2002 CHRYSLER CARAVAN light

POWER LIFTGATE SYSTEM
DESCRIPTION
Some vehicles are equipped with an automatic
opening and closing power liftgate system (Fig. 1).
This power liftgate system is a complex system con-
sisting of many components. Some of these compo-
nents are the liftgate gear motor assembly, latch
assembly, lift gear and rod, liftgate control module,
chime/thermistor, full open switch, engage actuator,
pinch sensor, liftgate handle switch, overhead console
switch, key fob switches (Fig. 2), pawl switch and
ratchet switch.
The power liftgate system has its own door control
module, located on the vehicles left body D-pillar
behind the trim panel. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/DOOR CON-
TROL MODULE - DESCRIPTION) The power
liftgate gear motor assembly is located just above the
control module. The latch assembly is located in the
bottom center of the power liftgate, below the exte-
rior liftgate handle switch. The power liftgate full
open switch, engage actuator, lift gear and rod are
part of the liftgate gear motor assembly. The pawl
and ratchet switches are part of the latch assembly.The pinch sensor or sensors are located along the
right and left sides of the power liftgate, just above
the body line. The liftgate handle switch is an power
release switch and is located in the rear light bar
assembly, just above the license plate. The overhead
console switch is an power open and close command
switch located in the vehicles overhead console.
Safety is of the utmost concern with the power lift-
gate system. Software technology has enabled the
power liftgate control module to detect resistance to
liftgate travel, which allows the power liftgate to stop
and reverse direction anytime an obstruction is felt
or any of the command switches are operated (only in
closing direction). Battery voltage is supplied to the
power liftgate system through a 40 amp fuse, located
in the Intelligent Power Module (IPM) assembly (Fig.
3). In the unlikely event that the power liftgate sys-
tem develops a fault the power liftgate can still be
operated manually with a key, just like a standard
manual liftgate.
Fig. 1 POWER LIFTGATE INTRODUCTION
8N - 2 POWER LIFTGATE SYSTEMRS
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The power liftgate system is designed with a num-
ber of system inhibitors. These inhibitors are neces-
sary for safety and / or feasibility of the power
liftgate system. Refer to power liftgate system inhib-
itors noted below:
POWER LIFTGATE SYSTEM INHIBITORS
²The Power Liftgate may not operate in extreme
temperatures. These extreme temperatures will be
approximately -12É F (-24.4É C) on the low side and
143É F (61.6É C) for the high side. A chime/thermister
assembly in the rear light bar assembly monitors the
outside temperature.
²The vehicles transmission must be in park or
neutral for the power liftgate to start a cycle.
²If multiple obstacles are detected during the
same power open or close cycle the liftgate goes into
manual operation.
²If severe Diagnostic Trouble Codes (DTC) are
stored in the power liftgate control module.
POWER LIFTGATE SYSTEM CAUTIONS AND
WARNINGS
WARNING: ALWAYS DISCONNECT THE NEGATIVE
BATTERY CABLE BEFORE ATTEMPTING ANY
POWER LIFTGATE SYSTEM SERVICE.
WARNING: THERE IS A SMALL AREA ON BOTH
SIDES OF THE LOWER POWER LIFTGATE WHICH
ARE NOT PROTECTED BY PINCH SENSORS.
EXTREME CARE MUST BE TAKEN TO PREVENT
OBJECTS FROM ENTERING THIS AREA ONCE THE
LIFTGATE REACHES THE SECONDARY LATCH
CONTACT (APPROXIMATELY 1/2 INCH BEFORE
FULLY CLOSED).
WARNING: NEVER ATTEMPT TO ENTER OR EXIT
THE VEHICLE WITH THE LIFTGATE IN MOTION.
YOU COULD DAMAGE THE POWER LIFTGATE SYS-TEM AND/OR COMPONENTS AND/OR CAUSE PER-
SONAL INJURY.
WARNING: NEVER STICK OBJECTS IN THE POWER
LIFTGATE WHEN CINCHING CLOSED. YOU COULD
DAMAGE THE VEHICLE, POWER LIFTGATE SYS-
TEM COMPONENTS AND/OR CAUSE PERSONAL
INJURY.
DIAGNOSIS AND TESTING - POWER LIFTGATE
SYSTEM
The power opening and closing power liftgate sys-
tem is a complex system containing many compo-
nents and modules. In order to obtain conclusive
testing the Programmable Communications Interface
(J1850) data bus network and all of the electronic
modules that provide inputs to, or receive outputs
from the power liftgate system must be checked.
The power liftgate system was designed to be diag-
nosed with an appropriate diagnostic scan tool, such
as the DRB IIIt. The most reliable, efficient, and
accurate means to diagnose the power liftgate system
requires the use of a DRB IIItscan tool and the
proper Body Diagnostic Procedures manual. The
DRB IIItcan be used to observe various switch sta-
tuses throughout the power liftgate system to help
the technician diagnose a defective switch or compo-
nent. The DRB IIItcan also be used to actuate var-
ious components throughout the power liftgate
system to help the technician diagnose a defective
component.
Before any testing of the power liftgate system is
attempted, the battery should be fully charged, all
built-in power liftgate system inhibitors read and
understood (Refer to power liftgate system operation)
and all wire harness and ground connections
inspected around the affected areas on the vehicle.
Following are quick reference diagnostic tables to
help when diagnosing and testing the power liftgate
system.
8N - 4 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)
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(5) Grab the latch assembly and unhook the key
cylinder link rod from the key cylinder (Fig. 13).
(6) Place the latch assembly on a bench and locate
the three wires leading from the actuator portion of
the latch assembly.
(7) Disengage the main connector retaining push
pins from the latch actuator housing.
(8) Back the three wires out of the main latch elec-
trical connector. Refer to the wiring section of the
service manual for detailed instructions.
(9) Flip the latch assembly over and remove the
latch actuator retaining screw(s).
(10) Remove the latch actuator from the latch
assembly.
INSTALLATION
(1) Install the latch actuator on the latch assem-
bly.
(2) Install the three latch actuator retaining
screws. Torque the screws to 4 in. lbs.
(3) Install the three wires in the main latch elec-
trical connector. Refer to the wiring section of the
service manual for detailed instructions.
NOTE: Be certain wires are reinstalled in the correct
wire cavities. Failure to do so could result in dam-
age to the latch actuator. Refer to Wiring Diagrams
if previous notes were not made.
(4) Secure the main connector retaining push pins
on the latch actuator housing.
(5) Grab the latch assembly and hook the key cyl-
inder link rod on the key cylinder.
(6) Position the latch and install the three latch
retaining bolts. Torque to 10 N´m (90 in. lbs.).
(7) Connect the power latch electrical connector.
(8) Install the lower liftgate trim panel. Refer to
Body for the procedure.
(9) Connect the negative battery cable.
EXTERIOR HANDLE SWITCH
DESCRIPTION
Vehicles equipped with a power liftgate or power
locks utilize a exterior handle switch. The exterior
handle switch is a electronic release switch mounted
to the rear license plate lamp housing assembly,
located just above the license plate. This switch con-
trols the power liftgate release function and is also
capable of reversing the power liftgate when it is in
motion. A full power open cycle cannot be performed
using this switch, only one of the power open com-
mand switches (key fob and overhead console
mounted) can be used to perform a full power open
cycle.The exterior handle switch is a serviceable compo-
nent. Consult your MoparŸ parts catalog for a spe-
cific part number.
OPERATION
When the exterior handle switch is depressed, with
the liftgate in the closed position. A message is sent
to the Body Control Module (BCM). The Body Con-
trol Module then sends a signal to the power liftgate
control module via the J1850 PCI data bus circuit.
The power liftgate control module then sends a sig-
nal to the power latch mounted actuator, which
moves the liftgate from the primary closed and
latched position to the open and movable position. If
the liftgate is not pulled open once the latch releases
within a few seconds, the latch will cinch closed
again.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Open the liftgate and remove the liftgate trim
panel. Refer to the Body section of the service man-
ual for the procedure.
(3) Remove the rear lamp bar assembly from the
vehicle. Refer to the Body section of the service man-
ual for the procedure.
(4) Locate the two wires going to the exterior han-
dle switch. Cut the tie strap and trace the wires to
the large electrical connector and back the wires out
of the large connector and through the grommet.
Refer to the Wiring section of the service manual for
detailed instructions.
(5) Depress the two exterior handle switch retain-
ing tabs and roll the switch out of the light bar
assembly (Fig. 14).
INSTALLATION
(1) Install the handle switch in the light bar
assembly.
(2) Locate the two wires going to the exterior han-
dle switch. Install the wires through the grommet
and in the large connector. Secure with a tie strap.
Refer to the Wiring section of the service manual for
detailed instructions.
NOTE: Be certain wires are reinstalled in the correct
wire cavities. Failure to do so could result in dam-
age to the handle switch. Refer to Wiring Diagrams
if previous notes were not made.
(3) Install the rear light bar. Refer to the Body sec-
tion of the service manual for the procedure.
(4) Install the liftgate trim panel. Refer to the
Body section of the service manual for the procedure.
(5) Connect the negative battery cable.
8N - 16 POWER LIFTGATE SYSTEMRS
LATCH ACTUATOR (Continued)
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(6) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
(7) Verify power liftgate system and handle switch
operation. Cycle the power liftgate through one com-
plete open and close cycle, this will allow the power
liftgate control module to relearn its cycle with the
new components.
CHIME/THERMISTOR
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
chime/thermistor assembly. The chime/thermistor
assembly is a small capacitor shaped electrical com-
ponent mounted to the rear license plate lamp hous-
ing assembly (Fig. 15) , located just above the license
plate. The chime portion of the assembly controls the
audible chime sound heard at the rear of the vehicle
when the power liftgate is in motion. The thermistor
portion of the assembly is a temperature sensor, used
by the power liftgate module.
The chime/thermistor assembly is a serviceable
component. Consult your MoparŸ parts catalog for a
specific part number.
OPERATION
The chime/thermistor assembly performs two dif-
ferent functions for the power liftgate system. First,
the chime portion provides an audible chime sound
which is controlled by the power liftgate module. Thechime/thermistor assembly is hardwired to the power
liftgate module. Second the thermistor provides a
outside temperature reading by way of a resistance
reading (V- ohms) supplied to the power liftgate
module. As temperature increases the resistance
reading (V- ohms) increases , as temperature
decreases the resistance reading (V- ohms)
decreases.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the rear light bar assembly from the
vehicle. Refer to Body for the procedure.
(3) Using your hands, grasp the light bar at its
sides next to thermistor/chime assembly and gently
pull the two sides of the light bar apart until the
thermistor/chime assembly can be removed.
INSTALLATION
(1) Gently pull the two sides of the light bar apart
until the thermistor/chime assembly can be installed.
(2) Install the rear light bar assembly on the vehi-
cle. Refer to the Body section of the service manual
for the procedure.
(3) Connect the negative battery cable.
Fig. 14 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
Fig. 15 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
RSPOWER LIFTGATE SYSTEM8N-17
EXTERIOR HANDLE SWITCH (Continued)
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OPERATION
With one end of the flex drive attached to the door
motor and the other attached to the lower drive unit,
the flex drive transfers the power and torque from
the motor to the drive unit. A square shaped drive
cable, inside the flex drive assembly engages the
motor drive and rotates to move the door accordingly.
REMOVAL
(1) Disconnect and isolate the negative cable.
(2) Remove the side door trim panel from the vehi-
cle. Refer to the Body section for the procedure.
(3) Remove the weathershield. Refer to the Body
section for the procedure.
(4) Remove the E-clip from the flex drive assembly
(Fig. 19).
(5) Pull the flex drive straight out of the motor
assembly.
(6) Remove the lower drive unit cover retaining
screws and remove the cover (Fig. 20).
(7) Expand the flex drive collar, next to the lower
drive unit until the flex drive can be pulled straight
off the lower drive unit.
(8) Remove the flex drive assembly from the vehi-
cle.
INSTALLATION
(1) Position the flex drive assembly in the vehicle.
(2) Install the flex drive on the lower drive unit.
Push straight on until it snaps in place. It may be
necessary to rotate drive unit gear slightly until the
flex drive seats in place.
(3) Install the lower drive unit cover and retaining
screws.
(4) Install the flex drive in the motor assembly.
Line up the square shaped inner shaft and push
straight on (Fig. 21).
(5) Install the E-clip on the flex drive assembly
(Fig. 19).
(6) Install the weathershield. Refer to Body for the
procedure.
(7) Install the side door trim panel on the vehicle.
Refer to Body for the procedure.
(8) Connect the negative cable.
Fig. 19 Flex Drive E-Clip
1 - Flex Drive Cable Retaining Clip
2 - Flex Drive Cable
3 - Side Door Motor Assembly
Fig. 20 Lower Hinge/Drive Assembly
1 - Lower Drive Unit Cover
2 - Lower Drive Unit Cover Retaining Screws
3 - Sliding Door
4 - Lower Hinge Arm Bracket
8N - 36 POWER SLIDING DOOR SYSTEMRS
FLEX DRIVE (Continued)
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POWER MIRRORS
TABLE OF CONTENTS
page page
POWER MIRRORS
DESCRIPTION.........................46
OPERATION...........................46
DIAGNOSIS AND TESTING - POWER
MIRRORS...........................46
AUTOMATIC DAY / NIGHT MIRROR
DESCRIPTION.........................47
OPERATION...........................47
DIAGNOSIS AND TESTING - AUTOMATIC DAY
/ NIGHT MIRROR......................48
REMOTE SWITCH
DIAGNOSIS AND TESTING - REMOTE
SWITCH............................49REMOVAL.............................49
INSTALLATION.........................49
SIDEVIEW MIRROR
REMOVAL.............................49
POWER FOLDAWAY MIRROR SWITCH -
EXPORT
DESCRIPTION.........................49
OPERATION...........................50
REMOVAL.............................50
INSTALLATION.........................50
POWER MIRRORS
DESCRIPTION
If equipped with power mirrors, the control switch
is located on the instrument panel to the left of the
headlamp switch.
OPERATION
The power mirrors are connected to battery feed at
all times. Each mirror head contains two electric
motors, two drive mechanisms, an electric heating
element, and the mirror glass. If the vehicle is
equipped with the optional memory system, each
mirror head also contains both a horizontal and a
vertical motor position sensor. One motor and drive
controls mirror up-and-down movement, and the
other controls right-and-left movement.
An optional driver side outside electrochromic mir-
ror is able to automatically change its reflectance
level. This mirror is controlled by the circuitry of the
automatic day/night inside rear view mirror. A thin
layer of electrochromic material between two pieces
of conductive glass make up the face of the mirror.Two photocell sensors on the inside rear view mirror
are used to monitor light levels and adjust the reflec-
tance of both the inside and driver side outside mir-
rors. This change in reflectance helps to reduce the
glare of headlamps approaching the vehicle from the
rear. (Refer to 8 - ELECTRICAL/POWER MIRRORS/
AUTOMATIC DAY / NIGHT MIRROR - DESCRIP-
TION) for more information on this system.
The motors which operate the mirrors are part of
the mirror assembly and cannot be serviced sepa-
rately.
DIAGNOSIS AND TESTING - POWER MIRRORS
(1) Remove Power Mirror Switch. (Refer to 8 -
ELECTRICAL/POWER MIRRORS/POWER MIRROR
SWITCH - REMOVAL).
(2) Disconnect wiring harness connector to the
power mirror switch and headlamp switch.
(3) Using two jumper wires:
²Connect one to a 12-volt source
²Connect the other to a good body ground
²Refer to the Mirror Test Chart for wire hookups
at the switch connector (Fig. 1).
8N - 46 POWER MIRRORSRS
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POWER MIRROR MOTOR TEST
SWITCH CONNECTOR
12 Volts Ground MIRROR REACTION
Right Left
PIN 12 PIN 6 Ð UP
PIN 7 PIN 6 Ð LEFT
PIN 6 PIN 12 Ð DOWN
PIN 6 PIN 7 Ð RIGHT
PIN 13 PIN 1 UP Ð
PIN 8 PIN 1 LEFT Ð
PIN 1 PIN 13 DOWN Ð
PIN 1 PIN 8 RIGHT Ð
PIN 5 PIN 11 LAMP LAMP
(4) If results shown in table are not obtained,
check for broken or shorted circuit, or replace mirror
assembly as necessary.
AUTOMATIC DAY / NIGHT
MIRROR
DESCRIPTION
An automatic dimming inside day/night rear view
mirror and an automatic dimming driver side outside
rear view mirror are available factory-installed
options on this model. Following is a general descrip-
tion of this optional equipment.
The automatic day/night mirror is able to automat-
ically change its reflectance. A thin layer of electro-
chromic material between two pieces of conductiveglass make up the face of the mirror. Two photocell
sensors are used to monitor light levels and adjust
the reflectance of the mirror to reduce the glare of
headlamps approaching the vehicle from the rear.
For removal procedures, (Refer to 23 - BODY/IN-
TERIOR/REAR VIEW MIRROR - REMOVAL).
OPERATION
The ambient photocell sensor faces forward, to
detect the outside light levels. A second sensor faces
rearward to detect the light level received through
the vehicles back window. When the difference
between the two light levels becomes too great (the
light level received at the rear of the mirror is much
higher than that at the front of the mirror), the mir-
ror begins to darken.
Fig. 1 Power Mirror Connector
RSPOWER MIRRORS8N-47
POWER MIRRORS (Continued)
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The mirror switch allows the driver a manual con-
trol of whether the automatic dimming feature is
operational. When AUTO is selected a small Light-
Emitting Diode (LED), to the right of the mirror
switch, is illuminated. The automatic dimming fea-
ture will only operate when the ignition switch is in
the On position. The mirror also senses the backup
lamp circuit, and will automatically disable its self-
dimming feature whenever the transmission gear
selector is in the Reverse position.
NOTE: The mirror always defaults to an ON state
upon ignition.
The driver side automatic dimming mirror is stan-
dard with the automatic dimming inside mirror. The
signal to control the dimming of that mirror is gen-
erated by the automatic day/night inside rear view
mirror circuitry. That signal is then delivered to the
driver side outside rear view mirror on a hard wired
circuit.
The automatic day/night mirror cannot be
repaired. If faulty or damaged, the entire inside rear
view mirror assembly must be replaced.
DIAGNOSIS AND TESTING - AUTOMATIC DAY /
NIGHT MIRROR
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring diagrams, proper wire and con-
nector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
(1) Check the fuse in the intelligent power module.
If OK, go to Step 2. If not OK, repair the shorted cir-
cuit or component as required and replace the faulty
fuse.
(2) Turn the ignition switch to the On position.
Check for battery voltage at the fuse in the intelli-
gent power module. If OK, go to Step 3. If not OK,
repair the open circuit to the ignition switch as
required.
(3) Unplug the wire harness connector from the
automatic day/night mirror. Check for battery voltage
at the fused ignition switch output circuit cavity of
the automatic day/night mirror wire harness connec-
tor. If OK, go to Step 4. If not OK, repair the open
circuit to the junction block as required.
(4) Turn the ignition switch to the Off position.
Check for continuity between the ground circuit cav-
ity of the automatic day/night mirror wire harness
connector and a good ground. There should be conti-
nuity. If OK, go to Step 5. If not OK, repair the cir-
cuit to ground as required.(5) Turn the ignition switch to the On position. Set
the parking brake. Place the transmission gear selec-
tor lever in the Reverse position. Check for battery
voltage at the backup lamp switch output circuit cav-
ity of the automatic day/night mirror wire harness
connector. If voltage is present, reinstall the auto-
matic day/night mirror wire harness connector and
go to Step 6. If not OK, repair the open circuit as
required.
(6) Place the transmission gear selector lever in
the Neutral position. Place the automatic day/night
mirror switch in the On (LED in the switch is
lighted) position. Cover the forward facing ambient
photocell sensor to keep out any ambient light.
NOTE: The ambient photocell sensor must be cov-
ered completely, so that no light reaches the sen-
sor. Use a finger pressed tightly against the sensor,
or cover the sensor completely with electrical tape.
(7) Shine a light into the rearward facing head-
lamp photocell sensor. The automatic day/night mir-
ror should darken. The automatic day/night mirror
should darken within 2 minutes if testing for the
first time. For immediate response, turn the vehicle
OFF and back ON with the forward-facing light sen-
sor still covered. This defeats the day-detect logic. If
OK, go to Step 8. If not OK, replace the faulty mirror
unit.
(8) With the mirror darkened, place the transmis-
sion gear selector lever in the Reverse position. The
automatic day/night mirror should return to its nor-
mal reflectance. If not OK, replace the faulty mirror
unit.
Bench testing both mirrors can be done, of care is
exercised. For an inside mirror, the pin closest to he
mount is 12V (+), the next is 12V (-). The third is
reverse override. The fourth is outside mirror (+),
and the fifth is outside mirror (-).Do not apply 12
volts to the fourth and fifth pins.With 12 volts
on pins 1 and 2, the mirror can be tested by blocking
the rear sensor and shining a light into the forward
sensor. For an outside mirror, there is a 2±pin con-
nector. Applying 1.2 volts will cause the mirror to
dim. If the mirror does not dim, the entire glass
assembly can be replaced just as it is when the glass
is broken.
WARNING: Do not apply 12 volts to the outside mir-
ror. Damage to the mirror will result.
8N - 48 POWER MIRRORSRS
AUTOMATIC DAY / NIGHT MIRROR (Continued)
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