2002 CHRYSLER CARAVAN Service Manual

auxiliary battery location battery capacity warning light air suspension child lock run flat

Page 545 of 2399

CHRYSLER CARAVAN 2002 Service Manual The power liftgate system is designed with a num-
ber of system inhibitors. These inhibitors are neces-
sary for safety and / or feasibility of the power
liftgate system. Refer to power liftgate syste

The power liftgate system is designed with a num-
ber of system inhibitors. These inhibitors are neces-
sary for safety and / or feasibility of the power
liftgate system. Refer to power liftgate system inhib-
itors noted below:
POWER LIFTGATE SYSTEM INHIBITORS
²The Power Liftgate may not operate in extreme
temperatures. These extreme temperatures will be
approximately -12É F (-24.4É C) on the low side and
143É F (61.6É C) for the high side. A chime/thermister
assembly in the rear light bar assembly monitors the
outside temperature.
²The vehicles transmission must be in park or
neutral for the power liftgate to start a cycle.
²If multiple obstacles are detected during the
same power open or close cycle the liftgate goes into
manual operation.
²If severe Diagnostic Trouble Codes (DTC) are
stored in the power liftgate control module.
POWER LIFTGATE SYSTEM CAUTIONS AND
WARNINGS
WARNING: ALWAYS DISCONNECT THE NEGATIVE
BATTERY CABLE BEFORE ATTEMPTING ANY
POWER LIFTGATE SYSTEM SERVICE.
WARNING: THERE IS A SMALL AREA ON BOTH
SIDES OF THE LOWER POWER LIFTGATE WHICH
ARE NOT PROTECTED BY PINCH SENSORS.
EXTREME CARE MUST BE TAKEN TO PREVENT
OBJECTS FROM ENTERING THIS AREA ONCE THE
LIFTGATE REACHES THE SECONDARY LATCH
CONTACT (APPROXIMATELY 1/2 INCH BEFORE
FULLY CLOSED).
WARNING: NEVER ATTEMPT TO ENTER OR EXIT
THE VEHICLE WITH THE LIFTGATE IN MOTION.
YOU COULD DAMAGE THE POWER LIFTGATE SYS-TEM AND/OR COMPONENTS AND/OR CAUSE PER-
SONAL INJURY.
WARNING: NEVER STICK OBJECTS IN THE POWER
LIFTGATE WHEN CINCHING CLOSED. YOU COULD
DAMAGE THE VEHICLE, POWER LIFTGATE SYS-
TEM COMPONENTS AND/OR CAUSE PERSONAL
INJURY.
DIAGNOSIS AND TESTING - POWER LIFTGATE
SYSTEM
The power opening and closing power liftgate sys-
tem is a complex system containing many compo-
nents and modules. In order to obtain conclusive
testing the Programmable Communications Interface
(J1850) data bus network and all of the electronic
modules that provide inputs to, or receive outputs
from the power liftgate system must be checked.
The power liftgate system was designed to be diag-
nosed with an appropriate diagnostic scan tool, such
as the DRB IIIt. The most reliable, efficient, and
accurate means to diagnose the power liftgate system
requires the use of a DRB IIItscan tool and the
proper Body Diagnostic Procedures manual. The
DRB IIItcan be used to observe various switch sta-
tuses throughout the power liftgate system to help
the technician diagnose a defective switch or compo-
nent. The DRB IIItcan also be used to actuate var-
ious components throughout the power liftgate
system to help the technician diagnose a defective
component.
Before any testing of the power liftgate system is
attempted, the battery should be fully charged, all
built-in power liftgate system inhibitors read and
understood (Refer to power liftgate system operation)
and all wire harness and ground connections
inspected around the affected areas on the vehicle.
Following are quick reference diagnostic tables to
help when diagnosing and testing the power liftgate
system.
8N - 4 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)
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CHRYSLER CARAVAN 2002 Service Manual LIFTGATE SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
Liftgate opens unexpectedly Failure of Power Liftgate or Body
Control moduleDisconnect then reconnect battery to reset
module, function l

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CHRYSLER CARAVAN 2002 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
Binding or sticking of components Establish location of binding and replace
necessary components
Wiring problems (system or vehicle) Troubleshoot using electrical

CONDITION POSSIBLE CAUSES CORRECTION
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 Liftgate
operationWiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Low battery voltage Charge battery
Failure of Power Liftgate or Body
Control ModuleDisconnect then reconnect battery to reset
module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Failure of motor assembly Check for no drive condition
No power latching in
primary and/or secondary
positionsFailure 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
Binding or sticking of components Establish location of binding and replace
necessary components
Failure of Power Liftgate or Body
Control ModuleDisconnect then reconnect battery to reset
module, function liftgate, 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 or other possible obstruction
Failure of motor assembly Check for no drive condition
Latch will not fully release
from primary positionFailure of latch assembly Check wire connections and for blown fuse
Check for foreign matter or damaged
components preventing the operation of
latch assembly
Troubleshoot using body electrical
troubleshooting manual Replace latch
assembly, if necessary
Failure of outside handle switch Troubleshoot using Body Diagnostic
Manual Replace switch, if necessary
Failure of Power Liftgate or Body
Control ModuleDisconnect then reconnect battery to reset
module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Binding or sticking of components Establish location of binding and replace
necessary components
8N - 6 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)
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CHRYSLER CARAVAN 2002 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
Key fob, Outside Handle or
overhead console switches
do not power operate
liftgateBlown Fuse Check fuse and replace
Battery voltage low Charge or replace battery i

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CHRYSLER CARAVAN 2002 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
Liftgate continues to cinch
closed during power modeFailure of latch assembly Check wire connections and for blown fuse
Check for foreign matter preventing the
ope

CONDITION POSSIBLE CAUSES CORRECTION
Liftgate 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 components, if necessary
Failure of Power Liftgate or Body
Control ModuleDisconnect then reconnect battery to reset
module, function liftgate, 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
Liftgate continues to open
during power mode
(runaway motor)Failure of Power Liftgate or Body
Control ModuleDisconnect then reconnect battery to reset
module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Failure of full open switch Check wire connections
Replace switch, if necessary
Failure of motor assembly Check for continuous drive condition
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to Wiring Diagrams
Liftgate opens very slowly Failure of liftgate motor assembly Check wire connections
Replace motor assembly, if necessary
Failure of liftgate prop rods Replace prop rods, if necessary
Binding or sticking of components Establish location of binding and replace
necessary components
Grade of vehicle too steep for power
operationOperate liftgate manually
Squeaks, Noises and rattles Foreign material in door
compartmentRemove foreign material
Loose components Check and tighten loose components
STANDARD PROCEDURE
STANDARD PROCEDURE - LIFTGATE
ADJUSTMENT
In order for the power liftgate system to function
properly the liftgate must move freely and smoothly.
The power liftgate system can acommodate for some
minor changes in the effort required to move the lift-
gate. However, in extreme conditions the liftgate may
need to be mechanicaly adjusted for proper fit and
finish. Refer to the Liftgate Adjustment procedure in
the Body section of the service manual for detailed
instructions.If a problem exists with the power liftgate and it is
suspected to be extreme effort check the liftgate prop
rods and hinges for free movement. Use a known
good vehicle for liftgate effort comparison.
NOTE: Routine application of Mopar MP-50Tor
equivalent on the chrome prop rod shafts and lift-
gate latch and hinges will help keep the liftgate in
good working order.
8N - 8 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)
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CHRYSLER CARAVAN 2002 Service Manual STANDARD PROCEDURE - POWER LIFTGATE
LEARN CYCLE
Any time a power liftgate component is removed,
replaced or a liftgate adjustment is performed a learn
cycle must be performed. This learn cycle enables

STANDARD PROCEDURE - POWER LIFTGATE
LEARN CYCLE
Any time a power liftgate component is removed,
replaced or a liftgate adjustment is performed a learn
cycle must be performed. This learn cycle enables the
power liftgate control module to learn or relearn
information (travel limits, resistance to door travel,
etc.) which allows it to perform properly and safely.
To perform a learn cycle do the following:
(1) Obtain a DRB IIItscan tool.
(2) Connect the DRB IIItto the vehicle and check
for any power liftgate system stored trouble codes,
correct and erase any stored codes.
(3) Using the DRB IIIt, Go into Test Routine
Menu and select the power open command.
(4) Select the power close command.
(5) The liftgate learn cycle is complete.
If a DRB IIItscan tool is not available the learn
cycle can be performed by actuating the liftgate by
using any of the normal command switches. Be cer-
tain to cycle the liftgate through a complete open and
close cycle before returning the vehicle to service.
NOTE: If the power liftgate will not complete a full
cycle a problem exists with the power liftgate sys-
tem. (Refer to 8 - ELECTRICAL/POWER DOORS -
DIAGNOSIS AND TESTING).
PINCH SENSOR
DESCRIPTION
Vehicles equipped with a power liftgate utilize two
pinch sensors, one is located on each side of the lift-
gate (Fig. 4). These sensors look like weather-strips,
however they consist of pieces of electrically conduc-
tive rubber (tapeswitch), wires, resistor, double sided
tape, and a plastic carrier. They are used to indicate
an obstruction during a power close cycle.
OPERATION
During a power liftgate close cycle, if either of the
two conductive rubber strips (tapeswitch) of the
pinch sensor come in contact with an obstacle, the
pinch sensor circuit is completed. This tells the
power liftgate control module that a obstruction is
felt. The control module will stop the liftgate imme-
diately and return it to the full open position.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove trim panel from liftgate. Refer to Body
for the procedure.(3) Disconnect the pinch sensor wire harness con-
nector (Fig. 4).
(4) Remove screws holding the pinch sensor to lift-
gate.
(5) Feed the pinch sensor wire harness out of the
liftgate and remove the sensor from the vehicle.
INSTALLATION
(1) Position the pinch sensor and install screws
holding the sensor to the liftgate. Torque screws to
25 in. lbs.
(2) Install wire harness grommet in liftgate flange
and route, connect the pinch sensor wire harness
connector.
(3) Install the trim panel on the liftgate. Refer to
the Body section for the procedure.
(4) Connect the negative battery cable.
(5) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes related to the pinch sensor.
(6) Verify power liftgate system and pinch sensor
operation. Cycle the power liftgate through one com-
plete open and close cycle, during the final close cycle
press the pinch sensor to verify the power liftgate
detects an obstruction and returns to the full open
position.
Fig. 4 PINCH SENSOR LOCATION
1 - LIFTGATE
2 - PINCH SENSOR ASSEMBLY
3 - POWER LIFTGATE LINK ROD
4 - PINCH SENSOR WIRE HARNESS CONNECTOR
5 - PINCH SENSOR WIRE HARNESS
RSPOWER LIFTGATE SYSTEM8N-9
POWER LIFTGATE SYSTEM (Continued)
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CHRYSLER CARAVAN 2002 Service Manual WARNING: USE EXTREME CAUTION WHEN TEST-
ING PINCH SENSOR OPERATION.
FULL OPEN SWITCH
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
full open switch. This switch is located on the gear

WARNING: USE EXTREME CAUTION WHEN TEST-
ING PINCH SENSOR OPERATION.
FULL OPEN SWITCH
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
full open switch. This switch is located on the gear
motor housing (Fig. 5) and is used to signal the
power liftgate module when the liftgate is in the full
open position. Two wires are used from the full open
switch contacts to the gear motor assemblies main
electrical connector.
The full open switch is a serviceable component.
Consult your Mopar parts catalog for a specific part
number.
OPERATION
When the power liftgate reaches the full open posi-
tion, the gear motor housing mounted full open
switch electrical contacts come in contact with each
other. This sends a ground signal to the power lift-
gate control module, telling the module that the lift-
gate has reached the full open position.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.(2) Remove the lift gear and link rod assembly
from the vehicle(Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - REMOVAL).
(3) Cut the two wires leading to the full open
switch or back the wires out of the electrical connec-
tor (Fig. 5). Refer to the Wiring section of the service
manual for detailed instructions.
(4) Remove the full open switch retaining screw
and remove the full open switch from the gear motor
housing assembly.
INSTALLATION
(1) Perform a wiring repair on the full open switch
wires following the approved procedure in the Wiring
section of the service manual. Or install new termi-
nals on the wire ends and reinstall in the main lift-
gate motor electrical connector.
(2) Position and install the full open switch retain-
ing screw.
(3) Install the power liftgate lift gear and link rod
assembly. (Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - INSTALLATION)
(4) Connect the negative battery cable.
(5) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
(6) Verify power liftgate system and full open
switch 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.
LIFTGATE MOTOR
DESCRIPTION
Vehicles equipped with a power liftgate, utilize a
liftgate gear motor assembly (Fig. 6). The gear motor
assembly consists of a DC motor, hall effect sensor,
engage actuator, full open switch, lift gear, aluminum
housing, drive gears and wire harness. The gears and
motor portion of the assembly provides the power
and torque required to open or close the liftgate
under the worst case conditions. The hall effect sen-
sor is used to provide the liftgate control module with
a speed reading, which is used to monitor the resis-
tance of liftgate travel. This speed reading also
allows the power liftgate control module to detect
obstructions and move the liftgate accordingly. The
engage actuator is used to toggle between power
open/close mode and full manual mode when desired.
The full open switch is used to let the power liftgate
control module know when the liftgate is approach-
ing the full open position.
Fig. 5 FULL OPEN SWITCH LOCATION
1 - FULL OPEN SWITCH
2 - GEAR MOTOR ASSEMBLY RETAINING BOLT (1 OF 3)
8N - 10 POWER LIFTGATE SYSTEMRS
PINCH SENSOR (Continued)
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Page 552 of 2399

CHRYSLER CARAVAN 2002 Service Manual Serviceable components of the power liftgate gear
motor assembly are the complete gear motor assem-
bly, motor and wire harness, lift gear and control rod,
engage actuator, full open switch and the tr

Serviceable components of the power liftgate gear
motor assembly are the complete gear motor assem-
bly, motor and wire harness, lift gear and control rod,
engage actuator, full open switch and the transverse
bracket. Refer to additional information in this group
for more component details.
OPERATION
With the push of a power liftgate command switch
(liftgate closed), the power liftgate control module
will signal the latch assembly to release the door
from its primary closed and latched position to the
released and movable position. The liftgate motor
mounted, engage actuator then engages the liftgate
motor assembly, which moves the liftgate into the
open position. The liftgate motor provides the torque
and power to move the door to its full open or closed
position(Refer to 8 - ELECTRICAL/POWER DOORS -
OPERATION) for additional information.
REMOVAL
The power liftgate motor can be serviced in two
different ways. The first of which is called out here,
the complete gear motor assembly. The second way
includes the motor, aluminum housing, drive gears
and wire harness assembly. To perform this service
procedure, use the following procedure to remove the
gear motor assembly from the vehicle. Then refer to
the other procedures called out this section to trans-fer the remaining components (engage actuator, full
open switch, transverse bracket and lift gear and
rod) to the replacement motor assembly.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the left rear D-pillar trim panel from
the vehicle. Refer to the Body section for the proce-
dure.
(3) Disconnect the wire harness connector from the
motor assembly (Fig. 6).
(4) Remove the two bolts from the motor housing
and the one bolt from the transverse mount bracket.
(5) Grab the liftgate motor assembly and lift
upward and out to unhook the motor assembly from
the D-pillar.
(6) Remove the liftgate motor assembly from the
vehicle.
INSTALLATION
(1) Using the motor housing tab, hook the liftgate
motor assembly on the D-pillar.
(2) Install the three motor assembly retaining
bolts. Torque the two rear most bolts first to 9.5 N´m
(85 in. lbs.). Torque the remaining bolt next to the
window actuator to 9.5 N´m (85 in. lbs.).
(3) Connect the liftgate motor assembly electrical
connector.
(4) Install the D-pillar trim panel on the vehicle.
Refer to Body for the procedure.
(5) Connect the negative battery cable.
(6) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes related to the door motor assembly.
(7) Verify power liftgate system 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.
ENGAGE ACTUATOR
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
power liftgate engage actuator (Fig. 7). The 12 volt
engage actuator provides the engagement and disen-
gagement of the liftgate gear motor to the lift gear by
way of an over center link, activated by a lever.
The engage actuator is a serviceable component
and cannot be repaired, if found to be faulty it must
be replaced.
OPERATION
The engage actuators normal position is disen-
gaged. When a power liftgate open or close command
is generated from any of the command switches, the
power liftgate control module signals the engage
Fig. 6 POWER LIFTGATE COMPONENTS
1 - POWER LIFTGATE GEAR MOTOR ASSEMBLY
2 - POWER LIFTGATE CONTROL MODULE
3 - ELECTRICAL GROUND LOCATION
RSPOWER LIFTGATE SYSTEM8N-11
LIFTGATE MOTOR (Continued)
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