2002 CHRYSLER CARAVAN battery

POWER SLIDING DOOR SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
Door opens unexpectedly Failure of sliding door control or
body control moduleDisconnect then reconnect battery to reset
module, function door, if no function exists
check for loose wire connections, Refer to
the Body Diagnostic Manual for detailed
procedures
Failure of latch assembly Check wiring/cable connections and for
blown fuse
Check for trouble codes, replace latch if
necessary
Failure of open/close command
switchCheck for shorted or defective switch
Failure of striker Striker misaligned or loose
Striker damaged
Replace striker if necessary
Door will not open manually
using inside handleFailure of inside handle assembly Check for broken inside handle assembly
Check cable connections at latch and
handle assembly.
Check for binds or kinks in cable.
Check for foreign matter preventing the
operation of handle assembly
Replace the handle if necessary
Failure of latch assembly Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Replace latch if necessary
Failure of inside handle cable
assemblyCheck cable for binding
Check cable for broken condition
Replace the cable, if necessary
Binding or sticking of components Check for foreign matter preventing the
operation of door
Establish location of binding
Replace necessary components
Door will not open manually
using outside handleFailure of outside handle assembly Check for broken outside handle assembly
Check cable connections at latch and
handle assembly.
Check for binds or kinks in cable.
Check for foreign matter preventing the
operation of handle assembly
8N - 22 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
Replace the handle if necessary
Failure of latch assembly Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Replace latch assembly, if necessary
Failure of outside handle cable
assemblyCheck cable for binding
Check cable for broken condition
Replace the cable, if necessary
Binding or sticking of components Check for foreign matter preventing the
operation of door
Establish location of binding
Replace necessary components
Sliding door will not
open/close manuallyBinding or sticking of components Establish location of binding. Disconnect
flex drive and recheck. Replace necessary
components
Failure of latch assembly Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Replace latch assembly, if necessary
Sliding door will not
open/close under powerFailure of sliding door control or
body control moduleDisconnect then reconnect battery to reset
module, function door, if no function exists
check for loose wire connections, see Body
Diagnostic Manual for detailed procedures
Failure of latch assembly Check wire connections and for blown fuse
Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
Failure of motor assembly Troubleshoot using body diagnostic manual
Failure of full open switch assembly Troubleshoot using body diagnostic manual
Failure of flex drive assembly Disconnect flex drive and check for broken
condition
Failure of lower drive unit assembly Remove lower drive unit and check for
broken condition
Binding or sticking of components Establish location of binding and replace
necessary components
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Power loss during power
door operationWiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
RSPOWER SLIDING DOOR SYSTEM8N-23
POWER SLIDING DOOR SYSTEM (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
Low battery voltage Charge battery
Failure of sliding door control or
body control moduleDisconnect then reconnect battery to reset
module, function door, if no function exists
check for loose wire connections, see Body
Diagnostic Manual for detailed procedures
Failure of drive assembly Remove lower drive unit and check for no
drive condition
No latching in primary
and/or secondary positionsFailure of inside/outside handle
assemblyGo to that9POSSIBLE CAUSE9and review
9CORRECTIONS9
Failure of latch assembly Check wire connections and for blown fuse
Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
Binding or sticking of components Establish location of binding and replace
necessary components
Failure of sliding door control or
body control moduleDisconnect then reconnect battery to reset
module, function door, if no function exists
check for loose wire connections, see Body
Diagnostic Manual for detailed procedures
Door seal force too high Inspect seals for damage, mis-assembly,
foreign matter. Refer to Door adjustment in
the Body section of the service manual for
specifications
Failure of drive assembly Remove lower drive unit and check for no
drive condition
Failure of striker Striker misaligned or loose
Striker damaged
Replace striker if necessary
Latch will not fully release
from primary positionFailure of latch assembly Check wire connections and for blown fuse
Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
Failure of fuel filler door lockout
mechanismCheck operation of fuel filler door lockout
mechanism. Refer to the Body section for
information
Failure of sliding door control or
body control moduleDisconnect then reconnect battery to reset
module, function door, if no function exists
check for loose wire connections, see Body
Diagnostic Manual for detailed procedures
Failure of striker Striker misaligned or loose
8N - 24 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
Striker damaged
Replace striker if necessary
Cables worn and stretched Replace cables as necessary
Binding or sticking of components Establish location of binding and replace
necessary components
Key fob, B-pillar or
overhead console switch
does not power operate
doorBlown Fuse Check fuse and replace
Battery voltage low Charge or replace battery
Failure of latch assembly Check for foreign matter preventing the
operation of latch assembly
Check wire connection
Pawl and/or ratchet switch inoperative
Replace latch if necessary
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Failure of body control module Check electrical connections
Refer to the body diagnostic manual for
additional checks
Replace BCM if necessary
Failure of key fob Replace key fob battery
Replace key fob if necessary
Failure of sliding door control module Disconnect then reconnect battery to reset
module, function door, if no function exists
check for loose wire connections, see Body
Diagnostic Manual for detailed procedures
Failure of door motor assembly Check for foreign matter preventing the
operation of gear motor assembly
Check wire connections
Gear motor clutch does not engage,
replace assembly
Full open switch inoperative, replace hold
open latch assembly
Replace motor assembly. if necessary
Door does not stay open Failure of hold open latch assembly Check wire/cable connections
Replace hold open latch, if necessary
Failure of hold open latch striker Replace hold open latch striker, if
necessary
High inside/outside opening
effortFailure of latch assembly Check wire connections and for blown fuse
Check cable connections
RSPOWER SLIDING DOOR SYSTEM8N-25
POWER SLIDING DOOR SYSTEM (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
Failure of inside/outside handle
assemblyGo to that9POSSIBLE CAUSE9and review
9CORRECTIONS9
Binding or sticking of components Establish location of binding and replace
necessary components
Door continues to cinch
closed during power modeFailure of latch assembly Check wire connections and for blown fuse
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
Failure of sliding door control or
body control moduleDisconnect then reconnect battery to reset
module, function door, if no function exists
check for loose wire connections, see Body
Diagnostic Manual for detailed procedures
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Door continues to open
during power mode
(runaway motor)Failure of sliding door control or
body control moduleDisconnect then reconnect battery to reset
module, function door, if no function exists
check for loose wire connections, see Body
Diagnostic Manual for detailed procedures
Failure of hold open latch assembly Check wire/cable connections
Replace hold open latch, if necessary
Failure of drive assembly Remove lower drive unit and check for no
drive condition
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Door opens very slowly Failure of door motor assembly Check wire/cable connections
Replace motor assembly, if necessary
Binding or sticking of components Establish location of binding and replace
necessary components
Squeaks, Noises and rattles Foreign material in door
compartmentRemove foreign material
Loose components Check and tighten loose components
Poor door track lubrication Lubricate the front portions of the side door
tracks with9Door EaseT9or equivalent
8N - 26 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)
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Use a known good vehicle for side door comparison
data. Refer to the Side Door Adjustment procedure in
the Body section of the service manual for detailed
instructions.
LATCH
DESCRIPTION
Vehicles equipped with a power side door or doors
utilize a power latch. One power latch is used for
each power door. The latch is located on the trailing
edge of the side door assembly (Fig. 5). This power
latch assembly is comprised of many different compo-
nents which have the ability to perform the power
cinch, release, lock, unlock and safety related opera-
tions. These components are the door latch, lock/un-
lock actuator, cinch/release actuator and child
lockout, pawl, ratchet and handle switches. The pawl
and ratchet switches are used to indicate the primary
and secondary latched positions. The cinch latch also
provides a connection point for the interior handle,
exterior handle and hold open latch cables.
The power latch is a replaceable component. Con-
sult your Mopar parts catalog for specific part num-
bers.
OPERATION
The power latch performs the same operation as a
full manual door latch as well as power cinch,
release, lock and unlock operations. The power latch
mounted actuator cinches the door closed and latches
it in its primary latched position. During a power
close cycle, the power cinch actuator will not operate
until the side door has reached its secondary latch
position (determined by pawl and ratchet switches).
During a power open cycle, the power release actua-
tor will stop once the side door has moved from pri-
mary latch position.
The power latch uses inputs from the lock/unlock
actuator, power side door control module and child
lockout, pawl, ratchet and handle switches to provide
safe power cinch and release operations. Refer to
Power Side Door Operation for additional informa-
tion.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate side door trim panel.
Refer to the Body section for the procedure.
(3) Remove the weather shield if necessary. Refer
to the Body section for the procedure.
(4) Open the side door all the way and remove the
door latch retaining bolts (Fig. 6).
Fig. 5 Removing/Installing Power Latch in Sliding
Door
1 - Power Latch Assembly
Fig. 6 Removing Latch Retaining Bolts
1 - Latch Retaining Bolts
2 - Side Door
8N - 28 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)
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(5) Partially close the door and pull the latch
assembly out of the side door inner panel.
(6) Disconnect all electrical connectors leading to
the latch assembly.
(7) Disconnect the inside and outside handle cables
from the latch assembly. Refer to the Body Section of
the service manual for the procedure.
(8) Disconnect the hold open latch cable from the
latch assembly. Refer to the Body Section of the ser-
vice manual for the procedure.
(9) Disconnect lock actuator link rod from the
latch assembly.
(10) Remove the latch assembly from the vehicle.
INSTALLATION
(1) Position the latch assembly in the vehicle. Be
certain all latch mounted components are installed
on the replacement latch assembly. If not, transfer
components from the old latch to the new latch
assembly.
(2) Connect the lock actuator link rod on the latch
assembly.
(3) Connect the hold open latch cable on the latch
assembly. Refer to the procedure in this section for
detailed instructions.
(4) Connect the inside and outside handle cables
on the latch assembly. Refer to the procedure in the
Body section for detailed instructions.
(5) Connect all electrical connectors leading to the
latch assembly.
(6) With assistance from another person, position
the side door and install the door latch retaining
bolts. Torque to 10 - 12 N´m (100 in. lbs.).
(7) Install the weathershield if necessary. Refer to
the procedure in the Body section for detailed
instructions.
(8) Install the appropriate side door trim panel.
Refer to the procedure in the Body section for
detailed instructions.
(9) Connect the negative battery cable.
SLIDING DOOR MOTOR
DESCRIPTION
Vehicles equipped with a power sliding door utilize
a door motor assembly. The door motor is located in
the center of the side door (Fig. 7) and is comprised
of three parts. The three parts of the door motor
assembly are the motor, gear reduction and clutch
assembly. The door motor assembly provides the
power and torque to move the sliding door from the
open/closed position to full closed/open position, after
the power latching mechanism has released.
Special wellnuts and screws are used in the side
door inner panel to retain the door motor to the doorpanel. Refer to Standard Procedures in this section
for additional wellnut information.
The door motor is replaced as a complete assembly,
which includes the DC motor, gear reduction and
clutch assemblies. Consult your Mopar parts catalog
for specific part numbers.
OPERATION
With the push of a Power Side Door (PSD) com-
mand switch, the PSD control module will signal the
latch assembly to release the door from its primary
locked position. The drive motor will then take over
to provide the power to open the door to its full open
or closed position. The gear reduction portion of the
motor assembly reduces the speed of the motor from
5800 to 260 rpm and also increases the torque to the
lower drive unit. The clutch portion of the motor
assembly engages the motor to drive the door under
power and disengages it so the door can be moved
easily under manual operation.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
Fig. 7 Side Door Components
1 - Sliding Door Control Module
2 - Module Retaining Screw
3 - Module Electrical Connectors
4 - Door Motor Assembly
5 - Flex Drive Assembly
6 - Door Motor Retaining Fasteners
7 - Door Motor Electrical Connector
RSPOWER SLIDING DOOR SYSTEM8N-29
LATCH (Continued)
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(2) Remove the door trim panel from the appropri-
ate side door. Refer to the Body section for the pro-
cedure.
(3) Remove water shield as necessary to gain
access to motor assembly.
(4) Remove retaining clip holding flex drive assem-
bly to the motor (Fig. 8). Pull flex drive cable straight
out of the motor assembly.
(5) Disconnect door motor electrical connector.
(6) Remove the 4 screws holding the motor to the
inner door panel.
(7) Remove the motor assembly from the vehicle.
INSTALLATION
(1) Position the motor assembly on the door inner
panel.
(2) Install the 4 screws holding the motor to the
inner door panel. Torque to 35 in. lbs.
(3) Install the flex shaft by lining up the square
shaped drive shaft with corresponding hole in motor
drive unit and push straight in.
(4) Install the E-clip to secure flex-shaft.
(5) Connect the negative battery cable.
(6) Install the weather shield. Refer to the Body
section of the service manual for the procedure.
(7) Install the door trim panel on the side door.
Refer to Body for the procedure.
FULL OPEN SWITCH
DESCRIPTION
Vehicles equipped with a power sliding door utilize
a full open switch. This switch is located in the hold
open latch (Fig. 9) under the side door lower hinge.
When the power side door module receives a ground
signal input from the full open switch, and as long as
the cinching latch actuator is not in power mode or
the handle switch is open, the signal indicates that
the door is at the full open position.
The full open switch is incorporated into the hold
open latch. If the full open switch proves faulty, the
entire hold open latch assembly must be replaced.
OPERATION
The full open switch is triggered by a pawl lever in
the hold open latch. When the full open switch is
closed (circuit to ground) the ratchet has engaged on
the hold open striker and the pawl lever has engaged
on the ratchet, locking the latch from opening and
holding the door in the full open position.
Fig. 8 Flex Drive Retaining Clip
1 - Flex Drive Cable Retaining Clip
2 - Flex Drive Cable
3 - Side Door Motor Assembly
Fig. 9 Full Open Switch Position & Orientation
1 - Hold Open Latch Assembly
2 - Hold Open Latch Cable
3 - Full Open Switch
8N - 30 POWER SLIDING DOOR SYSTEMRS
SLIDING DOOR MOTOR (Continued)
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