2002 CHRYSLER CARAVAN Service Manual

reset change wheel coolant temperature fuel bonnet service schedule

Page 2025 of 2399

CHRYSLER CARAVAN 2002 Service Manual LOCK CYLINDER
REMOVAL
(1) Remove the liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the electrical connector.
(3) Disconnect the latch r

LOCK CYLINDER
REMOVAL
(1) Remove the liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the electrical connector.
(3) Disconnect the latch rod.
(4) Rotate plastic lock cylinder nut one quarter
turn and remove nut and spring washer.
(5) Remove the lock cylinder from the liftgate.
INSTALLATION
(1) Install lock cylinder into liftgate.
(2) Install the plastic lock cylinder lock nut, spring
washer and rotate one quarter turn.
(3) Connect the electrical connector.
(4) Connect the latch rod.
(5) Install the trim panel. (Refer to 23 - BODY/
DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM
PANEL - INSTALLATION)
(6) Verify lock cylinder operation.
SUPPORT CYLINDER
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device in
the full open position.
(3) Pull liftgate opening weatherstrip from D-pillar
flange next to prop assembly end pivot.
(4) Remove bolt attaching end pivot to D-pillar
(Fig. 6).
(5) Remove bolt attaching prop assembly to lift-
gate.
(6) Remove prop assembly from vehicle.
INSTALLATION
Ensure that the cylinder end is attached to the
D-pillar and the shaft end is attached to the liftgate.
(1) Place prop assembly in position.
(2) Install bolt attaching prop assembly to liftgate.
(3) Install bolt attaching end pivot to D-pillar.
Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(4) Install liftgate opening weatherstrip to D-pillar
flange next to prop assembly end pivot.
(5) Close liftgate. Check liftgate operation.
TRIM PANEL
REMOVAL
(1) Remove the bolt attaching the lift motor link, if
equipped (Fig. 7).
(2) Remove liftgate upper frame molding (Fig. 8).
(3) Remove assist handle screws.
(4) Disengage hidden clips holding trim panel to
liftgate from around perimeter or liftgate (Fig. 8).
(5) Disconnect wire connector from lamps.
(6) Remove liftgate trim panel from vehicle.
Fig. 6 LIFTGATE PROP ASSEMBLY
1 - LIFTGATE
2 - PROP ASSEMBLY
Fig. 7 LIFTGATE MOTOR
1 - LIFTGATE MOTOR LINK BOLT
2 - LIFTGATE MOTOR
3 - LIFTGATE
23 - 42 DECKLID/HATCH/LIFTGATE/TAILGATERS
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Page 2026 of 2399

CHRYSLER CARAVAN 2002 Service Manual INSTALLATION
(1) Place liftgate trim panel in position on vehicle.
(2) Engage hidden clips to hold trim panel to lift-
gate and fasteners around perimeter of liftgate (Fig.
8).
(3) Connect wire connec

Page 2027 of 2399

CHRYSLER CARAVAN 2002 Service Manual EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL.............................44
INSTALLATION.........................45
COWL GRILLE
REMOVAL.............................50
INSTALLATION..

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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Page 2028 of 2399

CHRYSLER CARAVAN 2002 Service Manual INSTALLATION
Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig.
5)for proper location of fasteners to hold the molding
to the wheelhouse lip and rocker panels.
(1) If molding is to be reused;
(a

Page 2029 of 2399

CHRYSLER CARAVAN 2002 Service Manual Fig. 2 BODY SIDE MOLDINGS - HIGHLINE TYPICAL
1 - QUARTER PANEL
2 - FRONT FENDER
3 - POP-RIVET
4 - FENDER MOLDING
5 - FRONT DOOR MOLDING
6 - SLIDING DOOR MOLDING7 - GUIDE PINS
8 - QUARTER PANEL MOLDING

Page 2030 of 2399

CHRYSLER CARAVAN 2002 Service Manual Fig. 3 BODY SIDE MOLDINGS - PREMIUM TYPICAL
1 - QUARTER PANEL
2 - FRONT FENDER
3 - POP-RIVET
4 - FENDER MOLDING
5 - POP-RIVET
6 - FASCIA7 - FRONT DOOR MOLDING
8 - SLIDING DOOR MOLDING
9 - QUARTER PANE

Page 2031 of 2399

CHRYSLER CARAVAN 2002 Service Manual Fig. 4 BODY SIDE MOLDINGS - PREMIUM TYPICAL
1 - QUARTER PANEL
2 - FRONT FENDER
3 - POP-RIVET
4 - FENDER MOLDING
5 - POP-RIVET
6 - FASCIA7 - FRONT DOOR MOLDING
8 - SLIDING DOOR MOLDING
9 - QUARTER PANE

Page 2032 of 2399

CHRYSLER CARAVAN 2002 Service Manual Fig. 5 BODY SIDE MOLDINGS WITH APPLIQUE - TYPICAL
1 - FRONT ROCKER PANEL APPLIQUE
2 - FRONT DOOR MOLDING
3 - SLIDING DOOR MOLDING
4 - REAR ROCKER PANEL APPLIQUE5 - LIFTGATE MOLDING
6 - POP-RIVET
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