2002 CHRYSLER CARAVAN door lock

EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL.............................44
INSTALLATION.........................45
COWL GRILLE
REMOVAL.............................50
INSTALLATION.........................50
EXTERIOR NAME PLATES - TAPE ATTACHED
REMOVAL.............................50
INSTALLATION.........................51
EXTERIOR NAME PLATES - ADHESIVE
ATTACHED
REMOVAL.............................51
INSTALLATION.........................51
FRONT FENDER
REMOVAL.............................51
INSTALLATION.........................51
FUEL FILL DOOR
REMOVAL.............................52
INSTALLATION.........................52
FUEL FILL DOOR BLOCKER LATCH
REMOVAL.............................52
INSTALLATION.........................52
FUEL FILL DOOR BLOCKER LATCH STRIKER
REMOVAL.............................53
INSTALLATION.........................53
FUEL FILL DOOR BLOCKER LOCKOUT LINK
REMOVAL.............................53INSTALLATION.........................54
GRILLE OPENING REINFORCEMENT
REMOVAL.............................54
INSTALLATION.........................54
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL.............................55
INSTALLATION.........................55
LUGGAGE RACK RISER
REMOVAL.............................55
INSTALLATION.........................56
LUGGAGE RACK CROSSBAR
REMOVAL.............................56
INSTALLATION.........................57
REAR QUARTER PANEL/FENDER AIR
EXHAUSTER
DESCRIPTION.........................57
REMOVAL.............................57
INSTALLATION.........................58
ROOF JOINT MOLDING
REMOVAL.............................58
INSTALLATION.........................58
SIDE VIEW MIRROR
REMOVAL.............................58
INSTALLATION.........................58
SIDE VIEW MIRROR GLASS
REMOVAL.............................59
INSTALLATION.........................59
BODY SIDE MOLDINGS
REMOVAL
Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig.
5)for proper location of fasteners holding the molding
to the wheelhouse lip and rocker panels.
(1) Warm the affected stick on molding and body
metal to approximately 38É C (100É F) using a suit-
able heat lamp or heat gun.(2) If equipped, remove pop rivets holding molding
edge to wheelhouse lip.
(3) Pull stick on molding from painted surface.
(4) Remove adhesive tape residue from painted
surface of vehicle. Use a 3M Scotch-BriteŸ Molding
Adhesive and Stripe Removal Disc, or equivalent, to
clean adhesive residue from painted surfaces. These
products are available from automotive paint suppli-
ers. Refer to instructions supplied with the specific
product for proper usage.
23 - 44 EXTERIORRS
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FUEL FILL DOOR
REMOVAL
(1) Remove left quarter trim panel.
(2) Remove water shield patch covering access hole
in C-pillar.
(3) Disengage latch release link from clip on fuel
fill blocker latch arm (Fig. 12).
(4) Open fuel fill door.
(5) Remove screws holding fuel fill neck to fuel
filler housing.
(6) Position fuel fill neck out of the way.
(7) Reaching inside fuel filler housing, release clips
holding housing to quarter panel (Fig. 9).
(8) Remove fuel fill door from vehicle.
(9) Disengage clip holding link to fuel fill door
(Fig. 13).
(10) Remove link from fuel fill door.
INSTALLATION
(1) Install spring to housing and door
(2) Snap door into housing.
(3) Insert lockout link into clip on fuel fill door.
(4) Engage clip to hold link to fuel fill door.
(5) Insert lockout link through grommet in panel
between inner and outer quarter panel.
(6) Close fuel fill door.
(7) Install fuel filler housing to outer quarter
panel.
(8) Verify that all clips on fuel filler housing are
fully engaged to outer quarter panel.
(9) Place fuel fill neck in position.
(10) Install screws to hold fuel fill neck to fuel
filler housing.(11) Engage latch release link into clip on fuel fill
blocker latch arm.
(12) Verify fuel fill blocker latch operation.
(13) Install water shield patch to cover access hole
in C-pillar.
(14) Install left quarter trim panel.
FUEL FILL DOOR BLOCKER
LATCH
REMOVAL
(1) Remove left quarter trim panel.
(2) Remove water shield patch covering access hole
in C-pillar.
(3) Disengage latch release link from clip on fuel
fill blocker latch arm (Fig. 12).
(4) Remove screws holding fuel fill blocker latch to
C-pillar (Fig. 10).
(5) Remove fuel fill blocker latch from vehicle.
INSTALLATION
(1) Position fuel fill blocker latch on vehicle.
(2) Install screws to hold fuel fill blocker latch to
C-pillar.
(3) Engage latch release link into clip on fuel fill
blocker latch arm with fuel door in the closed posi-
tion.
(4) Install water shield patch to cover access hole
in C-pillar.
(5) Verify fuel fill blocker latch operation.
(6) Install left quarter trim panel.
Fig. 9 FUEL FILLER HOUSING AND DOOR
1 - FUEL FILLER HOUSING W/LATCH
2 - CLIP
3 - FUEL FILLER HOUSING DOOR
4 - CLIPS
5 - FIX CLIP
Fig. 10 FUEL FILL
1 - FUEL FILLER BLOCKER LATCH ARM
2 - C-PILLAR
23 - 52 EXTERIORRS
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FUEL FILL DOOR BLOCKER
LATCH STRIKER
REMOVAL
(1) Remove sliding door trim panel.
(2) Remove sound shield as necessary to access
striker
(3) Remove screws attaching fuel fill door blocker
latch striker to sliding door rear end frame (Fig. 11).
(4) Remove fuel fill door blocker latch striker from
vehicle.
INSTALLATION
(1) Position fuel fill door blocker latch striker on
vehicle.
(2) Install screws attaching fuel fill door blocker
latch striker to sliding door rear end frame.
(3) Install sliding door sound shield.
(4) Install sliding door trim panel.
FUEL FILL DOOR BLOCKER
LOCKOUT LINK
REMOVAL
(1) Remove left quarter trim panel.
(2) Remove water shield patch covering access hole
in C-pillar.
(3) Disengage fuel filler lockout link from clip on
fuel fill blocker latch arm (Fig. 12).
(4) Open fuel fill door.
(5) Remove screws holding fuel filler housing to
fuel filler tube neck.(6) Reaching inside fuel filler housing, release clips
holding housing to outer quarter panel.
(7) Remove fuel filler housing and lockout link
from vehicle.
(8) Disengage clip holding link to fuel fill door
(Fig. 13).
(9) Remove link from fuel fill door.
Fig. 11 FUEL FILL DOOR BLOCKER LATCH
STRIKER
1 - LEFT SLIDING DOOR
2 - FUEL FILLER STOP STRIKER
Fig. 12 FUEL FILLER LOCKOUT LINK AT LATCH
ARM
1 - FUEL FILLER LOCKOUT LINK
2 - C-PILLAR
3 - FUEL FILLER BLOCKER LATCH ARM
4 - PLASTIC LINK CLIP
5 - INNER QUARTER PANEL
Fig. 13 FUEL FILLER LOCKOUT LINK
1 - FUEL FILLER LOCKOUT LINK
2 - FUEL FILLER OPENING
3 - QUARTER PANEL
RSEXTERIOR23-53
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INSTALLATION
(1) Insert link into clip on fuel fill door.
(2) Engage clip to hold link to fuel fill door.
(3) Insert lockout link through grommet in panel
between inner and outer quarter panel.
(4) Close fuel fill door.
(5) Install fuel filler housing to outer quarter
panel.
(6) Verify that all clips on fuel filler housing are
fully engaged to outer quarter panel.
(7) Engage fuel filler lockout link into clip on fuel
fill blocker latch arm.
(8) Install water shield patch covering access hole
in C-pillar.
(9) Install left quarter trim panel.
GRILLE OPENING
REINFORCEMENT
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching hood latch to cross-
member and position latch out of the way.
(3) Remove radiator sight shield.
(4) Remove engine air inlet resonator.
(5) Remove hood cable.
(6) Remove hood prop rod.
(7) Remove screw attaching coolant recovery bottle
to crossmember.
(8) Remove bolts attaching radiator isolators to
crossmember.
(9) Remove bolts attaching ends of crossmember to
radiator closure panel (Fig. 14).
(10) Lift crossmember upward and away from
radiator closure panel.
(11) Remove crossmember from vehicle.
INSTALLATION
(1) Place radiator closure panel crossmember in
position on vehicle.
(2) Insert ends of crossmember between layered
metal sections of radiator closure panel at each side
of radiator.(3) Align with paint breaks around bolt heads.
(4) Install bolts attaching ends of crossmember to
radiator closure panel (Fig. 14) . Tighten bolts to 19
N´m (14 ft. lbs.) torque.
(5) Install bolts attaching radiator isolators to
crossmember.
(6) Install screw attaching coolant recovery bottle
to crossmember.
(7) Install bolt attaching air cleaner housing to
crossmember.
(8) Install engine air inlet resonator.
(9) Install radiator sight shield.
(10) Install hood prop rod.
(11) Align hood latch by placing latch over net
pierce tabs. If alignment is required, flatten tabs.
(12) Install bolts attaching hood latch to cross-
member. Tighten bolts to 13.5 N´m (10 ft. lbs.)
torque.
(13) Verify hood latch operation and hood align-
ment.
Fig. 14 RADIATOR CLOSURE PANEL
CROSSMEMBER
1 - RADIATOR CLOSURE PANEL CROSSMEMBER
2 - FRONT FASCIA
23 - 54 EXTERIORRS
FUEL FILL DOOR BLOCKER LOCKOUT LINK (Continued)
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INSTALLATION
NOTE: The crossbar assemblies are designed to be
installed in only one way. Check top and bottom
surfaces of the crossbar for the word FRONT and
directional arrows. The directional arrows must
point toward the front of the vehicle.
(1) Place crossbar in position on vehicle.
(2) Work from side to side sliding the crossbar
assembly back a little at a time to ensure it remains
perpendicular to the side rails.
(3) Position first crossbar assembly crossbar at the
second most rearward locator holes. Press the top of
the stanchion lever to lock it into position.
(4) Position the second crossbar assembly in the
second hole from the front. Lock into place.
(5) Place luggage rack riser into position.
(6) Install two fasteners into riser. Tighten fasten-
ers to 4 mm (35 in. lbs.) torque.
REAR QUARTER PANEL/
FENDER AIR EXHAUSTER
DESCRIPTION
Air exhausters, designed to conform to the body
structure, allow air entering at the front of the vehi-
cle to flow out the back. By reducing air pressure
within the vehicle, the exhausters also reduce blower
noise at any given air flow level compared to operat-
ing without them and help reduce door closing effort.
They are located in the lower rear comers of the
body.
REMOVAL
SHORT WHEELBASE
(1) Remove the rear fascia from the body. (Refer to
13 - FRAMES & BUMPERS/BUMPERS/REAR FAS-
CIA - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 19).
(3) Remove the air exhauster from the hole in the
lower aperture panel.
LONG WHEELBASE
NOTE: Models with the optional rear heater and air
conditioner do not have an air exhauster on the
right side of the vehicle, but have a plastic plug
installed in the right lower aperture panel. This plug
is removed using the same procedure used toremove the air exhauster from the short wheelbase
model. Refer to SHORT WHEELBASE .
(1) Remove the quarter trim panel from the inside
of the left or right quarter inner panel (Refer to 23 -
BODY/INTERIOR/RIGHT QUARTER TRIM PANEL
- REMOVAL) or (Refer to 23 - BODY/INTERIOR/
LEFT QUARTER TRIM PANEL - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 20).
(1) Remove the air exhauster from the hole in the
lower aperture panel.
Fig. 19 AIR EXHAUSTER - SWB
1 - LOWER APERTURE PANEL
2 - AIR EXHAUSTER
Fig. 20 AIR EXHAUSTER - LWB
1 - AIR EXHAUSTER
2 - PLUG
3 - LOWER APERTURE PANEL
RSEXTERIOR23-57
LUGGAGE RACK CROSSBAR (Continued)
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CUP HOLDER
REMOVAL
(1) Remove the screw access cover from the bottom
of the center bezel.
(2) Remove the center bezel attaching screws.
(3) Using a trim stick (special tool #C-4755) or
equivalent, gently pry out on the edge of the instru-
ment panel center bezel. Hang off to the side leaving
the accessory switches connected.
(4) Pull the cup holder assembly rearward to dis-
engage the rear guide studs from instrument panel
(Fig. 2).
INSTALLATION
(1) Ensure the cup holder assembly is in the closed
position. The cup holder assembly must be installed
as an assembly to ensure proper track position.
(2) Place the cup holder assembly into position in
the lower instrument panel and slide into opening
until the rear guide struts snap into place (Fig. 2).
(3) Install the center bezel.
(4) Install the center bezel attaching screws
(5) Install the cup holder. Align the cup holder
assembly with the track and firmly slide shut to
engage retaining tang.
(6) Install the screw access cover to the bottom of
the center bezel.
GLOVE BOX
REMOVAL
(1) Open glove box.
(2) Push in on sides of glove box bin and lower
door.
(3) Pivot glove box downward and disengage hinge
hooks from instrument panel.
(4) Remove glove box.
INSTALLATION
(1) Place glove box in position.
(2) Engage hinge hooks into instrument panel and
pivot glove box upward.
(3) Push in sides of glove box bin and snap glove
box assembly into instrument panel.
(4) Close glove box door.
GLOVE BOX LATCH
REMOVAL
(1) Open glove box.
(2) Push in on sides of glove box bin and lower
door.
(3) Pivot glove box downward and disengage hinge
hooks from instrument panel.
(4) Remove glove box.
(5) Remove the assembly screws.
(6) Disassemble the glove box.
(7) Separate the latch from the glove box assembly.
INSTALLATION
(1) Install the latch onto the glove box assembly.
(2) Assemble the glove box.
(3) Install the assembly screws.
(4) Engage hinge hooks into instrument panel and
pivot glove box upward.
(5) Push in sides of glove box bin and snap glove
box assembly into instrument panel.
(6) Close glove box door.
GLOVE BOX LATCH STRIKER
REMOVAL
(1) Open glove box door.
(2) Remove screws holding lock striker to instru-
ment panel.
(3) Remove glove box latch striker.
Fig. 2 CUP HOLDER
1 - LOWER INSTRUMENT PANEL
2 - CUPHOLDER AND TRACK
23 - 64 INSTRUMENT PANELRS
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INSTALLATION
(1) Install the glove box latch striker.
(2) Install the screws holding latch striker to
instrument panel.
(3) Close glove box door.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the lower console:
(a) Remove six retaining screws.
(b) Pull rearward and disconnect the auxiliary
power outlet.
(c) Remove lower console from vehicle.
(3) Remove the bolts attaching the lower supports
to the instrument panel frame (Fig. 3).
(4) Remove the bolts attaching the lower supports
to the floor pan.
(5) Disconnect the wire connectors from the Pas-
senger Airbag.
(6) Remove the two screws to each right and left
cowl trim covers.
(7) Remove the both left and right side A-pillar
trim covers using a trim stick (special tool #C-4755)
or equivalent gently pry out on the trim covers and
remove.
(8) Remove the glove box:
(a) Push in on sides of glove box bin and lower
door.
(b) Pivot glove box downward and disengage
hinge hooks from instrument panel.
(c) Remove glove box from vehicle.
(9) Disconnect the antenna lead connector from
behind the glove box.
(10) Remove the four screws to the lower steering
column cover.
(11) Remove the eight screws to the steering col-
umn backing plate.
(12) Unclip the Data Link Connector (DLC) from
the steering column backing plate.
(13) Remove two screws to the left side instrument
panel silencer and remove (Fig. 4).
(14) Disconnect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.
(c) Five harness connectors.
(d) Driver airbag connector.
(15) Remove the two screws to the hood release
handle.
(16) Remove five screws to steering column back-
ing plate and remove (Refer to 23 - BODY/INSTRU-
MENT PANEL/KNEE BLOCKER - REMOVAL).(17) Remove the two steering column shroud
retaining screws. Separate the shrouds and remove
from vehicle.
(18) Remove the screws attaching the instrument
panel reinforcement and remove (Fig. 5).
(19) Disconnect the steering column wiring. There
are seven connectors and then unclip the harness
from the column.
(20) Disconnect the Occupant Restraint Controller
(ORC) harness connector.
(21) Remove the four nuts retaining the steering
column to the dash panel steering column mounting
bracket and lower column to the floor (Fig. 6).
(22) Remove the four nuts attaching the instru-
ment panel to the brake pedal support bracket.
(23) Loosen the left side roll down bolt (Fig. 7).
(24) Remove the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(25) If equipped with a mechanical transmission
range indicator:
(a) Remove the indicator cable loop.
(b) Remove the clip holding gear shift cable end
to the gear selector adapter.
(c) Pull the cable end from gear selector.
(d) Disconnect the clip for the indicator cable
and guide tube from the shift cable bracket and
move out of the way.
(26) Remove the instrument panel top cover. Using
a trim stick or equivalent, gently pry up on the front
edge of the top cover, pull rearward and remove from
vehicle.
(27) Disconnect the right side wire connectors from
the HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(28) Remove the right end cover by pulling out-
board.
(29) Remove the right side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(30) Loosen the right side roll down bolt.
(31) Disconnect the two front window defroster
grid wire connectors. One on each side of vehicle.
(32) Remove both the left and right power mirrors:
(a) Using a trim stick or equivalent, gently pry
out on mirror trim cover.
(b) Open door and remove the three torx retain-
ing screws.
(c) Disconnect the wire connector and remove
mirror from the vehicle.
(33) Feed power mirror wire harness inboard
through the A-pillar.
(34) Remove the bolts attaching the instrument
panel frame to the dash panel below windshield
opening.
(35) With the help of an assistant remove the
instrument panel from vehicle. Lift the instrument
RSINSTRUMENT PANEL23-65
GLOVE BOX LATCH STRIKER (Continued)
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(4) Disengage hidden clips attaching trim to upper
C-pillar.
(5) Remove upper C-pillar trim from vehicle.
INSTALLATION
(1) Place upper C-pillar trim in position on vehicle
(Fig. 6).
(2) Engage hidden clips attaching trim to upper
C-pillar.
(3) Install screw attaching C-pillar trim panel to
C-pillar.
(4) Install seat belt turning loop onto height
adjuster. Tighten all seat belt bolts to 39 N´m (29 ft.
lbs.) torque.
(5) Install quarter trim panel.
DOOR SILL TRIM PLATE
REMOVAL
(1) Using trim stick (C-4755), disengage hidden
clips holding door sill plate from door sill.
(2) Remove sill plate from vehicle (Fig. 7).
INSTALLATION
(1) Place sill plate in position on vehicle (Fig. 7).
(2) Align interlock tabs at front and rear to mating
trim.
(3) Engage hidden clips to hold door sill plate to
door sill.
HEADLINER
REMOVAL
(1) Remove sun visors and vanity mirrors.
(2) Remove sun visor center supports.
(3) If equipped, remove coat hooks.
(4) If equipped, remove roof rail modules.
(5) Remove A-pillar trim covers.
(6) Remove B-pillar upper trim covers.
(7) Remove C-pillar upper trim covers.
(8) Remove D-pillar trim covers.
(9) Remove liftgate opening header trim.
(10) If equipped, remove overhead console screw.
(11) If equipped, remove reading lamp.
(12) Remove dome lamp.
(13) Remove push in locking fasteners attaching
headlining to rear roof header and roof bows (Fig. 8).
(14) Remove wiring connections.
(15) Remove headlining from roof.
(16) Extract headlining through liftgate opening.
INSTALLATION
(1) Insert headlining through liftgate opening.
(2) Place headlining in position on roof.
(3) Connect wire connectors.
(4) Install left sun visor support.
(5) Install push in locking fasteners attaching
headlining to rear roof header and bows (Fig. 8).
(6) Install right sun visor support.
(7) Install sun visors and vanity mirrors.
(8) If equipped, install roof rail modules.
(9) If equipped, install coat hooks.
(10) Install dome lamp.
(11) If equipped, install reading lamp.
Fig. 6 C-PILLAR
1 - C-PILLAR TRIM PANEL
2 - C-PILLAR
Fig. 7 DOOR SILL PLATE
1 - CLIPS
2 - SLIDING DOOR SILL TRIM PLATE
3 - FRONT DOOR SILL TRIM PLATE
23 - 76 INTERIORRS
C-PILLAR TRIM (Continued)
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