A25785-ND 7 3 TOP (If vehicle drivers seat with memory, drivers seat also has power and heat and passenger seat has power and heat) 2010 Chrysler Minivan C1 Driver Seat with Memory 2010 Power Seats - Driver w/ Power, Heat & Memory 9 5 1 8 2 47 Page 69 4 5 9 2 6 10 3 SEAT SIDE CONNECTOR # A25787-ND 8 1 TOP SEAT SIDE CONNECTOR # A16036-ND 7 11 16 13 12 14 15 10 6 3 TOP BK (20 GA.) - CAV 1/9 VT /DB (20 GA.) VT/GRY (20 GA.) BK/ORG (14 GA.) VT/LB (20 GA.) ORG/RED (14 GA.) WT/GRY (20 GA.) WT/OR (20 GA.) LG /LDB (20 GA.) LG / WT (20 GA.) All wires run in same sleeving RD (12 GA.) - CAV 7 PK/YL (16 GA.) - CAV 13 LB/VT (20 GA.) - CAV 14 OR/LB (20 GA.) - 12 LB/WT (20 GA.) - CAV 8 OR/LG (20 GA.) - 4 LG/GY (20 GA.) - CAV 2 BK (12 GA.) - CAV 1 LG/VT (18 GA.) - 6 WT/DG (20 GA.) - CAV 5 LG/WT (20 GA.)- CAV 3 PK/WT (20 GA.) - CAV 11 BK/RD (20 GA.) - CAV 16 OEM CONNECTORS 2010 Chrysler Minivan Driver Seat with Power, Heat and Memory - With Seat Detector Seat Side 2010 Power Seats - Driver w/ Power, Heat & Memory Page 70 CAV 1 3 4 5 9 6 2 7 8 13 7 1/9 4 12 16 11 CAV 3 5 2 1 6 8 14 1 2 5 7 8 9 10 12 14 OEM CAV 9 6 12 11 1 7 8 15 23 16 17 4 19 2 21 OEM CAV All wires run in same sleeving and are ALL part of #10010-007 C1 Driver Memory Seat - Seat Side #10010-007 (C1 OEM CONNECTOR NOT INCLUDED) COLOR PART # EXT. (FT.) FUNCTION LG / WT (20 GA.) 2075 9 ADJUSTABLE PEDALS MOTOR FORWARD LG/LB (20 GA.) 2023 9 ADJUSTABLE PEDALS MOTOR READWARD WT/OR (20 GA.) TWISTED 9 CAN INTERIOR BUS (-) WT/GRY (20 GA.) 3036 9 CAN INTERIOR BUS (+) ORG/RED (14 GA.) 2063 9 FUSED B (+) VT/LB (20 GA.) 2070 9 ADJUSTABLE PEDALS SENSOR SUPPLY BK/ORG (14 GA.) 10609 9 GROUND VT/GRY (20 GA.) 2073 9 ADJUSTABLE PEDALSSENSOR RETURN VT /DB (20 GA.) 2072 9 ADJUSTABLE PEDALS SENSOR SIGNAL PIN PART # A1648-ND A1648-ND A1648-ND A1648-ND A25068-ND A1648-ND A25068-ND A1648-ND A1648-ND C376 Driver Power, Heat and Memory - Seat Side #10010-007-SD (C376 OEM CONNECTOR NOT INCLUDED) COLOR PART # EXT. (FT.) FUNCTION SOCKET PART # LG/WT (20 GA.) 2075 9 FUSED RUN REALY OUTPUT A1661-ND WT/DG (20 GA.) 2042 9 LIN BUS A1661-ND LG/GY (20 GA.) 2022 9 DRIVERS SEAT BELT SWITCH SENSE A1661-ND BK (12 GA.) 3006 9 GROUND A25033-ND LG/VT (18 GA.) 2076 9 RIGHT SEAT HEATER B(+) DRIVER A1341-ND LB/WT (20 GA.) TWISTED DRIVERS SEAT POSITION SENSOR DATA A1661-ND 9 LB/VT (20 GA.) # 3037 DRIVERS SEAT POSITION SENSOR VOLTAGE A1661-ND LG/GY(18 GA.) NOT LEFT REAR HEATER B(+) DRIVER LG/GY (18 GA.) USED RIGHT REAR HEATER B(+) DRIVER PK/YL (16 GA.) 2077 9 FUSED RUN RELAY OUTPUT A1341-ND RD (12 GA.) 3012 9 FUSED B (+) A25033-ND BK (20 GA.) 2009 0.25 GROUND FOR DETECTING SEAT A1661-ND / A25033-ND ORG/LG (20 GA.) 2079 9 ADJUSTABLE PEDALS SWITCH REARWARD A1648-ND ORG/LB (20 GA.) 2078 9 ADJUSTABLE PEDALS SWITCH FORWARD A1648-ND BK/RD (20 GA.) 3048 9 GROUND A1661-ND PK/WT (20 GA,) 3018 9 SEAT BELT PRETENSIONER IR (-) PASS A1661-ND 2010 Chrysler Minivan Driver Seat with Power, Heat and Memory - With Seat Detector Seat Side (Continued) 2010 Power Seats - Driver w/ Power, Heat & Memory CAV 9 2 6 1 3 4 Page 71 1 5 10 8 7 OEM CAV 1 5 10 8 7 OEM CAV LG / VT (20 GA.) PK/LB (20 GA.) BK/RD (20 GA.) OR / RD (14 GA.) BK (12 GA.) Seat Side 4 10 3 6 9 2 5 TOP 8 1 4 10/30/2012 5 9 2 6 10 3 SEAT SIDE CONNECTOR # A25787-ND 8 1 TOP 7 SOCKET PART # A25069-ND A25069-ND A1661-ND A1661-ND A1661-ND BODY SIDE CONNECTOR # A25785-ND 7 BK/RD (20 GA.) PIN PART # A25068-ND A25068-ND A1650-ND A1648-ND A1648-ND A1648-ND C 378 Passenger Power and Heat - Body Side FUNCTION FUSED B(+) GROUND RIGHT SEAT HEATER B(+) DRIVER GROUND SEAT BELT PRETENSIONER IR (-) PASS OEM WIRE EXTENDED INSIDE SEAT SIDE PLUG WIRE HARNESS COLOR OR/RD (14 GA.) BK (16GA.) LG/VT (18 GA.) BK/RD (20 GA.) PK/LB (20 GA,) OEM WIRE EXTENDED AT CENTER DASH PK/LB (20 GA.) BK/RD (20 GA.) LG / VT (20 GA.) BK (12 GA.) OR / RD (12 GA.) YL (20 GA.) C378 Passenger Power and Heat - Seat Side #10010-004 (C378 OEM CONNECTOR NOT INCLUDED) COLOR PART # EXT. (FT.) FUNCTION OR/RD (14 GA.) 2063 9 FUSED B(+) BK (16GA.) 10592 9 GROUND LG/VT (18 GA.) 3066 9 RIGHT SEAT HEATER B(+) DRIVER BK/RD (20 GA.) 3048 9 GROUND PK/LB (20 GA,) 3085 9 SEAT BELT PRETENSIONER IR (-) PASS BK (20GA.) 2009 0.25 GROUND FOR DETECTING SEAT CAV 9 2 6 1 3 TO DRIVER’S SIDE SEAT PLUG Driver’s side Dual Seat Detector YL/GN YL RD BK LG/GY LB/WT LB/VT PK/WT BK/RD PK/BL BK/WT #08134-001ASM 2010 Chrysler Minivan C378 Passenger Seat with Power and Heat Body Side 2010 Power Seats - Passenger w/ Power & Heat Page 73 CAV OEM CAV Located Behind Driver’s Knee Bolster LB/WT LB/VT LG/GY #08134-001ASM YL/GN SEAT RD DETECTOR BK V 1.03 Body Side Wire 2 1 8 14 7 2 7 9 10 8 Seat Detector #08134-001ASM LG/GY (20 GA.) BK (12 GA.) LB/WT (20 GA.) LB/VT (20 GA.) RD (12 GA.) COLOR YL/GN (20 GA.) RD (20 GA.) BK (20GA.) LB/WT (20GA.) LB/VT (20 GA.) LG/GY(18 GA.) 25 A OR/RD TWISTED PAIR OR/RD (12 GA.) RD (12 GA.) - CAV 7 DRIVER'S SEAT BELT SWITCH SENSE GROUND DRIVER'S SEAT POSITION SENSOR DATA DRIVER'S SEAT POSITION SENSOR VOLTAGE FUSED B (+) C376 Driver Power Only - Body Side EXT. (FT.) FUNCTION 3.5 GROUND FOR DETECTING SEAT 3.5 POWER 3.5 GROUND TAPS TO DRIVER'S SEAT POSITION SENSOR DATA 3 TAPS TO DRIVER'S SEAT POSITION SENSOR VOLTAGE 3.5 TAPS TO DRIVER'S SEAT BELT SWITCH SENSE RELOCATED OEM CIRCUIT BREAKER PART # 3027 3013 2009 TWISTED # 3037 2022 RD (12 GA.) PK/YL (12 GA.) LB/VT (20 GA.) - CAV 14 LB/WT (20 GA.) - CAV 8 BK (12 GA.) - CAV 1 LG/GY (20 GA.) - CAV 2 YL/GN (20 GA.) - CAV 9 4 8 5 1 9 3 610 A1648-ND A25032-ND A1648-ND A1648-ND A25032-ND PIN PART # A1648-ND TO PASSENGER SEAT (PASSENGER SEAT SHARES POWER FROM DRIVERS SEAT) BODY SIDE CONNECTOR # A16030-ND 13 14 11 12 16 15 7 2 TOP 2008-2009 Chrysler Minivan C376 Driver Seat with Power Only - With Seat Detector Body Side 2008-2009 Power Seats - Driver w/ Power Only 9 5 1 8 Page 74 CAV 2 1 8 14 7 1/9 2 7 9 10 8 OEM CAV SEAT SIDE CONNECTOR # A16036-ND RD (12 GA.) - CAV 7 LB/VT (20 GA.) - CAV 14 LB/WT (20 GA.) - CAV 8 LG/GY (20 GA.) - CAV 2 BK (12 GA.) - CAV 1 C376 Driver Power Only - Seat Side #08010-000-SD (C376 OEM CONNECTOR NOT INCLUDED) COLOR PART # EXT. (FT.) FUNCTION LG/GY (20 GA.) 2022 3 or 9 DRIVER'S SEAT BELT SWITCH SENSE BK (12 GA.) 3006 3 or 9 GROUND LB/WT (20 GA.) TWISTED DRIVER'S SEAT POSITION SENSOR DATA 3 or 9 LB/VT (20 GA.) # 3037 DRIVER'S SEAT POSITION SENSOR VOLTAGE RD (12 GA.) 3012 3 or 9 FUSED B (+) BK (20 GA.) 2009 0.25 GROUND FOR DETECTING SEAT 2 47 11 16 13 12 14 15 10 6 3 TOP BK (20 GA.) - CAV 1/9 A1661-ND / A25033-ND SOCKET PART # A1661-ND A25033-ND A1661-ND A1661-ND A25033-ND OEM CONNECTOR 2008-2009 Chrysler Minivan C376 Driver Seat with Power Only - With Seat Detector Seat Side 2008-2009 Power Seats - Driver w/ Power and Heat Page 75 CAV Located Behind Driver’s Knee Bolster LB/WT LB/VT LG/GY #08134-001ASM YL/GN SEAT RD DETECTOR BK V 1.03 Body Side Wire OEM C AV 13 7 3 5 2 1 6 8 14 4 5 2 7 6 9 10 11 12 14 8 Seat Detector #08134-001ASM LG/W T (20 GA.) W T/DG (20 GA.) LG/GY (20 GA.) BK (12 GA.) LG/VT (20 GA.) LB/W T (20 GA.) LB/VT (20 GA.) LG/GY(18 GA.) LG/GY (18 GA.) PK/YL (20 GA.) RD (12 GA.) COLOR YL/GN (20 GA.) RD (20 GA.) BK (20GA.) LB/W T (20GA.) LB/VT (20 GA.) LG/GY(18 GA.) RD (12 GA.) LG/GY(18 GA.) 25 A OR/RD PK/YL (20 GA.) - CAV 13 TW ISTED PAIR PART # 3027 3013 2009 TW ISTED # 3037 2022 OR/RD (12 GA.) RD (12 GA.) - CAV 7 FUSED RUN REALY OUTPUT LIN BUS DRIVER'S SEAT BELT SW ITCH SENSE GROUND RIGHT SEAT HEATER B(+ ) DRIVER DRIVER'S SEAT POSITION SENSOR DATA DRIVER'S SEAT POSITION SENSOR VOLTAGE LEFT REAR HEATER B(+ ) DRIVER RIGHT REAR HEATER B(+ ) DRIVER FUSED RUN RELAY OUTPUT FUSED B (+ ) C376 Drive r Pow e r a nd He a t - Body Side EX T. (FT.) FUNCTION 3.5 GROUND FOR DETECTING SEAT 3.5 POW ER 3.5 GROUND TAPS TO DRIVER'S SEAT POSITION SENSOR DATA 3 TAPS TO DRIVER'S SEAT POSITION SENSOR VOLTAGE 3.5 TAPS TO DRIVER'S SEAT BELT SW ITCH SENSE RELOCATED OEM CIRCUIT BREAKER PK/YL (12 GA.) LG/GY (18 GA.) LB/VT (20 GA.) - CAV 14 LB/WT (20 GA.) - CAV 8 BK (12 GA.) - CAV 1 LG/VT (20 GA.) - 6 LG/GY (20 GA.) - CAV 2 WT/DG (20 GA.) - CAV 5 LG/WT (20 GA.)- CAV 3 YL/GN (20 GA.) - CAV 9 4 8 5 1 9 3 610 A1648-ND A1648-ND A1648-ND A25032-ND A1648-ND A1648-ND A1648-ND SOLDER TOGETHER A1648-ND A25032-ND PIN PART # A1648-ND TO PASSENGER SEAT (PASSENGER SEAT SHARES POWER FROM DRIVERS SEAT) BODY SIDE CONNECTOR # A16030-ND 13 14 11 12 16 15 7 2 TOP 2008-2009 Chrysler Minivan C376 Driver Seat with Power and Heat - With Seat Detector Body Side 2008-2009 Power Seats - Driver w/ Power & Heat 9 5 1 8 2 47 Page 76 13 7 1/9 CAV 3 5 2 1 6 8 14 4 5 2 7 6 9 10 11 12 14 8 OEM CAV SEAT SIDE CONNECTOR # A16036-ND 11 16 13 12 14 15 10 6 3 TOP BK (20 GA.) - CAV 1/9 A1661-ND / A25033-ND A1661-ND A25033-ND SOCKET PART # A1661-ND A1661-ND A1661-ND A25033-ND A1661-ND A1661-ND A1661-ND OEM CONNECTOR C376 Driver Power and Heat - Seat Side #08010-001-SD (C376 OEM CONNECTOR NOT INCLUDED) COLOR PART # EXT. (FT.) FUNCTION LG/WT (20 GA.) 2075 3 or 9 FUSED RUN REALY OUTPUT WT/DG (20 GA.) 2042 3 or 9 LIN BUS LG/GY (20 GA.) 2022 3 or 9 DRIVER'S SEAT BELT SWITCH SENSE BK (12 GA.) 3006 3 or 9 GROUND LG/VT (20 GA.) 2076 3 or 9 RIGHT SEAT HEATER B(+) DRIVER LB/WT (20 GA.) TWISTED DRIVER'S SEAT POSITION SENSOR DATA 3 or 9 LB/VT (20 GA.) # 3037 DRIVER'S SEAT POSITION SENSOR VOLTAGE LG/GY(18 GA.) NOT LEFT REAR HEATER B(+) DRIVER LG/GY (18 GA.) USED RIGHT REAR HEATER B(+) DRIVER PK/YL (20 GA.) 2077 3 or 9 FUSED RUN RELAY OUTPUT RD (12 GA.) 3012 3 or 9 FUSED B (+) BK (20 GA.) 2009 0.25 GROUND FOR DETECTING SEAT RD (12 GA.) - CAV 7 PK/YL (20 GA.) - CAV 13 LB/VT (20 GA.) - CAV 14 LB/WT (20 GA.) - CAV 8 LG/GY (20 GA.) - CAV 2 BK (12 GA.) - CAV 1 LG/VT (20 GA.) - 6 WT/DG (20 GA.) - CAV 5 LG/WT (20 GA.)- CAV 3 2008-2009 Chrysler Minivan C376 Driver Seat with Power and Heat - With Seat Detector Seat Side 2008-2009 Power Seats - Driver w/ Power & Heat Page 77 CAV OEM C AV Located Behind Driver’s Knee Bolster LB/WT LB/VT LG/GY #08134-001ASM YL/GN SEAT RD DETECTOR BK V 1.03 Body Side Wire 13 7 4 12 3 5 2 1 6 8 14 4 5 2 7 6 9 10 11 12 14 8 3 13 Seat Detector #08134-001ASM LG/W T (20 GA .) W T/DG (20 GA .) LG/GY (20 GA .) B K (12 GA .) LG/V T (20 GA .) LB /W T (20 GA .) LB /V T (20 GA .) LG/GY (18 GA .) LG/GY (18 GA .) P K /Y L (20 GA .) RD (12 GA .) ORG/LG (20 GA .) ORG/LB (20 GA .) COLOR Y L/GN (20 GA .) RD (20 GA .) B K (20GA .) LB /W T (20GA .) LB /V T (20 GA .) LG/GY (18 GA .) 25 A RELOCATED OEM CIRCUIT BREAKER OR/RD PK/YL (20 GA.) - CAV 13 LB/VT (20 GA.) - CAV 14 OR/RD (12 GA.) TW IS TE D P A IR FUS E D RUN RE A LY OUTP UT LIN B US DRIV E R'S S E A T B E LT S W ITCH S E NS E GROUND RIGHT S E A T HE A TE R B (+ ) DRIV E R DRIV E R'S S E A T P OS ITION S E NS OR DA TA DRIV E R'S S E A T P OS ITION S E NS OR V OLTA GE LE FT RE A R HE A TE R B (+ ) DRIV E R RIGHT RE A R HE A TE R B (+ ) DRIV E R FUS E D RUN RE LA Y OUTP UT FUS E D B (+ ) A DJUS TA B LE P E DA LS S W ITCH RE A RW A RD A DJUS TA B LE P E DA LS S W ITCH FORW A RD 4 8 5 TOP 1 9 3 610 TO PASSENGER SEAT (PASSENGER SEAT SHARES POWER FROM DRIVERS SEAT) BODY SIDE CONNECTOR # A16030-ND 13 14 11 12 16 15 7 2 A 1648-ND A 1648-ND A 1648-ND A 25032-ND A 1648-ND A 1648-ND A 1648-ND S OLDE R TOGE THE R A 1648-ND A 25032-ND A 1648-ND A 1648-ND P IN P ART # A 1648-ND RD (12 GA.) - CAV 7 C376 Drive r P ow e r, He a t a nd M e m ory- Body S ide P ART # EX T. (FT.) FUNCTION 3027 3.5 GROUND FOR DE TE CTING S E A T 3013 3.5 P OW E R 2009 3.5 GROUND TW IS TE D TA P S TO DRIV E R'S S E A T P OS ITION S E NS OR DA TA 3 # 3037 TA P S TO DRIV E R'S S E A T P OS ITION S E NS OR V OLTA GE 2022 3.5 TA P S TO DRIV E R'S S E A T B E LT S W ITCH S E NS E RD (12 GA.) PK/YL (12 GA.) LG/GY (18 GA.) LG/GY(18 GA.) LB/WT (20 GA.) - CAV 8 BK (12 GA.) - CAV 1 LG/VT (20 GA.) - 6 OR/LG (20 GA.) - 4 OR/LB (20 GA.) - 12 LG/GY (20 GA.) - CAV 2 WT/DG (20 GA.) - CAV 5 LG/WT (20 GA.)- CAV 3 YL/GN (20 GA.) - CAV 9 2008-2009 Chrysler Minivan C376 Driver Seat with Power, Heat and Memory - With Seat Detector Body Side 2008-2009 Power Seats - Driver w/ Power, Heat & Memory 9 5 1 8 2 47 RD (12 GA.) - CAV 7 PK/YL (20 GA.) - CAV 13 LB/VT (20 GA.) - CAV 14 OR/LB (20 GA.) - 12 LB/WT (20 GA.) - CAV 8 OR/LG (20 GA.) - 4 LG/GY (20 GA.) - CAV 2 BK (12 GA.) - CAV 1 LG/VT (20 GA.) - 6 WT/DG (20 GA.) - CAV 5 LG/WT (20 GA.)- CAV 3 OEM CONNECTOR Page 78 *After 9/9/2009, Rollx Vans changed seat wire harnesses to a longer harness with woven covering. This change allowed all vans to have a six-way seat installed without modifying the seat wire harness. When a six-way seat is not installed, the excess wire will be stored under the OEM Seat. If Memory Function is present, the added harness shares the same loom as the harness for power and heat. This part is #08180-007-SD. C376 Driver Power, Heat and Memory - Seat Side #08010-002-SD or #08180-007-SD after 9/9/2009* (C376 OEM CON NOT INCLUDED) CAV OEM CAV COLOR PART # EXT. (FT.) FUNCTION SOCKET PART # 3 4 LG/WT (20 GA.) 2075 3 or 9 FUSED RUN REALY OUTPUT A1661-ND 5 5 WT/DG (20 GA.) 2042 3 or 9 LIN BUS A1661-ND 2 2 LG/GY (20 GA.) 2022 3 or 9 DRIVER'S SEAT BELT SWITCH SENSE A1661-ND 1 7 BK (12 GA.) 3006 3 or 9 GROUND A25033-ND 6 6 LG/VT (20 GA.) 2076 3 or 9 RIGHT SEAT HEATER B(+) DRIVER A1661-ND 8 9 LB/WT (20 GA.) TWISTED DRIVER'S SEAT POSITION SENSOR DATA A1661-ND 3 or 9 14 10 LB/VT (20 GA.) # 3037 DRIVER'S SEAT POSITION SENSOR VOLTAGE A1661-ND 11 LG/GY(18 GA.) NOT LEFT REAR HEATER B(+) DRIVER 12 LG/GY (18 GA.) USED RIGHT REAR HEATER B(+) DRIVER 13 14 PK/YL (20 GA.) 2077 3 or 9 FUSED RUN RELAY OUTPUT A1661-ND 7 8 RD (12 GA.) 3012 3 or 9 FUSED B (+) A25033-ND 1/9 BK (20 GA.) 2009 0.25 GROUND FOR DETECTING SEAT A1661-ND / A25033-ND 4 3 ORG/LG (20 GA.) 2079 3 or 9 ADJUSTABLE PEDALS SWITCH REARWARD A1648-ND 12 13 ORG/LB (20 GA.) 2078 3 or 9 ADJUSTABLE PEDALS SWITCH FORWARD A1648-ND SEAT SIDE CONNECTOR # A16036-ND 11 16 13 12 14 15 10 6 3 TOP BK (20 GA.) - CAV 1/9 2008-2009 Chrysler Minivan C376 Driver Seat with Power, Heat and Memory - With Seat Detector Seat Side 2008-2009 Power Seats - Driver w/ Power, Heat & Memory CAV 1 3 4 5 3 6 2 7 8 Page 79 1 2 5 7 8 9 10 12 14 OEM CAV Body Side Wire COLOR LG / WT (20 GA.) LG/LB (20 GA.) WT/OR (20 GA.) WT/GRY (20 GA.) ORG/RED (14 GA.) VT/LB (20 GA.) BK/ORG (14 GA.) VT/GRY (20 GA.) VT /DB (20 GA.) FROM DRIVER POWER AND HEAT HARNESS (C376) PART # C1 Driver Memory Seat - Body Side EXT. (FT.) FUNCTION ADJUSTABLE PEDALS MOTOR FORWARD ADJUSTABLE PEDALS MOTOR READWARD CAN INTERIOR BUS (-) CAN INTERIOR BUS (+) FUSED B (+) ADJUSTABLE PEDALS SENSOR SUPPLY GROUND ADJUSTABLE PEDALSSENSOR RETURN ADJUSTABLE PEDALS SENSOR SIGNAL VT/DB (20 GA.) VT/GRY (20 GA.) BK/ORG (14 GA.) VT/LB (20 GA.) LG/WT (20 GA.) WT/GRY (20 GA.) LG/LB (20 GA.) WT/OR (20 GA.) ORG/RD (12 GA.) Body Side - Memory Plug 10 6 9 2 5 8 1 4 SOCKET PART # A1661-ND A1661-ND A1661-ND A1661-ND A25069-ND A1661-ND A25069-ND A1661-ND A1661-ND BODY SIDE CONNECTOR # A25785-ND 7 3 TOP (If vehicle drivers seat with memory, drivers seat also has power and heat and passenger seat has power and heat) 2008-2009 Chrysler Minivan C1 Driver Seat with Memory 2008-2009 Power Seats - Driver w/ Power, Heat & Memory 4 5 9 2 6 10 3 Page 80 VT /DB (20 GA.) VT/GRY (20 GA.) BK/ORG (14 GA.) VT/LB (20 GA.) OEM CONNECTOR OEM CAV C1 Driver Memory Seat - Seat Side #08010-006 or #08180-007-SD after 9/9/2009* (C376 OEM CON NOT INCLUDED) COLOR PART # EXT. (FT.) FUNCTION PIN PART # 1 LG / WT (20 GA.) 2075 3 or 9 ADJUSTABLE PEDALS MOTOR FORWARD A1648-ND 2 LG/LB (20 GA.) 2023 3 or 9 ADJUSTABLE PEDALS MOTOR READWARD A1648-ND 5 WT/OR (20 GA.) TWISTED 3 or 9 CAN INTERIOR BUS (-) A1648-ND 7 WT/GRY (20 GA.) 3036 3 or 9 CAN INTERIOR BUS (+) A1648-ND 8 ORG/RED (14 GA.) 2063 3 or 9 FUSED B (+) A25068-ND 9 VT/LB (20 GA.) 2070 3 or 9 ADJUSTABLE PEDALS SENSOR SUPPLY A1648-ND 10 BK/ORG (14 GA.) 10609 3 or 9 GROUND A25068-ND 12 VT/GRY (20 GA.) 2073 3 or 9 ADJUSTABLE PEDALSSENSOR RETURN A1648-ND 14 VT /DB (20 GA.) 2072 3 or 9 ADJUSTABLE PEDALS SENSOR SIGNAL A1648-ND 7 ORG/RED (14 GA.) WT/GRY (20 GA.) WT/OR (20 GA.) *After 9/9/2009, Rollx Vans changed seat wire harnesses to a longer harness with woven covering. This change allowed all vans to have a six-way seat installed without modifying the seat wire harness. When a six-way seat is not installed, the excess wire will be stored under the OEM Seat. If Memory Function is present, the added harness shares the same loom as the harness for power and heat. This part is #08180-007-SD. CAV 1 3 4 5 9 6 2 7 8 SEAT SIDE CONNECTOR # A25787-ND 8 1 TOP LG /LDB (20 GA.) LG / WT (20 GA.) Seat Side - Memory Plug (If vehicle drivers seat with memory, drivers seat also has power and heat and passenger seat has power and heat) Chrysler 2008-2009 Minivan C1 Driver Seat with Memory 2008-2009 Power Seats - Driver w/ Power, Heat & Memory 1 5 10 OEM CAV COLOR OR/RD (14 GA.) BK (16GA.) LG/VT (18 GA.) LB/WHT (20 GA.)* LB/VLT (20 GA.)* Page 81 CAV 9 2 6 1 5 10 OEM CAV OEM WIRE EXTENDED AT CENTER DASH LG / VT (20 GA.) OEM WIRE EXTENDED INSIDE SEAT SIDE PLUG WIRE HARNESS BK ( GA.) OR / RD (14 GA.) Seat Side 4 7 10 3 6 9 2 5 TOP 8 1 4 5 9 2 6 10 3 7 PIN PART # A25068-ND A25068-ND A1650-ND SEAT SIDE CONNECTOR # A25787-ND 8 1 TOP BODY SIDE CONNECTOR # A25785-ND C378 Passenger Power and Heat - Seat Side #08010-004 (C378 OEM CONNECTOR NOT INCLUDED) COLOR PART # EXT. (FT.) FUNCTION OR/RD (14 GA.) 2063 2 or 9 FUSED B(+) BK (16GA.) 10592 2 or 9 GROUND LG/VT (18 GA.) 3066 2 or 9 RIGHT SEAT HEATER B(+) DRIVER Seat Side Wire Harness and Connector LG / VT (20 GA.) BK (12 GA.) OR / RD (12 GA.) C 378 Passenger Power and Heat - Body Side FUNCTION SOCKET PART # FUSED B(+) A25069-ND GROUND A25069-ND RIGHT SEAT HEATER B(+) DRIVER A1661-ND DRIVERS SEAT POSITION SENSOR DATA RESISTED DRIVERS SEAT POSITION SENSOR VOLTAGE RESISTED * Resisted near driver's kick panel if OEM Airbag Modules has part # ending in AK or before Body Side Wire Harness and Connector Note: Newer OEM Airbag Modules with part # ending in AL only get the Driver Side resisted. Older OEM Airbag Modules with part # ending in AK get the Driver and Passenger Side resisted. At some point in 2008 Chrysler decided to leave the passenger side circuit open so it no longer needs resistence when the seat is moved. CAV 9 2 6 1 TO OEM WIRING VLT/LB (20 GA.) WHT/LB (20 GA.) FROM DRIVER SEAT (PASSENGER SEAT SHARES POWER FROM DRIVERS SEAT) NEAR DRIVERS KICK PANEL PASSENGER SEAT POSITION SENSOR IS RESISTED (SEE NOTE) 2008-2009 Chrysler Minivan C378 Passenger Seat with Power and Heat Body Side 2008-2009 Power Seats - Passenger w/ Power & Heat Power Seats (Pre Seat Detector) - Resistors 2008 Chrysler Minivan Air bag and Seatbelt Resistors for All Vans (Body side near driver’s kick panel) ALL RESISTORS ARE - 1K OHM 1/4 W 1% (#R171171506) DRIVER SEATBELT SENSOR (SEATBELT WARNING LIGHT) LG/GRY (20 GA.) DRIVERS SEAT BELT SWITCH SENSE *LG/GRY IS GROUNDED UNLESS VAN HAS MEMORY SEAT* PASSENGER SEATBELT SENSOR (SEATBELT WARNING LIGHT) LB/GRY (20 GA.) PASSENGER SEAT BELT SWITCH SENSE LB/TN (20 GA.) PASSENGER SEAT BELT SWITCH RETURN 1K DRIVER SEAT POSITION (AIRBAG WARNING LIGHT) LB/WHT (20 GA.) DRIVERS SEAT POSITION SENSOR DATA LB/VLT (20 GA.) DRIVERS SEAT POSITION SENSOR VOLTAGE 1K PASSENGER SEAT POSITION (AIRBAG WARNING LIGHT) WHT/LB (20 GA.) PASSENGER SEAT TRACK POSITION SENSOR SIGNAL VLT/LB (20 GA.) PASSENGER SEAT TRACK POSITION SENSOR SUPPLY 1K Note: Newer OEM Airbag Modules with part # ending in AL only get the Driver Side resisted. Older OEM Airbag Modules with part # ending in AK get the Driver and Passenger Side resisted. At some point in 2008 Chrysler decided to leave the passenger side circuit open so it no longer needs resistence when the seat is moved. Page 83 CAV 1 7 Page 84 7 8 OEM CAV BK (12 GA.) 1K OR/RD 4 1 9 13 3 610 11 12 16 15 8 5 BODY SIDE CONNECTOR # A16030-ND 14 7 2 TOP C376 Driver Power Only - Seat Side #08010-001 (C376 OEM CONNECTOR NOT INCLUDED) COLOR PART # EXT. (FT.) FUNCTION BK (12 GA.) 3006 3 GROUND RD (12 GA.) 3012 3 FUSED B (+) RD (12 GA.) BK (12 GA.) Seat Side 16 1 8 13 12 14 15 9 5 11 2 4 7 SOCKET PART # A25033-ND A25033-ND SEAT SIDE CONNECTOR # A16036-ND 10 6 3 TOP C376 Driver Power Only - Body Side DESCRIPTION PIN PART # GROUND A25032-ND FUSED B (+) A25032-ND DRIVERS SEAT BELT SWITCH SENSE GROUNDED DRIVERS SEAT POSITION SENSOR DATA RESISTED DRIVERS SEAT POSITION SENSOR VOLTAGE RESISTED * Present if seat is manual (no power) PK/YL (12 GA.) RELOCATED OEM CIRCUIT BREAKER LB/WHT (20 GA.) LB/VLT (20 GA.) LG/GRY (20 GA.) OEM CONNECTOR .) CAV 1 7 COLOR BK (12 GA.) RD (12 GA.) LG/GRY (20 GA.)* LB/WHT (20 GA.)* LB/VLT (20 GA.)* 2 GA 7 8 2 9 10 OEM CAV Body Side Wire RESISTOR IS 1K OHM 1/4 W 1% (#R171171506) RD (1 RD (1 2 GA.) 2008 Chrysler Minivan C376 Driver Seat with No Power (Manual) or Power Only Body Side Power Seats (Pre Seat Detector) Manual or Driver Power Only Page 85 9 11 13 CAV 1 15 2 3 5 6 7 7 1 2 4 5 6 8 9 10 11 12 14 OEM CAV RD (12 GA.) COLOR BK (12 GA.) OR / RD (12 GA.) LG/GRY (20 GA.) LG/W T (20 GA.) W T/DG (20 GA.) LG/VT (20 GA.) RD (12 GA.) LB/W HT (20 GA.) LB/VLT (20 GA.) LG/GRY(18 GA.) LG/GRY (18 GA.) PNK/YLW (20 GA.) TO PASSENGER SEAT (PASSENGER SEAT SHARES POWER FROM DRIVERS SEAT) Body Side Wire 25 A OR/RD RD (12 GA.) C376 Dri ve r Pow er and Heat - Body Si de DESCRIPTION GROUND FUSED B(+) DRIVERS SEAT BELT SW ITCH SENSE FUSED RUN REALY OUTPUT LIN BUS RIGHT SEAT HEATER B(+) DRIVER FUSED B (+) DRIVERS SEAT POSITION SENSOR DATA DRIVERS SEAT POSITION SENSOR VOLTAGE LEFT REAR HEATER B(+) DRIVER RIGHT REAR HEATER B(+) DRIVER FUSED RUN RELAY OUTPUT OR/RD (12 GA.) PK/YL (12 GA.) RELOCATED OEM CIRCUIT BREAKER PNK/YLW (20 GA.) LG/GRY (18 GA.) LB/WHT (20 GA.) LB/VLT (20 GA.) LG/GRY(18 GA.) BK (12 GA.) LG/WT (20 GA.) WT/DG (20 GA.) LG/GRY (20 GA.) RESISTOR IS 1K OHM 1/4 W 1% (#R171171506) 1K 4 1 9 13 3 610 11 12 16 15 8 5 TOP PIN PART # A25032-ND A25032-ND GROUNDED A1648-ND A1648-ND A1648-ND A25032-ND RESISTED RESISTED A1648-ND A1648-ND A1648-ND BODY SIDE CONNECTOR # A16030-ND 14 7 2 2008 Chrysler Minivan C376 Driver Seat with Power and Heat Body Side Power Seats (Pre Seat Detector) - Driver w/ Power and Heat CAV 1 3 5 6 7 9 11 13 Page 86 7 4 5 6 8 11 12 14 OEM CAV PNK/YLW (20 GA.) RD (12 GA.) (OR/RD) C376 Driver Pow er and Heat - Seat Side #08010-001 (C376 OEM CONNECTOR NOT INCLUDED) COLOR PART # EXT. (FT.) FUNCTION BK (12 GA.) 3006 3 GROUND LG/WT (20 GA.) 2075 3 FUSED RUN REALY OUTPUT WT/DG (20 GA.) 2042 3 LIN BUS LG/VT (20 GA.) 2076 3 RIGHT SEAT HEATER B(+) DRIVER RD (12 GA.) 3012 3 FUSED B (+) LG/GRY(18 GA.) 2022 3 LEFT REAR HEATER B(+) DRIVER LG/GRY (18 GA.) 2022 3 RIGHT REAR HEATER B(+) DRIVER PNK/YLW (20 GA.) 8077 3 FUSED RUN RELAY OUTPUT OEM CONNECTOR LG/GRY (20 GA.) LG/VLT (20 GA.) LG/GRY(20 GA.) BK (12 GA.) WT/DG (20 GA.) LG/WT (20 GA.) 2008 Chrysler Minivan C376 Driver Seat with Power and Heat Seat Side 9 5 1 8 2 47 SOCKET PART # A25033-ND A1661-ND A1661-ND A1661-ND A25033-ND A1661-ND A1661-ND A1661-ND SEAT SIDE CONNECTOR # A16036-ND 11 16 13 12 14 15 10 6 3 TOP Power Seats (Pre Seat Detector) - Driver w/ Power and Heat Page 87 RD (12 GA.) 9 11 12 13 CAV 1 2 3 4 5 6 7 7 2 4 3 5 6 8 9 10 11 12 13 14 OEM CAV COLOR BK (12 GA.) LG/GRY (20 GA.) LG/WT (20 GA.) ORG/LG (20 GA.) WT/DG (20 GA.) LG/VT (20 GA.) RD (12 GA.) LB/WHT (20 GA.) LB/VLT (20 GA.) LG/GRY(18 GA.) LG/GRY (18 GA.) ORG/LB (20 GA.) PNK/YLW (20 GA.) TO PASSENGER SEAT (PASSENGER SEAT SHARES POWER FROM DRIVERS SEAT) Body Side Wire Harness LG/GRY (18 GA.) ORG/LB (20 GA.) PNK/YLW (20 GA.) LB/WHT (20 GA.) LB/VLT (20 GA.) LG/GRY(18 GA.) BK (12 GA.) LG/GRY (20 GA.) ORG/LG (20 GA.) LG/WT (20 GA.) WT/DG (20 GA.) 1K 25 A OR/RD OR/RD (12 GA.) RD (12 GA.) C376 Driver Memory, Pow er and Heat - Body Side DESCRIPTION GROUND DRIVERS SEAT BELT SWITCH SENSE FUSED RUN REALY OUTPUT ADJUSTABLE PEDALS SWITCH REARWARD LIN BUS RIGHT SEAT HEATER B(+) DRIVER FUSED B (+) DRIVERS SEAT POSITION SENSOR DATA DRIVERS SEAT POSITION SENSOR VOLTAGE LEFT REAR HEATER B(+) DRIVER RIGHT REAR HEATER B(+) DRIVER ADJUSTABLE PEDALS SWITCH FORWARD FUSED RUN RELAY OUTPUT OR/RD (12 GA.) PK/YL (12 GA.) RELOCATED OEM CIRCUIT BREAKER RESISTOR IS 1K OHM 1/4 W 1% (#R171171506) 4 9 13 3 610 11 12 16 15 8 5 1 PIN PART # A25032-ND A1648-ND A1648-ND A1648-ND A1648-ND A1648-ND A25032-ND RESISTED RESISTED A1648-ND A1648-ND A1648-ND A1648-ND TO DRIVER MEMORY HARNESS BODY SIDE CONNECTOR # A16030-ND 14 7 2 TOP 2008 Chrysler Minivan C376 Driver Seat with Memory, Power and Heat Body Side - Power and Heat Plug Power Seats (Pre Seat Detector) - Dr. w/ Memory, Pwr and Heat CAV 1 2 3 4 5 6 7 9 11 12 13 Page 88 7 2 4 3 5 6 8 11 12 13 14 OEM CAV 9 5 1 8 2 47 SEAT SIDE CONNECTOR # A16036-ND 11 16 13 12 14 15 10 6 3 TOP C376 Driver Memory, Pow er and Heat - Seat Side #08010-002 (C376 OEM CONNECTOR NOT INCLUDED) COLOR PART # EXT. (FT.) FUNCTION SOCKET PART # BK (12 GA.) 3006 3 GROUND A25033-ND LG/GRY (20 GA.) 2022 3 DRIVERS SEAT BELT SWITCH SENSE A1661-ND LG/WT (20 GA.) 2075 3 FUSED RUN REALY OUTPUT A1661-ND ORG/LG (20 GA.) 2079 3 ADJUSTABLE PEDALS SWITCH REARWARD A1661-ND WT/DG (20 GA.) 2042 3 LIN BUS A1661-ND LG/VT (20 GA.) 2076 3 RIGHT SEAT HEATER B(+) DRIVER A1661-ND RD (12 GA.) 3012 3 FUSED B (+) A25033-ND LG/GRY(18 GA.) 2022 3 LEFT REAR HEATER B(+) DRIVER A1661-ND LG/GRY (18 GA.) 2022 3 RIGHT REAR HEATER B(+) DRIVER A1661-ND ORG/LB (20 GA.) 2078 3 ADJUSTABLE PEDALS SWITCH FORWARD A1661-ND PNK/YLW (20 GA.) 2077 3 FUSED RUN RELAY OUTPUT A1661-ND OEM CONNECTOR LG/GRY (18 GA.) ORG/LB (20 GA.) PNK/YLW (20 GA.) RD (12 GA.) LG/GRY (20 GA.) LG/VLT (20 GA.) LG/GRY(18 GA.) BK (12 GA.) ORG/LG (20 GA.) LG/WT (20 GA.) WT/DG (20 GA.) 2008 Chrysler Minivan C376 Driver Seat with Memory, Power and Heat Seat Side - Power and Heat Plug Power Seats (Pre Seat Detector) - Dr. w/ Memory, Pwr and Heat CAV 1 2 4 5 2 6 9 7 8 Page 89 1 2 5 7 8 9 10 12 14 OEM CAV Body Side Wire COLOR LG / WT (20 GA.) LG/LB (20 GA.) WT/OR (20 GA.) WT/GRY (20 GA.) ORG/RED (14 GA.) VT/LB (20 GA.) BK/ORG (14 GA.) VT/GRY (20 GA.) VT /DB (20 GA.) FROM DRIVER POWER AND HEAT HARNESS (C376) PART # C1 Driver Memory Seat - Body Side EXT. (FT.) FUNCTION ADJUSTABLE PEDALS MOTOR FORWARD ADJUSTABLE PEDALS MOTOR READWARD CAN INTERIOR BUS (-) CAN INTERIOR BUS (+) FUSED B (+) ADJUSTABLE PEDALS SENSOR SUPPLY GROUND ADJUSTABLE PEDALSSENSOR RETURN ADJUSTABLE PEDALS SENSOR SIGNAL VT/DB (20 GA.) VT/GRY (20 GA.) BK/ORG (14 GA.) VT/LB (20 GA.) LG/WT (20 GA.) WT/GRY (20 GA.) LG/LB (20 GA.) WT/OR (20 GA.) ORG/RD (12 GA.) Body Side - Memory Plug 10 6 9 2 5 8 1 4 SOCKET PART # A1661-ND A1661-ND A1661-ND A1661-ND A25069-ND A1661-ND A25069-ND A1661-ND A1661-ND BODY SIDE CONNECTOR # A25785-ND 7 3 TOP (If vehicle drivers seat with memory, drivers seat also has power and heat and passenger seat has power and heat) 2008 Chrysler Minivan C1 Driver Seat with Memory Power Seats (Pre Seat Detector) - Dr. w/ Memory, Pwr and Heat CAV 1 2 4 5 2 6 9 7 8 Page 90 1 2 5 7 8 9 10 12 14 OEM CAV VT /DB (20 GA.) C1 Driver Memory Seat - Seat Side #08010-006 (C1 OEM CONNECTOR NOT INCLUDED) COLOR PART # EXT. (FT.) FUNCTION LG / WT (20 GA.) 2075 3 ADJUSTABLE PEDALS MOTOR FORWARD LG/LB (20 GA.) 2023 3 ADJUSTABLE PEDALS MOTOR READWARD WT/OR (20 GA.) TWISTED 3 CAN INTERIOR BUS (-) WT/GRY (20 GA.) 3036 3 CAN INTERIOR BUS (+) ORG/RED (14 GA.) 2063 3 FUSED B (+) VT/LB (20 GA.) 2070 3 ADJUSTABLE PEDALS SENSOR SUPPLY BK/ORG (14 GA.) 10609 3 GROUND VT/GRY (20 GA.) 2073 3 ADJUSTABLE PEDALSSENSOR RETURN VT /DB (20 GA.) 2072 3 ADJUSTABLE PEDALS SENSOR SIGNAL OEM CONNECTOR VT/GRY (20 GA.) BK/ORG (14 GA.) VT/LB (20 GA.) ORG/RED (14 GA.) WT/GRY (20 GA.) WT/OR (20 GA.) LG /LDB (20 GA.) LG / WT (20 GA.) Seat Side - Memory Plug 4 5 9 2 6 10 3 PIN PART # A1648-ND A1648-ND A1648-ND A1648-ND A25068-ND A1648-ND A25068-ND A1648-ND A1648-ND SEAT SIDE CONNECTOR # A25787-ND 8 1 TOP (If vehicle drivers seat with memory, drivers seat also has power and heat and passenger seat has power and heat) Chrsyler 2008 Minivan C1 Driver Seat with Memory 7 Power Seats (Pre Seat Detector) - Dr. w/ Memory, Pwr and Heat Page 91 1 5 10 OEM CAV COLOR OR/RD (14 GA.) BK (16GA.) LG/VT (18 GA.) LB/WHT (20 GA.)* LB/VLT (20 GA.)* For Driver Memory Seat Shunt Plug, see next page. CAV 9 2 6 1 5 10 OEM CAV LG / VT (20 GA.) BK (12 GA.) OR / RD (12 GA.) OEM WIRE EXTENDED AT CENTER DASH 4 C378 Passenger Power and Heat - Seat Side #08010-004 (C378 OEM CONNECTOR NOT INCLUDED) COLOR PART # EXT. (FT.) FUNCTION OR/RD (14 GA.) 2063 2 FUSED B(+) BK (16GA.) 10592 2 GROUND LG/VT (18 GA.) 3066 2 RIGHT SEAT HEATER B(+) DRIVER LG / VT (20 GA.) OEM WIRE EXTENDED INSIDE SEAT SIDE PLUG WIRE HARNESS BK ( GA.) OR / RD (14 GA.) Seat Side C 378 Passenger Power and Heat - Body Side FUNCTION SOCKET PART # FUSED B(+) A25069-ND GROUND A25069-ND RIGHT SEAT HEATER B(+) DRIVER A1661-ND DRIVERS SEAT POSITION SENSOR DATA RESISTED DRIVERS SEAT POSITION SENSOR VOLTAGE RESISTED * Resisted near driver's kick panel if OEM Airbag Modules has part # ending in AK or before Body Side Wire Harness and Connector Seat Side Wire Harness and Connector CAV 9 2 6 1 TO OEM WIRING VLT/LB (20 GA.) WHT/LB (20 GA.) FROM DRIVER SEAT (PASSENGER SEAT SHARES POWER FROM DRIVERS SEAT) NEAR DRIVERS KICK PANEL PASSENGER SEAT POSITION SENSOR IS RESISTED 7 10 3 6 9 2 5 TOP 8 1 4 5 9 2 6 10 3 PIN PART # A25068-ND A25068-ND A1650-ND SEAT SIDE CONNECTOR # A25787-ND 8 1 TOP 7 BODY SIDE CONNECTOR # A25785-ND 2008 Chrysler Minivan C378 Passenger Seat with Power and Heat Body Side Power Seats (Pre Seat Detector) - Ps. w/ Pwr and Heat Page 92 CAV 2 1 2 7 OEM CAV PART # 2009 COLOR BK (20 GA.) 9 5 1 8 2 47 20 GAUGE SHORTING WIRE Shunt Plug - Memory 2008 #08011-001 EXT. (FT.) FUNCTION DRIVERS SEAT BLET SWITCH SENSE 0.25 GROUND SEAT SIDE CONNECTOR # A16036-ND 11 16 13 12 14 15 10 6 3 TOP PIN PART # A1661-ND A25033-ND (To be installed in place of the Power and Heat Plug if van has memory seat and the seat is removed) 2008 Chrysler Minivan C376 Driver Seat Shunt Plug Power Seats (Pre Seat Detector) - Dr Memory Seat Shunt Plug Must be installed if seat that has memory function is removed. If not Seatbelt Waning Light will stay on. Rollx Vans Motor Bar Power Door System Rollx Vans Power Door (M NC NO COM DOOR LOCK LIMIT SWITCH #6X284 IN PASSENGER DOOR (WHEN CLOSED, SENDS POWER TO HARDWIRED SWITCHES) 10 AMP CIRCUIT OR 15 AMP GLAS VT (14) PK (14) OPEN OEM VT/DG (14) FOR DOOR AJAR WT (14) BR (14 GA.) YL (14 GA.) DG (14 GA.) OFF FUSE 15 A KNEEL TN (14 GA.) RD (10 GA.) COM ON BUTT CONNECT 26 24 25 RD (10) CLOSE NEUTRAL SAFETY NC NO RAMP POWER SWITC DASH KNEEL DOWN L.E.D. RD (14) FUSE 30 A RMP DWN OPEN Fuse Holder #03220-019(X2) KIT R0004 DOOR BR COM DASH USER SWITCH #8981K520 13 11 12 DG (14) NC NO U DB (14 GA.) 85 87 RAMP UP LIMIT SWITCH #03220-004 WT (14 GA.) 87A BK (16 GA.) VT (16 GA.) 86 RAMP BK (14) 30 BR (14 GA.) BK (14) RD (14 GA.) RD (14) YL (14) YL (14 GA.) RD (16 GA.) ROLLX VANS REMOTE (BEHIND GLOVE BOX) BK #8 VT #2 PK #3 RD #1 TOUCHTRONICS MODULE CLOSE ROLLX VANS REMOTE (BEHIND GLOVE BOX) KNEEL ON/OFF SWITCH #8981K519 GY (16 GA.) GREY WRAP BK (14) WT (14) 30 86 87A 87A 87 FIREWALL 30 85 8 RD (14 GA.) BK (14 GA.) DOOR OPEN DOO LO Page 93 Rollx Vans Motor Bar Power Door System Motor Bar) Wiring Diagram T BREAKER SS FUSE YL (16 GA.) TO OEM DOOR AJAR NC VT (14) NO MOTOR BAR DG NC NO NC NO COM COM KNEEL UP LIMIT SWITCH #03220-014 TN (16 GA.) DG YL KNEEL DN LIMIT SWITCH #03220-013 OR CLOSE 30 86 87A 85 86 87A 87 85 30 WT (16 GA.) 86 87A 87 85 87 85 DG (16 GA.) 87 30 YL (16 GA.) 86 BR (16 GA.) 30 OR (16 GA.) YL (14 GA.) 87A 85 YL (14 GA.) BK (14 GA.) GY (14 GA.) 87 86 PK (14 GA.) BR (16 GA.) RAMP DOWN RAMP UP KNEEL DOWN KNEEL UP RELAYS (#5-1393302-8) OCATED IN OEM SPARE TIRE KIT COMPARTMENT Page 94 5 3 1 6 4 2 JONES BLOCK #3-142 BR TO DASH L.E.D. YL KNEELER GY (16 GA.) YL (16 GA.) 12 11 13 DG WT RD (16 GA.) COM Toggle Switch #4X203 CH COM NC NO YL RD #310-1059 DOOR OPEN LIMIT SWITCH (CHERRY) #E19-50H BR C PILLAR USER SWITCH NC NO COM DG (16 GA.) DB DOOR 13 11 12 BR(16 GA.) Rollx Vans Motor Bar Power Door System Rollx Vans Power Door (M Touchtronic Power Touch 155 ROLLX VANS REMOTE (BEHIND GLOVE BOX) NC NO COM NC NO COM RAMP POWER SWIT DASH KNEEL DOWN L.E.D. WT (14 GA.) ON BUTT CONNECT YL (14 GA.) DG (14 GA.) BK (14) WT (14) BR (14 GA.) OFF FUSE 15 A KNEEL 26 24 25 TN (14 GA.) RD (10 GA.) RMP DWN CLOSE DOOR 13 11 12 RD (10) COM DASH USER SWITCH #8981K520 RD (14) FUSE 30 A NC NO U DB (14 GA.) RAMP UP LIMIT SWITCH #03220-004 VT (16 GA.) BR (14 GA.) BK (16 GA.) OPEN Soldier all remote connections RD (14 GA.) BR DG FUSE 10 A FUSE 1A RD (20) NEUTRAL SAFETY RAMP OEM VT/DG (14) FOR DOOR AJAR PNK #10 (12V IN) GRN #9 BLU #8 BLK #3 (GND) RED #4 (12V LOGIC) PNK #5 (12V IN) YEL #6 (OUT 1, 5A) ORG #7(OUT 2, 5A) GRY/RED #2 RD (16 GA.) CHASSIS GROUND Fuse Holder #03220-019(X2) KIT R0004 10 AMP CIRCUIT OR 15 AMP GLAS VT (14) TOUCHTRONICS MODULE (#P1510-R) WHT/RED #1 DOOR LOCK LIMIT SWITCH #6X284 IN PASSENGER DOOR (WHEN CLOSED, SENDS POWER TO HARDWIRED SWITCHES) KNEEL ON/OFF SWITCH #8981K519 GY (16 GA.) GREY WRAP BK (14) WT (14) 30 86 87A 87A 87 FIREWALL 30 85 RD (14 GA.) BK (14 GA.) DOOR OPEN DO LO Page 95 Rollx Vans Motor Bar Power Door System Motor Bar) Wiring Diagram v2 50-R Remote System (Jan. 2011) T BREAKER SS FUSE YL (16 GA.) TO OEM DOOR AJAR NC VT (14) NO MOTOR BAR DG NC NO NC NO KNEEL UP LIMIT SWITCH #03220-014 COM COM TN (16 GA.) DG YL KNEEL DN LIMIT SWITCH #03220-013 86 87A 85 OOR CLOSE 86 87A 87 85 30 86 87A 87 85 30 WT (16 GA.) 86 87A 87 85 87 85 DG (16 GA.) 87 30 YL (16 GA.) 30 OR (16 GA.) YL (14 GA.) BR (16 GA.) 86 YL (14 GA.) BK (14 GA.) GY (14 GA.) 0 PK (14 GA.) BR (16 GA.) RAMP DOWN RAMP UP KNEEL DOWN KNEEL UP RELAYS (#5-1393302-8) OCATED IN OEM SPARE TIRE KIT COMPARTMENT Page 96 5 3 1 6 4 2 JONES BLOCK #3-142 BR TO DASH L.E.D. YL KNEELER GY (16 GA.) YL (16 GA.) 12 11 13 DG WT RD (16 GA.) COM Toggle Switch #4X203 TCH COM NC NO YL RD #310-1059 DOOR OPEN LIMIT SWITCH (CHERRY) #E19-50H BR C PILLAR USER SWITCH NC NO COM DG (16 GA.) DB DOOR OPEN 13 11 12 CLOSE BR(16 GA.) Motor Bar Remote Wiring (Before Jan. 2011) Rollx Vans Power Door (Motor Bar) Wiring Diagram v2 Touchtronic Power Touch 1550-R Remote System Only Before (Jan. 2011) BK (14) 86 87A 85 87 PK (14) TN (14 GA.) WT (14) OFF Page 97 KNEEL 26 24 25 NEUTRAL SAFETY RD (10) ON BUTT CONNECT FUSE 30 A CLOSE DASH KNEEL DOWN L.E.D. RD (14) FUSE 15 A OPEN BR DOOR 13 11 12 DG (14) DASH USER SWITCH #8981K520 BK (14) 30 BR (14 GA.) YL (14 GA.) RD (14) YL (14) RD (14 GA.) BK #8 PK #3 VT #2 RD #1 TOUCHTRONICS MODULE COM ROLLX VANS REMOTE (BEHIND GLOVE BOX) NC NO KNEEL ON/OFF SWITCH #8981K519 Motor Bar Remote Wiring (After Jan. 2011) ROLLX VANS REMOTE (BEHIND GLOVE BOX) Rollx Vans Power Door (Motor Bar) Wiring Diagram v2 Touchtronic Power Touch P1550-ROL-02 Remote System Only (After Jan. 2011) NC NO COM PNK #10 GRN #9 BLU #8 BLK #3 RED #4 PNK #5 YEL #6 ORG #7 GRY/RED #2 WHT/RED #1 TOUCHTRONICS MODULE (#P1510-R) DASH USER SWITCH #8981K520 RD (10) RD (10 GA.) WT (14) BR (14 GA.) YL (14 GA.) OFF FUSE 30 A KNEEL 26 24 25 TN (14 GA.) FUSE 15 A FIREWALL CLOSE NEUTRAL SAFETY OPEN DOOR 13 11 12 DASH KNEEL DOWN L.E.D. RD (14) BUTT CONNECT BK (14) BUTT CONNECT BR (14 GA.) RD (20) RD (14 GA.) BR DG FU S 5A E FUSE 1A SE FU 5 A CHASSIS GROUND KNEEL ON/OFF SWITCH #8981K519 DG (14 GA.) PROGRAMMING THE REMOTE ENROLLING NEW TRANSMITTERS-Self-Learning Receiver 1. Remove and reconnect power to unit. This will automatically place unit into LEARN mode for 5-seconds. 2.Press any button on transmitter once. Wait 5-seconds and confirm the transmitter has been enrolled by pressing any button and verifyint the correct output turned ON. OR 1. Remove cover from receiver enclosure. 2.Locate LEARN switch (small, push-button style switch located in the corner of the printed circuit board). 3.Press and release the LEARN switch (The red LEARN LED next to the switch will flash). 4.Press any button on NEW transmitter.(The red LEARN LED double blinks to confirm enrollment). 5.Press any button on the new transmitter to confirm that the new transmitter code has been enrolled. 6.Replace receiver enclosure cover. Page 98 Maintenance Information Doors Door track - Periodically make sure lower door track is free of debris and vacuum track out. Make certain to clear out any water and ice that may be present. In the front of each door track there are plugs that can be removed to allow an air hose to be inserted to help remove debris. Rollx Vans power door (If equipped) - Every 6 months lube the gear rack (bar) with a high quality white lithium grease. Make sure to clean off any old grease first. Kneel System Kneel chain - Every 6 months spray the chain inside the rubber boot with a high quality oil to lubricate and protect. DO NOT USE WD40. Ramps Folding ramp - Every 6 months spray the ramp’s lower and upper hinge with high quality silicon lubricant. In The Floor ramp - Every 6 months spray the ramp access cover’s flap hinge with a high quality silicon lubricant. Also spray the two silver strips on the underside of the ramp to reduce friction. Warranty New Rollx Vans Van Warranty Coverage Information Rollx Vans provids a limited warranty on its minivan against defects in material or workmanship for a period of 3 years or 36,000 miles, whichever comes first. For warranty specifics please refer to an Owner’s Manual or contact Rollx Vans Customer Service. For all warranty or reimbursement needs, you must have prior authorization by the Rollx Vans Service Department. 1. Call 1-800-956-6668, and a Rollx Vans Customer Service Representative will assist you in any concerns or issues you have with your van. 2. The service representative will evaluate what repair is needed, and either set up an appointment with an “At Home” Service Technician or direct you to a nearby service facility. An authorization number must be issued. Rollx Vans will work with many repair facilities. Rollx Vans reserves the right to approve a repair shop or recommend an alternative. Rollx Vans may request that defective parts be returned to our Customer Service Department for inspection. If defective parts are found to be defective because of abuse or neglect, reimbursement for the new replacement parts may be denied. Rollx Vans reserves the right to use rebuilt components. Rollx Vans will ship all warranted replacement parts by nationwide carrier. In most cases, shipment will be by ground transport and absorbed by Rollx Vans. Any other mode of transportation Our Mission To improve the quality of life of people with disabilities of all income levels by delivering the best modified vehicle. We intend to keep that customer for life by following up with a level of service that exceeds all of their expectations. Our Values Quality • Compassion • Honesty • Integrity • Fairness