2002 CHRYSLER CARAVAN door lock

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Page 2062 of 2399

CHRYSLER CARAVAN 2002 Service Manual (6) Position quarter trim panel on inner quarter
panel.
(7) Install screws attaching rear edge of quarter
trim to attaching bracket or inner quarter panel.
(8) Install screws attaching quarter trim to

Page 2064 of 2399

CHRYSLER CARAVAN 2002 Service Manual (5) Engage interlock tabs at lower B-pillar and
quarter trim panel.
SUN VISOR
REMOVAL
All vehicles with driver and passenger side air
bags must have a colored coded five Bullet point air
bag warning l

Page 2091 of 2399

CHRYSLER CARAVAN 2002 Service Manual (4) Remove A-pillar trim panels.
(5) Disconnect wire connectors to windshield
defroster grid.
(6) Place protective covers over instrument panel
and hood.
(7) Remove windshield molding. Using pliers, p

(4) Remove A-pillar trim panels.
(5) Disconnect wire connectors to windshield
defroster grid.
(6) Place protective covers over instrument panel
and hood.
(7) Remove windshield molding. Using pliers, pull
outward on molding at the bottom of A-pillars.
(8) Using a sharp cold knife, cut urethane adhe-
sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 1). A power
cutting device can be used if available.
(9) Remove windshield from vehicle.
WINDSHIELD REMOVAL ± INTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Remove instrument panel top cover. Refer to
Group 8E, Instrument Panel and Systems.
(3) Remove A-pillar trim covers.
(4) Disconnect wire connectors to windshield
defroster grid.
(5) Place protective covers over instrument panel
and hood.
(6) Using a reciprocating or oscillating power
knife, cut urethane adhesive holding the windshield
to the A-pillars, roof header and cowl pinch weld
fences. Refer to instructions provided with the equip-
ment being used.
(7) Remove windshield from vehicle.
INSTALLATION
The urethane adhesive holding the windshield to
the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-senger compartment. If a door is slammed before
urethane bonding is cured, water leaks can result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.
To avoid stressing the replacement windshield, the
urethane bonding material on the windshield fence
should be smooth and consistent to the shape of
the replacement windshield . The support spacers
should be cleaned and properly installed on weld
studs or repair screws at bottom of windshield
opening.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the compression spacers.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement windshield. If not, the pinch weld fence
must be formed to the shape of the new glass.
(3) Remove replacement windshield from wind-
shield opening.
(4) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 2).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(5) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.
(6) Install molding to perimeter of windshield.
(7) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of windshield and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.
(8) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying time.
(9) Using a razor knife, remove as much original
urethane as possible. Do not damage paint on wind-
shield fence.
(10) Apply pinch weld primer 19 mm (0.75 in.)
wide around the windshield fence. Allow at least
three minutes drying time.
(11) If a low viscosity urethane adhesive is used,
install compression spacers on the fence around the
windshield opening (Fig. 3).
(12) Apply a 10 mm (0.4 in.) bead of urethane on
center line of windshield fence.
(13) With the aid of a helper, position the wind-
shield over the windshield opening.
(14) Slowly lower windshield glass to windshield
opening fence. Guide the molding into proper position
as necessary. Push windshield inward until molding
is flush to roof line and A-pillars (Fig. 3).
Fig. 1 CUT URETHANE AROUND WINDSHIELD
1 - COLD KNIFE
2 - WINDSHIELD
23 - 108 STATIONARY GLASSRS
WINDSHIELD (Continued)
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Page 2092 of 2399

CHRYSLER CARAVAN 2002 Service Manual (15) Clean access urethane from exterior with
MopartSuper Kleen or equivalent.
(16) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place unt

(15) Clean access urethane from exterior with
MopartSuper Kleen or equivalent.
(16) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place until urethane cures.
(17) Engage wire connectors to windshield
defroster grid.
(18) Install A-pillar trim panels.
(19) Install cowl cover and wipers.
(20) Install inside rear view mirror.
(21) After urethane has cured, remove tape strips
and water test windshield to verify repair.SLIDING DOOR GLASS
REMOVAL
The temperature of the vehicle should be at least
21É C (70É F) before removing the stationary quarter/
sliding door glass. Butyl sealer becomes more pliable
at high temperatures.
(1) Remove interior trim as necessary to gain
access attaching locations on back of glass.
(2) Remove nuts holding stationary glass to fence.
(3)
Using razor knife, cut butyl sealer holding glass
to fence from between the mounting studs (Fig. 4).
(4) Push glass from opening.
INSTALLATION
The temperature of the vehicle should be at least
21É C (70É F) before removing the stationary quarter/
sliding door glass. Butyl sealer becomes more pliable
at high temperatures.
The stationary glass fence should be cleaned of all
old butyl sealer.
(1) Applya6mm(0.25 in.) butyl tape around
perimeter of glass assembly encapsulation track.
Ensure that the butyl tape is wrapped around the
mounting studs.
(2) Place the glass into the opening and insert
mounting studs through holes in fence.
(3) Install nuts to hold stationary glass to fence.
CAUTION: Tighten nuts to 3.4 N´m (30 in. lbs.)
torque in the sequence indicated. Do not over
torque, or glass breakage may result (Fig. 4).
(4) Install interior trim. (Refer to 23 - BODY/
DOORS - SLIDING/TRIM PANEL - INSTALLATION)
(5) Verify alignment and flushness.
Fig. 2 WORK SURFACE SET UP AND MOLDING
INSTALLATION
1 - WINDSHIELD AND MOLDINGS
2 - BLOCKS
Fig. 3 LOWER WINDSHIELD INTO POSITION
1 - WINDSHIELD
2 - COMPRESSION SPACERS
Fig. 4 SLIDING DOOR STATIONARY GLASS
1 - NUMBERS INDICATE THE TIGHTENING SEQUENCE
2-6mmBEAD OF BUTYL TAPE
3 - BODY SIDE/SLIDING DOOR GLASS
RSSTATIONARY GLASS23 - 109
WINDSHIELD (Continued)
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Page 2094 of 2399

CHRYSLER CARAVAN 2002 Service Manual (1) Place replacement glass into rear window open-
ing.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement rear window. If not, the fence mus

(1) Place replacement glass into rear window open-
ing.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement rear window. If not, the fence must be
formed to the shape of the new glass.
(3) Using a grease pencil, mark the glass and lift-
gate in several locations to aid installation.
(4) Remove replacement glass from liftgate open-
ing.
(5) Position the rear window inside up on a suit-
able work surface with two padded, wood 10 cm by
10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks,
placed parallel 75 cm (2.5 ft.) apart (Fig. 2).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN REAR WINDOW BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(6) Clean inside of rear window with ammonia
based glass cleaner and lint-free cloth.
(7) Apply molding to top and bottom of rear win-
dow.
(8) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of rear window and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.
(9) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of rear window. Allow at least three min-
utes drying time.
(10) Apply Pinch weld Primer 19 mm (0.75 in.)
wide around the rear window fence. Allow at least
three minutes drying time.
(11) If a low viscosity urethane adhesive is used,
install compression spacers on the fence around the
rear window opening (Fig. 7).(12) Apply a 10 mm (0.4 in.) bead of urethane
along center line of rear window fence.
(13) With the aid of a helper, position the rear
window over the rear window opening and align the
reference marks.
(14) Slowly lower the glass to rear window opening
fence. Guide the molding into proper position as nec-
essary. Push glass inward until molding is flush to
liftgate surface (Fig. 7).
(15) Clean excess urethane from exterior with
MopartSuper Kleen, or equivalent.
(16) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place until urethane cures.
(17) Install rear window side moldings and wiper
arm (Fig. 6).
(18) Install interior trim.
(19) After urethane has cured, remove tape strips
and water test rear window to verify repair.
Fig. 7 LOWER REAR WINDOW INTO POSITION
1 - REAR WINDOW WITH MOLDING
2 - LIFTGATE
RSSTATIONARY GLASS23 - 111
REAR DOOR GLASS (Continued)
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Page 2096 of 2399

CHRYSLER CARAVAN 2002 Service Manual FRONT DOOR OUTER BELT
MOLDING
REMOVAL
(1) Remove the side view mirror. (Refer to 23 -
BODY/EXTERIOR/SIDE VIEW MIRROR -
REMOVAL)
(2) Remove door trim panel.
(3) Roll door glass down.
(4) Using a hook t

Page 2247 of 2399

CHRYSLER CARAVAN 2002 Service Manual REAR CONTROL PANEL
With the rear control active, temperature selection
dictates indirectly the mode (floor or overhead air) of
the rear unit: a low temperature setting directs flow
to the overhead out

REAR CONTROL PANEL
With the rear control active, temperature selection
dictates indirectly the mode (floor or overhead air) of
the rear unit: a low temperature setting directs flow
to the overhead outlets and a high temperature set-
ting to the floor.
OPERATION - THREE ZONE ATC
Comfort temperature or perceived temperature is
affected by air flow, sun impinging on exposed skin,
etc. The air temperature may be higher or lower than
the comfort temperature. Three infrared sensors, two
in the instrument panel center stack, and one in the
overhead-mounted rear control panel, independently
measure the temperature of the driver, front passen-
ger, and rear compartment occupants to determine
their comfort level relative to the selected comfort
temperature. The HVAC computer in the control
module adjusts the air flow rate and temperature to
maintain the customer-perceived comfort tempera-
ture. The air temperature in the passenger compart-
ment at any time may be slightly higher or lower
than the comfort temperature. For instance, on
sunny summer days the air flow will probably be
cooler than the comfort temperature; on cold or
cloudy days and at night it will probably be slightly
warmer. Infrared Three-Zone Temperature Control
provides side-to-side and front-to-rear variation in
comfort temperature settings. The Infrared Three-
Zone Automatic Temperature Control fan provides a
continuously variable air flow rate to meet occupant
comfort requirements.
FRONT CONTROL PANEL
²AUTO HI/LO± This system features two sets of
automatic control logic that allow either a rapid cool-
down rate or a somewhat slower cool-down rate with
less fan noise. HI-AUTO controls the system to reach
its assigned temperature quickly with a higher fan
speed. LO-AUTO controls the system to reach its
assigned temperature somewhat slower with less fan
noise. Both modes will automatically engage auto
recirculation.
²DE-FROST± The front de-frost function is
active when the rear window defogger function is
active or when the defog/defrost mode is selected.
²RECIRC± The RECIRC button will close the
air inlet door. If the system is in auto recirc (indica-
tor being displayed automatically), pressing the man-
ual recirc button will disable the auto recirc function
until one of the auto keys are pressed or the ignition
is cycled. If Auto HI/LO is pressed while manual
recirc is active, manual recirc will be deactivated.
²REAR WINDOW DEFOGGER± Pushing the
button sends a PCI bus message to the Intelligent
Power Module which controls the Rear WindowDefogger and side view mirror (if equipped) circuitry.
The defogger function will be active for 10 minutes
and can be turned off by a switch press. The defogger
will function while the control is in the OFF mode.
²FAN/MODE± The Fan and Mode knobs have
17 manual selectable positions. Manually changing
either of the rotary knobs for mode or fan speed set-
tings makes control of that function alone manual for
as long as the ignition is on. If only one is changed
manually, the other remains under automatic control.
Pressing the HI-AUTO/LO-AUTO rocker switch
restores full automatic control.
²REAR CONTROL± When the Rear System
control knob is moved to the OFF position, there will
be a delay of approximately 1 second before the sys-
tem actually turns off. This delay is to prevent an
undesired blower dropout if the knob is moved
through OFF to the other selections.
²BLOWER DELAY TIMER± The word DELAY
is displayed at start-up to signify that the system is
waiting so that cold air will not be blowing. This tells
the operator that it is unnecessary to turn the sys-
tem off, raise the temperature setting or turn the fan
speed setting down to prevent cold air from blowing.
A countdown in minutes and seconds until the engine
is warm enough to begin delivering heat to the pas-
sengers alternates with the DELAY message at 25
second intervals. This countdown is based on actual
measurement of the rate of engine coolant tempera-
ture change. During the delay time, Defrost mode is
selected and the fan operates at a low speed to keep
the windshield fog free.
REAR CONTROL PANEL
Primary control of the rear compartment unit is in
the instrument panel center stack. The rear unit con-
trol knob there allows the driver to turn the rear
unit off, allow control by the intermediate seat occu-
pants by switching to the REAR position, or provide
fully automatic control based on the temperature set-
ting shown on the front control display.
²REAR CONTROL± Selecting automatic control
of the rear unit at the instrument panel, illuminates
a Locked Padlock in the rear control panel display.
Selecting REAR activates the rear control panel and
the Padlock then appears unlocked.
²FAN KNOB± The rear fan control has Off and
AUTO positions and a range of manual speed set-
tings that override the AUTO setting.
²MODE KNOB± The mode control allows inter-
mediate seat occupants to manually override the
automatic mode and select any balance of air flow
between overhead and floor outlets from full over-
head to full floor.
²SET TEMP± The rear set temp control will
operate identical to the front controls. If the front
24 - 4 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)
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Page 2273 of 2399

CHRYSLER CARAVAN 2002 Service Manual bezel with the snap clip receptacles on the retainer
above the headliner.
(7) Using hand pressure, press the top edge of the
rear heater-A/C control bezel upward until the two
snap clips are fully sea

bezel with the snap clip receptacles on the retainer
above the headliner.
(7) Using hand pressure, press the top edge of the
rear heater-A/C control bezel upward until the two
snap clips are fully seated in their receptacles.
(8) Reconnect the battery negative cable.
(9) Using the DRB-IIItreset the Rear Tempera-
ture Selector calibration values.
(10) Verify that the Actuator Calibration of the
Front Control has passed. If an Actuator Calibration
has not passed correct any errors before proceeding
further.
(11) Rotate the Rear Temperature Selector counter
clockwise to the Cold Position, allow the Selector to
remain in the Cold Position for 5 seconds.
(12) Rotate the Rear Temperature Selector Clock-
wise to the Hot Position, allow the Selector to remain
in the Cold Position for 5 seconds.
(13) calibration is now complete.
BLEND DOOR ACTUATOR
DESCRIPTION
The blend door actuator is a reversible, 12-volt
Direct Current (DC), servo motor (Fig. 3). The single
blend door actuator is located on the outboard side of
the rear heater-A/C unit housing, below the mode
door actuator. The blend door actuator is mechani-
cally connected to the blend air door. The blend door
actuator is interchangeable with the actuator for the
mode door. Each actuator is contained within an
identical black molded plastic housing with an inte-gral wire connector receptacle. Two integral mount-
ing tabs allow the actuator to be secured with two
screws to the rear heater-A/C unit housing. Each
actuator also has an identical output shaft with
splines that connects it to the pivot or linkage of the
proper door. The blend door actuator does not require
mechanical indexing to the blend air door pivot, as it
is electronically calibrated by the front heater-A/C
control module. The blend door actuator cannot be
adjusted or repaired and, if damaged or faulty, it
must be replaced.
OPERATION
The blend door actuator is connected to the front
heater-A/C control module through the vehicle elec-
trical system by a dedicated two-wire take out and
connector of the rear HVAC wire harness. The blend
door actuator can move the blend air door in two
directions. When the front heater-A/C control module
pulls the voltage on one side of the motor connection
Fig. 2 Heater-A/C Control Bezel
1 - BEZEL
2 - SNAP CLIP (2)
3 - HEATER-A/C CONTROL
4 - SCREW (3)
5 - LOCATOR TAB (2)
Fig. 3 Blend Door Actuator
1 - SCREW (2)
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - CONNECTOR
5 - BLEND DOOR ACTUATOR
6 - CONNECTOR
24 - 30 CONTROLS - REARRS
A/C-HEATER CONTROL (Continued)
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