2002 CHRYSLER CARAVAN hood release

STARTER MOTOR
REMOVAL
REMOVAL - 2.4L
(1) Release hood latch and open hood (Fig. 4).
(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect solenoid wire connector from termi-
nal (Fig. 5).
(4) Remove nut holding B+ wire to terminal.
(5) Disconnect solenoid and B+ wires from starter
terminals.
(6) Remove the lower bolt.
(7) Remove the upper bolt and ground wire (Fig.
6).
(8) Remove starter.
Fig. 4 STARTER 2.4L
Fig. 5 BATTERY CABLE AND FIELD WIRE 2.4L
Fig. 6 Upper Bolt and Ground Wire
8Fa - 38 STARTINGRG
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REMOVAL - 3.3/3.8L
(1) Release hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Hoist and support vehicle on safety stands.
(4) Remove nut holding B+ terminal to starter
solenoid (Fig. 7).
(5) Disconnect solenoid connector from starter.
(6) Remove bolts holding starter to transaxle bell-
housing (Fig. 8).(7) Remove starter from bellhousing (Fig. 9).
(8) Separate starter spacer from transaxle bell-
housing.
REMOVAL - 3.5L
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support
(3) Disconnect the battery positive cable at starter
(Fig. 10).
Fig. 7 Starter
1 - SOLENOID CONNECTOR
2 - B+ CONNECTOR
Fig. 8 Starter Bolts
1-STARTER
2 - STARTER BOLTS
3 - TRANSAXLE
4 - ENGINE MOUNT
Fig. 9 STARTER 3.3/3.8L
1 - BELL HOUSING PLATE
2 - FLYWHEEL
3 - ENGINE MOUNT
4-STARTER
5 - SPACER
Fig. 10 ELECTRICAL CONNECTIONS
RGSTARTING8Fa-39
STARTER MOTOR (Continued)
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ure. The electronics module is faulty and must be
replaced.
c.Failed J1850 Communication (EVIC only),
BUS (CT, CMTC)- The electronics module is not
receiving proper message input through the J1850
PCI data bus circuit. This can result from one or
more faulty electronic modules in the vehicle, or from
a faulty PCI data bus. The use of a DRB IIItscan
tool and the proper Diagnostic Procedures manual
are required for further diagnosis.
NOTE: If the compass functions, but accuracy is
suspect, it may be necessary to perform a variation
adjustment. This procedure allows the compass
unit to accommodate variations in the earth's mag-
netic field strength, based on geographic location.
Refer to Compass Variation Adjustment in the Ser-
vice Procedures section of this group.
NOTE: If the compass reading displays dashes, and
only ªCALº appears in the display, demagnetizing
may be necessary to remove excessive residual
magnetic fields from the vehicle. Refer to Compass
Demagnetizing in the Service Procedures section of
this group.
STANDARD PROCEDURE
STANDARD PROCEDURE - READING/
COURTESY LAMP REPLACEMENT
(1) Open hood, disconnect and isolate the negative
battery cable remote terminal from the remote bat-
tery post.
(2) Remove the reading/courtesy lamp lens. Using
a trim stick, gently pry the forward edge of the read-
ing/courtesy lamp lens outward.
(3) Remove the reading/courtesy lamp socket from
the overhead console. Rotate the reading/courtesy
lamp socket one quarter turn counter clockwise.
(4) Remove the lamp and socket assembly.
(5) Reverse the above procedure to install.
STANDARD PROCEDURE - COMPASS
CALIBRATION
CAUTION: Do not place any external magnets, such
as magnetic roof mount antennas, in the vicinity of
the compass. Do not use magnetic tools when ser-
vicing the overhead console.
The electronic compass unit features a self-cali-
brating design, which simplifies the calibration pro-
cedure. This feature automatically updates the
compass calibration while the vehicle is being driven.This allows the compass unit to compensate for small
changes in the residual magnetism that the vehicle
may acquire during normal use. If the compass read-
ings appear to be erratic or out of calibration, per-
form the following calibration procedure. Also, new
service replacement Electronic Modules (EVIC,
CMTC, CT) must have their compass calibrated
using this procedure. Do not attempt to calibrate the
compass near large metal objects such as other vehi-
cles, large buildings, or bridges; or, near overhead or
underground power lines.
NOTE: Whenever the compass is calibrated manu-
ally, the variance number must also be reset. Refer
to Compass Variation Adjustment in this group.
Calibrate the compass manually as follows:
(1) Turn the ignition switch to the On position. If
the compass/thermometer data is not currently being
displayed, momentarily depress and release the C/T
push button to reach the compass/thermometer dis-
play.
(2) On Electronic Vehicle Information Center
(EVIC) and Compass Mini-Trip Computer (CMTC)
equipped vehicles depress the Reset push button and
hold the button down until ªCALº appears in the dis-
play. This takes about ten seconds, and appears
about five seconds after ªVAR = XXº is displayed. On
Compass Temperature Module (CT) equipped vehicles
depress the C/T push button and US/M push button
down until ªCALº appears in the display. This takes
about ten seconds, and appears about five seconds
after ªVAR = XXº is displayed.
(3) Release the push button(s).
(4) Drive the vehicle on a level surface, away from
large metal objects and power lines, through three or
more complete circles at between five and eight kilo-
meters-per-hour (three and five miles-per-hour) in
not less than 48 seconds. The ªCALº message will
disappear from the display to indicate that the com-
pass is now calibrated.
NOTE: If the ªCALº message remains in the display,
either there is excessive magnetism near the com-
pass, or the unit is faulty. Repeat the calibration
procedure one more time.
NOTE: If the wrong direction is still indicated in the
compass display, the area selected for calibration
may be too close to a strong magnetic field. Repeat
the calibration procedure in another location.
RSMESSAGE SYSTEMS8M-3
OVERHEAD CONSOLE (Continued)
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OPERATION
On the power cinch/release latch, the latch
mounted actuator provides the torque required to
close the power liftgate from the secondary to the pri-
mary closed and latched position. On the power
cinch/release latch and the power release only latch,
the actuator releases the liftgate from the primary
closed and latched position to the fully unlatched and
movable position.
REMOVAL
(1) Open the hood, disconnect and isolate the neg-
ative battery cable.
(2) Open the liftgate and remove the liftgate trim
panel. Refer to Body for the procedure.
(3) Disconnect the power latch electrical connector
(Fig. 12).
(4) Remove the power latch retaining bolts.
(5) Disconnect the liftgate lock cylinder link rod
from the key cylinder or latch assembly. To discon-
nect from latch, rotate the plastic retaining clip 90 É
to unsnap clip from linkrod. Then pull link rod
straight out of latch arm.
INSTALLATION
(1) Connect the liftgate lock cylinder link rod on
the cinch latch assembly. Rotate the plastic retaining
clip 90 É to lock retaining clip on linkrod.
(2) Connect the link rod on the lock cylinder.
(3) Install the power latch retaining bolts. Torque
to 10 N´m (90 in. lbs.).
(4) Connect the power latch electrical connector
and secure push pin retainers.
(5) Connect the negative battery cable.
(6) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes related to the power latch.
(7) Verify power liftgate system and power cinch /
release latch operation. Cycle the power liftgate
through one complete open and close cycle, this will
allow the power liftgate control module to relearn its
cycle with the new components.
(8) Verify power liftgate manual operation. Using
liftgate key rotate the lock cylinder to verify door
operation. Pull door open using exterior liftgate han-
dle / switch.
(9) Install the liftgate trim panel. Refer to Body for
the procedure.
LATCH ACTUATOR
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
power cinch latch or power release latch (Fig. 13).
The power cinch and/or power release is made possi-ble by a latch actuator attached to the leading edge
of the power latch assembly. This 12 volt latch actua-
tor contains a small drive gear that meshes with the
latch assemblies internal gears to perform the power
cinch close / power release operations. Refer to the
Latch assembly for more information.
The power cinch/release actuator is serviceable
component. Consult your MoparŸ parts catalog for
specific part numbers.
OPERATION
During a power close cycle, the power cinch actua-
tor provides the torque required to close the power
liftgate from the secondary to the primary closed and
latched position. During a power open cycle, the
power release actuator releases the liftgate from the
primary closed and latched position to the fully
unlatched and movable position.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Open the liftgate and remove the lower liftgate
trim panel. Refer to Body for the procedure.
(3) Disconnect the power latch electrical connector
(Fig. 13).
(4) Remove the three latch retaining bolts.
Fig. 13 POWER LATCH ORIENTATION
1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
RSPOWER LIFTGATE SYSTEM8N-15
LATCH (Continued)
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(6) Refer to the proper Body Diagnostic Procedures
manual if any diagnostic codes are found in Step 4 or
Step 5.
(7) Erase stored diagnostic codes if there are no
active diagnostic codes. If problems remain, diagnos-
tic codes will not erase. Refer to the Proper Body
Diagnostic Procedures Manual to diagnose the prob-
lem.If airbag warning lamp either fails to light,
or goes on and stays on, there is a system mal-
function. Refer to the proper Body Diagnostic
Procedures manual to diagnose the problem.
CLOCK SPRING
DESCRIPTION
The clock spring is screwed to a plastic mounting
platform on the steering column behind the steering
wheel. The clock spring is used to maintain a contin-
uous electrical circuit between the wiring harness
and the drivers airbag.
OPERATION
This assembly consists of a flat ribbon like electri-
cally conductive tape which winds and unwinds with
the steering wheel rotation. The clock spring cannot
be repaired. If the clock spring is faulty, damaged, or
if the airbag has been deployed, the clock spring
must be replaced.
STANDARD PROCEDURE - CLOCK SPRING
CENTERING
If the rotating tape (wire coil) in the clock spring is
not positioned properly with the steering wheel and
the front wheels, the clock spring may fail. The fol-
lowing procedure MUST BE USED to center the
clock spring if it is not known to be properly posi-
tioned, or if the front wheels were moved from the
straight ahead position.
(1) Adjust the steering wheel so that the tires are
in a straight ahead position.
(2) Remove Driver Airbag from steering wheel.
(3) Disconnect wire connectors from back of airbag.
(4) Remove steering wheel.
(5) Rotate the clock spring rotor clockwise until
the rotor stops. Do not apply excessive force.
(6) From the end of travel, rotate the rotor two
turns counterclockwise until the wires end up at the
top.
(7) Install steering wheel and airbag.
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
REMOVAL
(1) Position steering wheel and front wheels
straight ahead.
(2) Release hood latch and open hood. Disconnect
and isolate the battery negative cable.
(3) Remove driver airbag from steering wheel.
(4) Disconnect wire connectors from back of driver
airbag.
(5) Disconnect the 2±way connector from remote
radio control harness and the 4-way connector from
the speed control/horn harness.
(6) Remove steering wheel.
(7) Remove steering column shrouds.
(8) Disconnect 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(9) Remove clock spring from housing assembly by
removing the two retaining screws retaining the
clock spring.
INSTALLATION
(1) Position the clock spring into the housing.
Install the two retaining screws to clock spring.
(2) Connect the 4-way and 6-way harness between
the clock spring and the instrument panel.
(3) Install the steering wheel. Refer to Steering,
Column, Steering Wheel, Installation.
(4) Connect the harness connector to the driver
airbag.
(5) Connect the remote radio control harness and
the speed control/horn harness.
(6) Install the driver airbag into the steering
wheel.
(7) Install the steering column upper and lower
shrouds.
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
DRIVER AIRBAG
DESCRIPTION
The Driver Airbag is located in the center of the
steering wheel. The most visible part of the airbag is
the cover/horn switch.
OPERATION
The Driver Airbag cover contains the horn switch,
inflator device, and a fabric bag. The airbag cover/
horn switch is serviced separately from the inflator
and bag components.
RSRESTRAINTS8O-3
RESTRAINTS (Continued)
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CABLE
DESCRIPTION
The speed control servo cable is connected between
the speed control vacuum servo diaphragm and the
throttle body control linkage.
OPERATION
This cable causes the throttle control linkage to
open or close the throttle valve in response to move-
ment of the vacuum servo diaphragm.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove speed control cable from throttle cam
by sliding clasp out hole used for throttle cable.
(3) Compress the retaining tabs on the cable and
slide cable out of bracket.
(4) Disconnect electrical connectors and vacuum
hose from servo.
(5) Remove two nuts attaching speed control cable
and mounting bracket to servo.
(6) Pull cable away from servo to expose retaining
clip and remove clip attaching cable to servo.
(7) Remove speed control cable.
INSTALLATION
(1) Slide cable into throttle cable bracket and
engage retaining tabs.
(2) Rotate the throttle cam forward to the wide
open position and install speed control cable clasp.
(3) Rotate the throttle cam forward to the wide
open position and install throttle cable clasp.
(4) Install retaining clip that attaches cable to
servo.
(5) Insert servo studs through holes in the mount-
ing bracket and speed control cable.
(6) Install nuts, tighten to 6.7 N´m (60 in. lbs.).
(7) Connect vacuum hose to servo.
(8) Connect electrical connector.
(9) Install servo and bracket and tighten nuts and
bolt.
(10) Connect negative battery cable.
SERVO
DESCRIPTION
The servo unit consists of a solenoid valve body,
and a vacuum chamber. The solenoid valve body con-
tains three solenoids:
²Vacuum
²Vent
²Dump
The vacuum chamber contains a diaphragm with a
cable attached to control the throttle linkage.
OPERATION
The PCM controls the solenoid valve body. The
solenoid valve body controls the application and
release of vacuum to the diaphragm of the vacuum
servo. The servo unit cannot be repaired and is ser-
viced only as a complete assembly.
Power is supplied to the servo by the PCM through
the brake switch. The PCM controls the ground path
for the vacuum and vent solenoids.
The dump solenoid is energized anytime it receives
power. If power to the dump solenoid is interrupted, the
solenoid dumps vacuum in the servo. This provides a
safety backup to the vent and vacuum solenoids.
The vacuum and vent solenoids must be grounded by
the PCM to operate. When the PCM grounds the vac-
uum servo solenoid, the solenoid allows vacuum to enter
the servo and pull open the throttle plate using the
cable. When the PCM breaks the ground, the solenoid
closes and no more vacuum is allowed to enter the
servo. The PCM also operates the vent solenoid via
ground. The vent solenoid opens and closes a passage to
bleed or hold vacuum in the servo as required.
The PCM cycles the vacuum and vent solenoids to
maintain the set speed, or to accelerate and deceler-
ate the vehicle. To increase throttle opening, the
PCM grounds the vacuum and vent solenoids. To
decrease throttle opening, the PCM removes the
grounds from the vacuum and vent solenoids.
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect the negative battery cable.
(3) Disconnect the throttle and speed control cable
ends from throttle body (Fig. 2).
Fig. 2 Speed Control Cable End
1 - SPEED CONTROL VACUUM HOSE
2 - THROTTLE BODY
3 - SPEED CONTROL CABLE
8P - 4 SPEED CONTROLRS
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(2) Turn off ignition.
(3) Remove the air bag, refer to the restraint sec-
tion for more information.
(4) Remove the screw from bottom of the switch.
(5) Remove switch from steering wheel.
(6) Disconnect two-way electrical connector.
(7) Repeat for the other switch.
INSTALLATION
The speed control switches are mounted in the
steering wheel and wired through the clock spring
device under the airbag module.
WARNING: IF REMOVAL OF AIRBAG MODULE IS
NECESSARY, REFER TO THE RESTRAINT SYS-
TEMS SECTION FOR MORE INFORMATION.
(1) Connect two-way electrical connector.
(2) Install switch.
(3) Install screw for the switch.
(4) Repeat for the other switch.
(5) Install the air bag, refer to the restraint section
for more information.
(6) Install the negative battery cable.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoir is located in the engine com-
partment. It is made of plastic.
OPERATION
The reservoir stores engine vacuum. Manifold vac-
uum is supplied from the brake booster check valve.
The speed control vacuum supply hose has a check
valve at the source (brake booster) to maintain the
highest available vacuum level in the servo, reservoir
and vacuum hoses. When engine vacuum drops, as in
climbing a grade while driving, the reservoir supplies
the vacuum needed to maintain proper speed control
operation. The vacuum reservoir cannot be repaired
and must be replaced if faulty.
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect the negative battery cable.
(3) Disconnect the vacuum line to the battery tray/
vacuum reservoir.
(4) Remove battery tray/vacuum reservoir, refer to
the Battery section for more information.
INSTALLATION
(1) Install battery tray/vacuum reservoir, refer to
the Battery section for more information.
(2) Connect vacuum line that leads to the battery
tray/vacuum reservoir.
(3) Connect the negative battery cable.
8P - 6 SPEED CONTROLRS
SWITCH (Continued)
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CLEANING
Wiper blades exposed to the weather for a long
period of time tend to lose their wiping effectiveness.
Periodic cleaning of the wiper blade is recommended
to remove the accumulation of salt and road grime.
The wiper blades, arms and windshield should be
cleaned with a sponge or cloth and a mild detergent
or nonabrasive cleaner. If the wiper blades continue
to streak or smear, they should be replaced. The
wiper blade should run smoothly across the wind-
shield in both directions. The wiper blade should
slightly roll over center when the blade reverses
direction. A wiper blade insert that has lost flexibility
or a wiper arm that has lost spring tension, will
cause the blade to skip or chatter across the wind-
shield. If the wiper blades are new and the wiper
arm spring tension is OK and a chattering sound is
emitted from the wiper(s), the wiper blade is not roll-
ing over center. If this condition exists, (refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER ARMS -
ADJUSTMENTS).
INSTALLATION
(1) Position the blade onto the arm.
(2) Engage the blade to the retainer by pulling up
on the blade until the tabs snap into position (Fig. 8).
WIPER LINKAGE
REMOVAL
(1) Remove the front windshield wiper unit from
vehicle (Refer to 8 - ELECTRICAL/WIPERS/WASH-
ERS/WIPER MODULE - REMOVAL).
(2) Place the wiper unit on a suitable work sur-
face.
(3) Remove nuts holding the cowl cover brackets to
the wiper unit.
(4) Remove cowl cover brackets from the wiper
unit.
(5) Remove nuts holding linkage to the wiper unit.
(6) Remove the wiper linkage from the wiper unit.
(7) Disconnect the wire connectors from back of
the wiper motor.
INSTALLATION
(1) Connect the wire harness connector.
(2) Install the linkage on the wiper unit.
(3) Install the nut holding the linkage to the wiper
unit.
(4) Install the cowl cover brackets to the wiper
nut.
(5) Install the front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).(6) Install the cowl cover.
(7) Install the wiper arms and blades.
WIPER MODULE
REMOVAL
(1) Release the hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the wiper arms.
(4) Remove the cowl cover (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL).
(5) Disconnect the positive lock on the wiper mod-
ule wire connector (Fig. 10).
(6) Disconnect the wiper module wire connector
from the engine compartment wire harness.
(7) Disconnect the windshield washer hose from
coupling outside the module.
(8) Disconnect the drain tubes from nipples on bot-
tom of the wiper module.
(9) Remove nuts holding wiper module to lower
windshield fence.
(10) Remove bolts holding the wiper module to the
dash panel (Fig. 11).
(11) Lift wiper module from weld-studs on lower
windshield fence.
CAUTION: Do not allow wiper module to rest on
brake master cylinder reservoir, damage to brake
system can result.
(12) Remove wiper module.
Fig. 10 WIPER MODULE WIRE CONNECTOR
1 - WIPER SYSTEM WIRE CONNECTOR
2 - LOCK TAB
3 - POSITIVE LOCK
4 - WIPER MODULE
RSWIPERS/WASHERS8R-19
WIPER BLADES (Continued)
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