2002 CHRYSLER CARAVAN transfer

(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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LEFT B-PILLAR SWITCH
DESCRIPTION
Vehicles equipped with power sliding side door/s
utilize B-pillar switches. These switches are located
on the interior of the vehicle, on the B-pillar trim
panels. These switches serve as an open and close
command switch for the appropriate power side door.
The B-pillar switches are replaceable. Consult your
Mopar parts catalog for a specific part number.
OPERATION
When the Pillar switch is depressed a signal is
sent to the Body Control Module (BCM), this signal
is then sent to the Power Sliding Door Module, tell-
ing it to start a power open or close cycle. The child
lockout feature must be disabled and the side door
must be unlocked in order for the Pillar switch to
function.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Using a trim stick or other small flat-bladed
pry tool, gently pry the leading upper edge of the
B-pillar switch away from the B-pillar trim.
(3) Once the upper edge is free from pillar trim,
rock the switch out of the switch opening.
(4) Disconnect the B-pillar switch electrical con-
nector. First, slide the connector lock away from the
switch then, depress connector retaining tab while
pulling straight apart.
(5) Remove the B-pillar switch from the vehicle.
INSTALLATION
(1) Connect the B-pillar switch electrical connector.
Slide connector lock toward the switch to lock in
place.
(2) Hook the lower edge of the B-pillar switch on
the B-pillar trim and then push the switch firmly
into position.
(3) Connect the negative battery cable.
RIGHT B-PILLAR SWITCH
DESCRIPTION
Vehicles equipped with power sliding side door/s
utilize B-pillar switches. These switches are located
on the interior of the vehicle, on the B-pillar trim
panels. These switches serve as an open and close
command switch for the appropriate power side door.
The B-pillar switches are replaceable. Consult your
Mopar parts catalog for a specific part number.
OPERATION
When the Pillar switch is depressed a signal is
sent to the Body Control Module (BCM), this signal
is then sent to the Power Sliding Door Module, tell-
ing it to start a power open or close cycle. The child
lockout feature must be disabled and the side door
must be unlocked in order for the Pillar switch to
function.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Using a trim stick or other small flat-bladed
pry tool, gently pry the leading upper edge of the
B-pillar switch away from the B-pillar trim.
(3) Once the upper edge is free from pillar trim,
rock the switch out of the switch opening.
(4) Disconnect the B-pillar switch electrical con-
nector. First, slide the connector lock away from the
switch then, depress connector retaining tab while
pulling straight apart.
(5) Remove the B-pillar switch from the vehicle.
INSTALLATION
(1) Connect the B-pillar switch electrical connector.
Slide connector lock toward the switch to lock in
place.
(2) Hook the lower edge of the B-pillar switch on
the B-pillar trim and then push the switch firmly
into position.
(3) Connect the negative battery cable.
LOWER DRIVE UNIT
DESCRIPTION
Vehicles equipped with a power sliding side door
utilize a lower drive unit. The lower drive unit is
located on the sliding door lower hinge assembly
(Fig. 10). This drive unit is used to transfer the lat-
eral rotation of the flex drive assembly into longitu-
dinal movement via the drive unit gear and door
track rack teeth (Fig. 10).
The lower drive unit is a replaceable component.
Consult your Mopar parts catalog for specific part
numbers.
OPERATION
During a power open or close cycle, the power drive
unit is driven by the flex drive assembly. The lower
drive units main gear engages the lower door tracks
rack teeth, this moves the side door assembly accord-
ingly.
RSPOWER SLIDING DOOR SYSTEM8N-31
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OPERATION
With one end of the flex drive attached to the door
motor and the other attached to the lower drive unit,
the flex drive transfers the power and torque from
the motor to the drive unit. A square shaped drive
cable, inside the flex drive assembly engages the
motor drive and rotates to move the door accordingly.
REMOVAL
(1) Disconnect and isolate the negative cable.
(2) Remove the side door trim panel from the vehi-
cle. Refer to the Body section for the procedure.
(3) Remove the weathershield. Refer to the Body
section for the procedure.
(4) Remove the E-clip from the flex drive assembly
(Fig. 19).
(5) Pull the flex drive straight out of the motor
assembly.
(6) Remove the lower drive unit cover retaining
screws and remove the cover (Fig. 20).
(7) Expand the flex drive collar, next to the lower
drive unit until the flex drive can be pulled straight
off the lower drive unit.
(8) Remove the flex drive assembly from the vehi-
cle.
INSTALLATION
(1) Position the flex drive assembly in the vehicle.
(2) Install the flex drive on the lower drive unit.
Push straight on until it snaps in place. It may be
necessary to rotate drive unit gear slightly until the
flex drive seats in place.
(3) Install the lower drive unit cover and retaining
screws.
(4) Install the flex drive in the motor assembly.
Line up the square shaped inner shaft and push
straight on (Fig. 21).
(5) Install the E-clip on the flex drive assembly
(Fig. 19).
(6) Install the weathershield. Refer to Body for the
procedure.
(7) Install the side door trim panel on the vehicle.
Refer to Body for the procedure.
(8) Connect the negative cable.
Fig. 19 Flex Drive E-Clip
1 - Flex Drive Cable Retaining Clip
2 - Flex Drive Cable
3 - Side Door Motor Assembly
Fig. 20 Lower Hinge/Drive Assembly
1 - Lower Drive Unit Cover
2 - Lower Drive Unit Cover Retaining Screws
3 - Sliding Door
4 - Lower Hinge Arm Bracket
8N - 36 POWER SLIDING DOOR SYSTEMRS
FLEX DRIVE (Continued)
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PASSENGER AIRBAG
DESCRIPTION
WARNING: NEVER DISASSEMBLE THE PASSEN-
GER AIRBAG, THE PASSENGER AIRBAG HAS NO
SERVICEABLE PARTS.
The Passenger Airbag is located beneath the
instrument panel and pad assembly. The airbag is
mounted to the back side of the instrument panel
reinforcement.
The instrument panel top pad is the most visible
part of the passenger airbag system. Located under
the instrument panel top pad are the airbag door, the
passenger airbag cushion and the airbag cushion
supporting components.
The passenger airbag includes a magnesium hous-
ing within which the cushion and inflator are
mounted and sealed.
Following a passenger airbag deployment, the pas-
senger airbag and the instrument panel must be
replaced. The passenger airbag cannot be repaired,
and must be replaced if deployed or damaged in any
way.
OPERATION
The passenger airbag is equipped with two infla-
tors, each with three levels of pressure output. The
inflators seal the hole in the airbag cushion so it can
discharge the gas it produces directly into the cush-
ion when supplied with the proper electrical signal.
Following an airbag deployment, the airbag cushion
quickly deflates by venting this gas through the
cushion material towards the instrument panel.
The passenger airbag is secured with screws to the
instrument panel beneath the instrument panel top
pad and above the glove box opening. The instrument
panel top pad above the glove box opening conceals
the airbag door and a predetermined hinge line
beneath its decorative cover. Upon airbag deploy-
ment, the top pad will bend at the hinge line and the
door will fold back out of the way onto the top of the
instrument panel.
When the front airbag system is deployed, the fol-
lowingMUSTbe replaced:
²Complete Steering Column Assembly.
²Lower Steering Column Coupler.
²Steering Wheel.
²Clock Spring.
²Driver Airbag.
²Passenger Airbag.
²Upper Instrument Panel with Pad.
CARE OF UNDEPLOYED AIRBAGS
Airbags must be stored in their original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag. When carrying or handling an
undeployed airbag, the trim side of the airbag should
be pointing away from the body to minimize possibil-
ity of injury if accidental deployment occurs. Do not
place undeployed airbag face down on a solid surface,
the airbag will propel into the air if accidental
deployment occurs.
STANDARD PROCEDURE - CLEAN UP
Roll or fold the passenger airbag towards the
instrument panel surface and close the door over the
folded bag. Then tape the door shut.
Use a vacuum cleaner to remove any residual pow-
der from the vehicle interior. Work from the outside
in to avoid kneeling or sitting in a contaminated
area. Vacuum the heater and A/C outlets as well. If
HVAC was in RECIRC mode at time of airbag
deployment, operate HVAC blower on low speed/heat
and vacuum powder residue expelled from the heat
outlets. Multiple vacuum cleaning may be necessary
to decontaminate the interior of the vehicle.
REMOVAL
DEPLOYED AIRBAG
(1) Clean powder residue from interior of vehicle.
Refer to Electrical, Restraints, Passenger Airbag,
Standard Procedure - Passenger Airbag Clean Up.
(2) Remove instrument panel. Refer to Body,
Instrument Panel, Removal.
(3) Remove all reusable components from the
upper instrument panel and transfer to the new
instrument panel.
UNDEPLOYED AIRBAG
(1) Remove instrument panel. Refer to Body,
Instrument Panel, Removal.
(2) De-trim the instrument panel enough to gain
access to the passenger airbag fasteners.
(3) Disconnect yellow wire connector from passen-
ger airbag.
(4) Remove three bolts to the passenger airbag.
(5) Remove airbag from instrument panel through
rear of instrument panel.
INSTALLATION
DEPLOYED AIRBAG
Transfer all reusable components to the new
instrument panel.
(1) Install new Passenger Airbag into instrument
panel.
8O - 6 RESTRAINTSRS
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(4) Depress lock tabs holding speed control and
throttle cable casing to cable mount bracket.
(5) Disconnect vacuum line from speed control
servo that leads to the battery tray/vacuum reservoir.
(6) Remove battery tray/vacuum reservoir, refer to
the Battery section for more information (Fig. 3).
(7) Remove speed control servo and bracket (Fig.
4).
(8) Disconnect wire connector from speed control
servo.
(9) Remove speed control servo.
INSTALLATION
Transfer speed control cable to replacement speed
control servo.(1) Install retaining clip to cable at servo.
(2) Install 2 nuts at cable to servo and servo
bracket, tighten to 7 N´m (60 ins. lbs.).
(3) Connect electrical connector to servo.
(4) Connect vacuum line to speed control servo
that leads to the battery tray/vacuum reservoir.
(5) Install speed control servo and bracket.
(6) Install battery tray/vacuum reservoir, refer to
the Battery section for more information.
(7) Install speed control and throttle cable casing
to cable mount bracket.
(8) Connect the throttle and speed control cable
ends to throttle body.
(9) Connect the negative battery cable.
SWITCH
DESCRIPTION
There are two separate switch pods that operate
the speed control system and are located on the
steering wheel.
OPERATION
The speed control system has five separate resis-
tive switches that provide a single multiplexed
(MUX) voltage inputs to the PCM.The switch names
are: ON, OFF, SET, COAST, RESUME, ACCEL, TAP-
UP, COAST, and CANCEL. Based on conditions when
the buttons are pushed (and released), the five volt-
ages ranges provided to the PCM result in the follow-
ing functions: ON, OFF, SET, COAST, RESUME,
ACCEL, TAP-UP, TAP-DOWN, COAST, and CAN-
CEL. Refer to the Speed Control Section for more
information
Also the PCM receives an input from the brake
switch to sense whether the brake pedal has been
depressed. When the PCM receives the brake
depressed input, it turns off power to the speed con-
trol servo and disengages speed control. Also the
power to the servo is supplied through the brake
switch, which opens the circuit when the brake pedal
is depressed.
The individual switches cannot be repaired. If one
switch fails, the entire switch module must be
replaced.
REMOVAL
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) Remove the negative battery cable.
Fig. 3 BATTERY TRAY/VACUUM RESERVOIR
Fig. 4 SPEED CONTROL SERVO
RSSPEED CONTROL8P-5
SERVO (Continued)
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DESCRIPTION - CIRCUIT FUNCTIONS
All circuits in the diagrams use an alpha/numeric
code to identify the wire and it's function. To identify
which circuit code applies to a system, refer to the
Circuit Identification Code Chart. This chart shows
the main circuits only and does not show the second-
ary codes that may apply to some models.
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION
CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS
(GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL
MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY
FEED)
Q POWER OPTIONS (IGNITION
FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/
TRANSFER CASE
U OPEN
V SPEED CONTROL, WIPER/
WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
DESCRIPTION - SECTION IDENTIFICATION AND
INFORMATION
The wiring diagrams are grouped into individual
sections. If a component is most likely found in a par-
ticular group, it will be shown complete (all wires,
connectors, and pins) within that group. For exam-
ple, the Auto Shutdown Relay is most likely to be
found in Group 30, so it is shown there complete. It
can, however, be shown partially in another group if
it contains some associated wiring.
Splice diagrams in Section 8W-70 show the entire
splice and provide references to other sections the
splices serves. Section 8W-70 only contains splice dia-
grams that are not shown in their entirety some-
where else in the wiring diagrams.
Section 8W-80 shows each connector and the cir-
cuits involved with that connector. The connectors
are identified using the name/number on the dia-
gram pages.
WIRING SECTION CHART
GROUP TOPIC
8W-01 thru
8W-09General information and Diagram
Overview
8W-10 thru
8W-19Main Sources of Power and
Vehicle Grounding
8W-20 thru
8W-29Starting and Charging
8W-30 thru
8W-39Powertrain/Drivetrain Systems
8W-40 thru
8W-49Body Electrical items and A/C
8W-50 thru
8W-59Exterior Lighting, Wipers and
Trailer Tow
8W-60 thru
8W-69Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-91 Connector, Ground and Splice
Locations
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATIONRS
WIRING DIAGRAM INFORMATION (Continued)
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(4) Tighten the bolts to 27 N´m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn)Do not use a torque
wrench for last step.
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 45). Refer to clearance specifications
(Refer to 9 - ENGINE - SPECIFICATIONS).
CRANKSHAFT
DESCRIPTION
The crankshaft is made of nodular cast iron and
includes five main bearing journals and four connect-
ing rod journals (Fig. 46). The number three journal
is the location for the thrust bearing. The mains and
connecting rod journals have undercut fillet radiuses
that are rolled for added strength. To optimize bear-
ing loading, eight counterweights are used.
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder to the flywheel or flex-
plate.
STANDARD PROCEDURE - CRANKSHAFT END
PLAY
(1) Using Dial Indicator C-3339 and Mounting
Post L-4438, attach to front of engine, locating probe
perpendicular on nose of crankshaft (Fig. 47).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Engine Specifica-
tions.
REMOVAL
NOTE: Crankshaft can not be removed when engine
is in vehicle.(1) Remove engine assembly from vehicle. (Refer to
9 - ENGINE - REMOVAL)
(2) Separate engine from transaxle.
(3) Remove flex plate and crankshaft rear oil seal.
(4) Mount engine on a repair stand.
(5) Drain engine oil and remove oil filter.
(6) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(7) Remove engine mount support bracket.
(8) Remove the crankshaft damper and timing belt
covers. (Refer to 9 - ENGINE/VALVE TIMING/TIM-
ING BELT / CHAIN COVER(S) - REMOVAL)
(9) Remove the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
Fig. 45 Connecting Rod Side Clearance
Fig. 46 Crankshaft - Typical
1 - MAIN BEARING JOURNALS
2 - COUNTER BALANCE WEIGHTS
Fig. 47 CHECKING CRANKSHAFT END PLAY
9 - 38 ENGINE 2.4LRS
CONNECTING ROD BEARINGS (Continued)
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(33)AWD equipped:Remove the power transfer
unit (PTU) (Refer to 21 - TRANSMISSION/TRANS-
AXLE/POWER TRANSFER UNIT - REMOVAL).
(34) Disconnect exhaust pipe from the manifold
(Fig. 7).
(35) Remove front engine mount and bracket as an
assembly.
(36) Remove the engine rear mount bracket.
(37) Remove the engine to transaxle struts (Fig. 8).
(38) Remove transaxle case cover (Fig. 8).
(39) Remove flex plate to torque converter bolts.
Mark torque converter to flex plate for orientation for
reassembly.
(40) Remove the power steering pressure hose sup-
port clip attaching bolt.
(41) Disconnect the knock sensor electrical connec-
tor (3.8L only).(42) Disconnect the engine block heater electrical
connector (if equipped).
(43) Remove the accessory belt splash shield.
(44) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(45) Disconnect the radiator lower hose.
(46) Remove air conditioning compressor from
engine.
(47) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
Fig. 7 Catalytic Converter to Exhaust Manifold
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
Fig. 8 POWERTRAIN SUPPORTS AND DUST COVER
1 - BRACKET - ENGINE REAR MOUNT
2 - BOLT - TRANSAXLE CASE COVER
3 - STRUT - TRANSAXLE TO ENGINE HORIZONTAL
4 - BOLT - HORIZONTAL STRUT
5 - BOLT - STRUT TO TRANSAXLE
6 - COVER - TRANSAXLE CASE LOWER
7 - STRUT - TRANSAXLE TO ENGINE
8 - BOLT - STRUT TO ENGINE
9 - BOLT - ENGINE REAR MOUNT BRACKET
9 - 88 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
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