2002 CHRYSLER CARAVAN wiring

BODY
TABLE OF CONTENTS
page page
BODY
DESCRIPTION - VEHICLE IDENTIFICATION....1
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 1
DIAGNOSIS AND TESTING - WIND NOISE . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR........................3
STANDARD PROCEDURE - HEAT STAKING . 10
SPECIFICATIONS
TORQUE............................11
BODY LUBRICATION...................12SPECIAL TOOLS
BODY..............................13
DOOR - FRONT.........................14
DOORS - SLIDING.......................24
DECKLID/HATCH/LIFTGATE/TAILGATE.......39
EXTERIOR.............................44
HOOD.................................60
INSTRUMENT PANEL.....................63
INTERIOR..............................72
PAINT.................................83
SEATS................................85
STATIONARY GLASS....................107
WEATHERSTRIP/SEALS..................112
BODY STRUCTURE.....................115
BODY
DESCRIPTION - VEHICLE IDENTIFICATION
Throughout this group, references to the
DaimlerChrysler Corporation vehicle family identifi-
cation code are used when describing a procedure
that is unique to that vehicle. Refer to Introduction
Group of this manual for detailed information on
vehicle identification. If a procedure is common to all
vehicles covered in this manual, no reference will be
made to a vehicle family code.
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE A OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL ± BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE THAT
IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
Do not weld exterior panels unless combustiblematerial on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use when
welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning solvents
on painted or upholstered surfaces. Damage to fin-
ish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
RSBODY23-1
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cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehi-
cle. If noise goes away after a piece of tape is applied,
remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
²Moldings standing away from body surface can
catch wind and whistle.
²Gaps in sealed areas behind overhanging body
flanges can cause wind-rushing sounds.
²Misaligned movable components.
²Missing or improperly installed plugs in pillars.
²Weld burn through holes.
STANDARD PROCEDURE
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR
There are many different types of plastics used in
today's automotive environment. We group plastics in
three different categories: Rigid, Semi-Rigid, and
Flexible. Any of these plastics may require the use of
an adhesion promoter for repair. These types of plas-
tic are used extensively on DaimlerChrysler Motors
vehicles. Always follow repair material manufactur-
er's plastic identification and repair procedures.
Rigid Plastics:
Examples of rigid plastic use: Fascias, Hoods,
Doors, and other Body Panels, which include SMC,
ABS, and Polycarbonates.
Semi-Rigid Plastics:
Examples of semi-rigid plastic use: Interior Panels,
Under Hood Panels, and other Body Trim Panels.
Flexible Plastics:
Examples of flexible plastic use: Fascias, Body
Moldings, and upper and lower Fascia Covers.
Repair Procedure:
The repair procedure for all three categories of
plastics is basically the same. The one difference is
the material used for the repair. The materials must
be specific for each substrate, rigid repair material
for rigid plastic repair, semi-rigid repair material for
semi-rigid plastic repair and flexible repair material
for flexible plastic repair.
Adhesion Promoter/Surface Modifier:
Adhesion Promoters/Surface Modifiers are required
for certain plastics. All three categories may have
plastics that require the use of adhesion promoter/
surface modifiers. Always follow repair material man-
ufacturer's plastic identification and repair
procedures.
SAFETY PRECAUTION AND WARNINGS
WARNING:
²EYE PROTECTION SHOULD BE USED WHEN
SERVICING COMPONENTS. PERSONAL INJURY
CAN RESULT.
²USE AN OSHA APPROVED BREATHING MASK
WHEN MIXING EPOXY, GRINDING, AND SPRAYING
PAINT OR SOLVENTS IN A CONFINED AREA. PER-
SONAL INJURY CAN RESULT.
²AVOID PROLONGED SKIN CONTACT WITH
RESIN, PETROLEUM, OR ALCOHOL BASED SOL-
VENTS. PERSONAL INJURY CAN RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT PROPERLY SUPPORTED ON
SAFETY STANDS. PERSONAL INJURY CAN
RESULT.
NOTE:
²When holes must be drilled or cut in body pan-
els, verify locations of internal body components
and electrical wiring. Damage to vehicle can result.
²Do not use abrasive chemicals or compounds
on undamaged painted surfaces around repair
areas. Damage to finish can result.
RSBODY23-3
BODY (Continued)
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DOOR
REMOVAL
(1) Remove front wheelhouse splash shield. (Refer
to 23 - BODY/EXTERIOR/LF WHEELHOUSE
SPLASH SHIELD - REMOVAL)
(2) Disengage clips attaching door harness wire
connector to inner fender brace.
(3) Disconnect positive lock slide on the side of the
wire connectors (Fig. 3).
(4) Depress lock tab attaching wire connector
halves together.
(5) Disconnect door harness from body wiring har-
ness.
(6) Remove bolts attaching door check strap to
A-pillar (Fig. 4).
(7) Support door on suitable lifting device.
(8) Remove bolts attaching lower hinge to door end
frame (Fig. 5).
(9) Steady door on lifting device and remove bolts
attaching upper hinge to door end frame.
(10) Remove door from vehicle.
Fig. 1 FRONT DOOR APPLIQUE
1 - GLASS RUN WEATHERSTRIP
2 - CLIPS
3 - APPLIQUE
4 - FRONT DOOR
Fig. 2 FRONT DOOR CHECK STRAP
1 - FRONT DOOR
2 - DOOR CHECK STRAP
Fig. 3 FRONT DOOR WIRE CONNECTORS
1 - LOCK TAB
2 - POSITIVE LOCK
3 - BODY HARNESS CONNECTOR
4 - FRONT FENDER
5 - DOOR HARNESS CONNECTOR
6 - BODY HARNESS
RSDOOR - FRONT23-15
CHECK STRAP (Continued)
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INSTALLATION
NOTE: If new hinge pins are to be used, verify that
the knurling on the hinge pin is aligned with the
knurling on in the door hinge prior to driving in the
pin. Also, verify that the hinge pin is fully seated to
the door hinge and a new retaining clip is installed.
(1) Support door on suitable lifting device.
(2) Position door to vehicle. Verify net pierce nub-
bin is engaged if reusing original hinges.
(3) Steady door on lifting device and install bolts
attaching upper hinge to door end frame. Tighten
bolts to 34 N´m (25 ft. lbs.) torque.
(4) Install bolts attaching door check strap to
A-pillar. Tighten bolts to 12 N´m (105 in. lbs.) torque.
(5) Install bolts attaching lower hinge to door end
frame. Tighten bolts to 34 N´m (25 ft. lbs.) torque.
Align door to achieve equal spacing to surrounding
body panels. Panels should be flush across all gaps.
(6) Connect door harness into body wiring harness.
(7) Connect positive lock slide on the side of the
wire connectors.
(8) Connect clips attaching door harness wire con-
nector to inner fender brace.
(9) Install front wheelhouse splash shield.
(10) Verify door operation and alignment. Adjust
as necessary.
DOOR GLASS
REMOVAL
(1) Remove watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(2) Remove inner belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - REMOVAL)
(3) Remove outer belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR OUTER BELT
MOLDING - REMOVAL)
(4) Position glass to gain access to front and rear
regulator lift plates through front and rear access
holes in door panel.
(5) Remove clips attaching door glass to regulator
lift plates (Fig. 6).
(6) Remove glass from regulator lift plates.
(7) Disengage glass from glass run weatherstrip.
(8) Insert front of glass between glass run channel
and outer door panel.
(9) Lift glass upward and out of exterior side of
the opening at top of door (Fig. 7).
(10) Remove glass from vehicle.
Fig. 4 FRONT DOOR - HINGE PIN REMOVAL
1 - FRONT DOOR
2 - CLIP
3 - A-PILLAR
4 - HINGE PIN
5 - CLIP
6 - DOOR CHECK STRAP
Fig. 5 FRONT DOOR - HINGE BOLT REMOVAL
1 - FRONT DOOR
2 - UPPER HINGE
3 - CHECK STRAP
4 - LOWER HINGE
23 - 16 DOOR - FRONTRS
DOOR (Continued)
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(12) Remove front door trim panel from vehicle.
INSTALLATION
(1) Hold top of trim panel away from door to gain
access to latch linkage.
(2) Place linkage rod in position on latch handle.
(3) Engage clip to hold linkage rod to inside latch
release handle.
(4) Place front door trim panel in position on door.
(5) Install trim panel into inner belt molding at
top of door.
(6) Install clips to attach door trim to door frame
around perimeter of panel.
(7) If equipped, install screw to attach door trim to
door panel behind inside latch release handle.
(8) If equipped, connect power switch into wire
connector.
(9) Place power accessary switch in position on
door trim.
(10) Connect wire connector into memory seat/mir-
ror switch and install switch into trim panel.
(11) Install screws to attach accessary switch
panel to door trim.
(12) Install screw cover into switch panel.
(13) If equipped, install window crank.
(14) If equipped, install screws to attach trim
panel to door inside map pocket.
(15) If equipped, install screw to attach door pull
cup to inner door panel.
(16) If equipped, install screws to attach door
assist handle to inner door panel.
(17) Connect wire connector into courtesy lamp.
(18) Install lamp in door trim.
(19) Install switch bezel.
WATERSHIELD
REMOVAL
(1) Remove door trim panel.
(2) Remove the front door speaker.
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
INSTALLATION
(1) Insure that enough adhesive remains to
securely retain the water dam. Replace as necessary.
(2) Place the sound shield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(3) Install door trim panel.
WINDOW CRANK
REMOVAL
(1) Using a window crank removal tool, disengage
clip attaching window crank to regulator shaft (Fig.
14).
NOTE: Wrap a shop towel around the window crank
to catch the clip when it springs out.
(2) Pull window crank from regulator shaft.
INSTALLATION
(1) Place the clip on to the window crank handle.
(2) Position window crank to regulator shaft.
(3) Push window crank onto regulator shaft to
engage retaining clip.
Fig. 13 INSIDE DOOR HANDLE LINKAGE
1 - DOOR LATCH HANDLE
2 - DOOR TRIM
3 - LATCH LINKAGE
4 - CLIP
5 - MEMORY SEAT SWITCH
Fig. 14 WINDOW CRANK - TYPICAL
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
RSDOOR - FRONT23-21
TRIM PANEL (Continued)
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(7) Install inside door handle assembly (Refer to
23 - BODY/DOORS - SLIDING/INSIDE LATCH
HANDLE - INSTALLATION).
(8) Install foam block.
(9) Engage external cable to latch/lock assembly.
(10) Engage link rod to bellcrank.
(11) Engage hold open latch cable from lower
hinge.(12) Engage clip to hold bellcrank link to latch/lock
control.
(13) Verify sliding door operation.
(14) Install latch/lock cover.
(15) Insure that enough adhesive remains to
securely retain the watershield. Replace as necessary.
(16) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(17) Install sliding door stop bumper.(Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(18) Install sliding door trim panel.(Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
CENTER STRIKER
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove bolts attaching stop bumper. Remove
stop bumper from door.
(3) Remove screws attaching center striker assem-
bly to door end frame (Fig. 6).
(4) Remove center striker assembly from door
through access hole.
INSTALLATION
(1) Place center striker in position on door through
access hole (Fig. 6).
(2) Install screws to attach center striker to door
end frame.
Fig. 4 SLIDING DOOR LATCH/LOCK ASSEMBLY
1 - SLIDING DOOR
2 - LATCH LOCK ASSEMBLY
Fig. 5 REMOVING SLIDING DOOR LATCH/LOCK
ASSEMBLY
1 - WIRE HARNESS
2 - LATCH/LOCK ASSEMBLY
3 - BELLCRANK LINK ROD
4 - LINK AND SLEEVE ASSEMBLY
Fig. 6 SLIDING DOOR CENTER STRIKER
ASSEMBLY
1 - STRIKER BOLT ASSEMBLY
2 - SLIDING DOOR
RSDOORS - SLIDING23-27
LATCH / LOCK ASSEMBLY (Continued)
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(5) Disengage cable end from clip on release han-
dle mechanism.
(6) Disengage cable end from release handle mech-
anism.
(7) Remove push pin fastener attaching cable end
to release handle.
(8) Disengage cable casing end from release handle
(Fig. 20).
(9) Disengage cable end from latch handle.
(10) Remove handle from vehicle.INSTALLATION
(1) Place inside latch handle in position on vehicle.
(2) Engage cable end into latch handle.
(3) Engage cable casing end into release handle.
(4) Install push pin fastener to hold cable into
release handle.
(5) Engage cable end into release handle mecha-
nism.
(6) Engage clip to hold cable end into release han-
dle mechanism.
(7) Place latch handle in position on sliding door.
(8) Install screw to hold top of inside release han-
dle to sliding door.
(9) Install screws to hold bottom of inside latch
handle to sliding door.
(10) Verify sliding door operation. Adjust as neces-
sary. (Refer to 23 - BODY/DOORS - SLIDING/SLID-
ING DOOR - ADJUSTMENTS)
(11) Install sliding door trim panel.(Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
BELLCRANK
REMOVAL
(1) Remove stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - REMOVAL).
(2) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel as necessary to gain
access to latch bellcrank.
(4) Disengage key cylinder link (Fig. 21).
(5) Disengage lock link.
(6) Disengage link and sleeve
(7) Remove bellcrank by rotating bellcrank to
release it from door.
(8) Remove bellcrank from vehicle.
INSTALLATION
(1) Position bellcrank on vehicle.
(2) Rotate bellcrank into position.
(3) Place lock link into position and engage clip
(Fig. 21).
(4) Place link and sleeve into position and engage
clip.
(5) Place key cylinder link into position and
engage clip.
(6) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(7) Install sliding door trim panel (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION).
Fig. 19 SLIDING DOOR INSIDE HANDLE
1 - INSIDE ASSIST HANDLE
2 - SLIDING DOOR
3 - LATCH BELLCRANK
4 - INSIDE RELEASE HANDLE CABLE
Fig. 20 RELEASE HANDLE CABLE
1 - ASSIST HANDLE MECHANISM
2 - SLIDING DOOR INSIDE ASSIST HANDLE
3 - RELEASE HANDLE CABLE
23 - 34 DOORS - SLIDINGRS
INSIDE LATCH HANDLE (Continued)
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(8) Install stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - INSTALLA-
TION).
OUTSIDE HANDLE
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel as necessary to access
outside release handle fasteners.
(4) Disengage clip attaching outside door handle
linkage to door cable.
(5) Remove linkage from outside door handle.
(6) Remove three nuts attaching outside door han-
dle to outer door panel (Fig. 22).
(7) Remove outside door handle from vehicle.
INSTALLATION
(1) Position outside door handle on vehicle.
(2) Install nuts attaching outside door handle to
outer door panel.
(3) Engage clip attaching linkage to outside door
handle.
(4) Engage rigging cam to latch/lock control mech-
anism.
(5) Move clip on latch/lock control to bottom of slot
and engage linkage to latch/lock control.
(6) Verify sliding door operation. Adjust as neces-
sary.
(7) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(8) Install sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(9) Install sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
Fig. 21 BELLCRANK
1 - LOCK LINK
2 - LATCH LINK
3 - LINK AND SLEEVE - OUTSIDE HANDLE
4 - BELLCRANK
5 - KEY CYLINDER LINK
Fig. 22 SLIDING DOOR OUTSIDE LATCH RELEASE
HANDLE
1 - OUTSIDE DOOR PANEL
2 - LOCK LINK
3 - LATCH LINK
4 - LOCKING LINK AND SLEEVE LINK
5 - BELLCRANK
6 - KEY CYLINDER LOCK LINK
7 - KEY CYLINDER
RSDOORS - SLIDING23-35
BELLCRANK (Continued)
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