2002 CHRYSLER CARAVAN Service Manual

fog light bulb battery tire pressure boot power steering oil level

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CHRYSLER CARAVAN 2002 Service Manual actuator to move its lever to the engaged position.
This engages the gear motor to the lift gear, so when
the motor turns the lift gate moves upward or down-
wards depending on its current position.
D

actuator to move its lever to the engaged position.
This engages the gear motor to the lift gear, so when
the motor turns the lift gate moves upward or down-
wards depending on its current position.
During a manual liftgate open or close cycle the
engage actuator is disengaged, allowing unrestricted
liftgate movement.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the left rear D-pillar trim from the
vehicle. Refer to Body for the procedure.
(3) Using your hand manually engage the actuator
link rod, this must be done to access one of the
engage actuator retaining screws.
(4) Remove the two engage actuator retaining
screws (Fig. 8).
(5) Disconnect the engage actuator electrical con-
nector and remove the engage actuator from the
vehicle.
INSTALLATION
(1) Position the engage actuator and connect the
engage actuator electrical connector.
(2) Install the two engage actuator retaining
screws.
(3) Manually disengage the actuator.(4) Install the left rear D-pillar trim on the vehi-
cle. Refer to Body for the procedure.
(5) Connect the negative battery cable.
(6) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes.
(7) Verify power liftgate system and engage actua-
tor operation. Cycle the power liftgate through one
complete open and close cycle.
TRANSVERSE BRACKET
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
transverse bracket (Fig. 9). This bracket is not differ-
ent than any other metal bracket which is used to
support and secure the power liftgate gear motor
assembly to the vehicles left rear body D-pillar.
The transverse bracket is a serviceable power lift-
gate component. Consult your MoparŸ parts catalog
for a specific part number.
OPERATION
The power liftgate transverse bracket supports the
gear motor assembly by supplying an additional
attachment point. Located on the leading edge of the
gear motor assembly, one end of the transverse
bracket attaches to the motor assembly the other to
the leading edge of the vehicles D-pillar.
Fig. 7 LIFTGATE GEAR MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Fig. 8 LIFTGATE GEAR MOTOR ASSEMBLY
1 - ENGAGE ACTUATOR RETAINING SCREWS
2 - LIFT GEAR RETAINING BOLTS
8N - 12 POWER LIFTGATE SYSTEMRS
ENGAGE ACTUATOR (Continued)
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CHRYSLER CARAVAN 2002 Service Manual REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the left D-pillar trim from the vehicle.
Refer to Body for the procedure.
(3) Disconnect the gear motor assembly electrical
co

REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the left D-pillar trim from the vehicle.
Refer to Body for the procedure.
(3) Disconnect the gear motor assembly electrical
connector and disengage retaining pushpin.
(4) Loosen the gear motor assembly retaining bolts
to allow room for transverse bracket to be removed.
(5) Remove the transverse bracket retaining bolts
(Fig. 10).
(6) Remove the transverse bracket from the vehi-
cle.
INSTALLATION
(1) Position the transverse bracket in the vehicle.
Be certain the transverse bracket is properly posi-
tioned. The bracket should just touch the engage
actuator arm and be positioned between the actuator
arm and the motor housing.
(2) Torque the transverse bracket retaining bolts
to the gear motor assembly to 9.5 N´m (85 in. lbs.)..
Do not tighten the transverse bracket retaining bolt,
located under the window actuator at this time.
(3) Torque the gear motor assembly retaining bolts
to 9.5 N´m (85 in. lbs.)..
(4) Torque the final transverse bracket retaining
bolt to 9.5 N´m (85 in. lbs.).(5) Connect the gear motor assembly electrical con-
nector and engage retaining pushpin.
(6) Install the appropriate D-pillar trim from the
vehicle. Refer to Body for the procedure.
LIFT GEAR & LINK ROD
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
lift gear and rod assembly. This lift gear and rod
assembly are located in the left rear of the vehicle
and are visible without removing the D-pillar trim
(Fig. 10). The lift gear provides the leverage to move
the liftgate from the closed to the open position. The
lift gear attaches to a bearing on the gear motor
assembly with four bolts. On the outboard side of the
lift gear are rivited on teeth, which mesh with the
gear motor assembly drive gears during a open or
close operation. The rod assembly is a steel shaft,
equipped with two spherical rod ends which attaches
the lift gear to the liftgate.
The lift gear and rod assembly are serviceable com-
ponents. Consult your MoparŸ parts catalog for a
part number.
Fig. 9 LIFTGATE GEAR MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Fig. 10 LIFTGATE GEAR MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
RSPOWER LIFTGATE SYSTEM8N-13
TRANSVERSE BRACKET (Continued)
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CHRYSLER CARAVAN 2002 Service Manual OPERATION
One end of the rod assembly is attached to the lift-
gate, the other attached to the lift gear. When the lift
gear is driven by the gear motor assembly the lift-
gate is moved to the open or

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CHRYSLER CARAVAN 2002 Service Manual OPERATION
On the power cinch/release latch, the latch
mounted actuator provides the torque required to
close the power liftgate from the secondary to the pri-
mary closed and latched position. On the

OPERATION
On the power cinch/release latch, the latch
mounted actuator provides the torque required to
close the power liftgate from the secondary to the pri-
mary closed and latched position. On the power
cinch/release latch and the power release only latch,
the actuator releases the liftgate from the primary
closed and latched position to the fully unlatched and
movable position.
REMOVAL
(1) Open the hood, disconnect and isolate the neg-
ative battery cable.
(2) Open the liftgate and remove the liftgate trim
panel. Refer to Body for the procedure.
(3) Disconnect the power latch electrical connector
(Fig. 12).
(4) Remove the power latch retaining bolts.
(5) Disconnect the liftgate lock cylinder link rod
from the key cylinder or latch assembly. To discon-
nect from latch, rotate the plastic retaining clip 90 É
to unsnap clip from linkrod. Then pull link rod
straight out of latch arm.
INSTALLATION
(1) Connect the liftgate lock cylinder link rod on
the cinch latch assembly. Rotate the plastic retaining
clip 90 É to lock retaining clip on linkrod.
(2) Connect the link rod on the lock cylinder.
(3) Install the power latch retaining bolts. Torque
to 10 N´m (90 in. lbs.).
(4) Connect the power latch electrical connector
and secure push pin retainers.
(5) Connect the negative battery cable.
(6) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes related to the power latch.
(7) Verify power liftgate system and power cinch /
release latch 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.
(8) Verify power liftgate manual operation. Using
liftgate key rotate the lock cylinder to verify door
operation. Pull door open using exterior liftgate han-
dle / switch.
(9) Install the liftgate trim panel. Refer to Body for
the procedure.
LATCH ACTUATOR
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
power cinch latch or power release latch (Fig. 13).
The power cinch and/or power release is made possi-ble by a latch actuator attached to the leading edge
of the power latch assembly. This 12 volt latch actua-
tor contains a small drive gear that meshes with the
latch assemblies internal gears to perform the power
cinch close / power release operations. Refer to the
Latch assembly for more information.
The power cinch/release actuator is serviceable
component. Consult your MoparŸ parts catalog for
specific part numbers.
OPERATION
During a power close cycle, the power cinch actua-
tor provides the torque required to close the power
liftgate from the secondary to the primary closed and
latched position. During a power open cycle, the
power release actuator releases the liftgate from the
primary closed and latched position to the fully
unlatched and movable position.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Open the liftgate and remove the lower liftgate
trim panel. Refer to Body for the procedure.
(3) Disconnect the power latch electrical connector
(Fig. 13).
(4) Remove the three latch retaining bolts.
Fig. 13 POWER LATCH ORIENTATION
1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
RSPOWER LIFTGATE SYSTEM8N-15
LATCH (Continued)
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CHRYSLER CARAVAN 2002 Service Manual (5) Grab the latch assembly and unhook the key
cylinder link rod from the key cylinder (Fig. 13).
(6) Place the latch assembly on a bench and locate
the three wires leading from the actuator portion o

(5) Grab the latch assembly and unhook the key
cylinder link rod from the key cylinder (Fig. 13).
(6) Place the latch assembly on a bench and locate
the three wires leading from the actuator portion of
the latch assembly.
(7) Disengage the main connector retaining push
pins from the latch actuator housing.
(8) Back the three wires out of the main latch elec-
trical connector. Refer to the wiring section of the
service manual for detailed instructions.
(9) Flip the latch assembly over and remove the
latch actuator retaining screw(s).
(10) Remove the latch actuator from the latch
assembly.
INSTALLATION
(1) Install the latch actuator on the latch assem-
bly.
(2) Install the three latch actuator retaining
screws. Torque the screws to 4 in. lbs.
(3) Install the three wires in the main latch elec-
trical connector. Refer to the wiring section of the
service manual for detailed instructions.
NOTE: Be certain wires are reinstalled in the correct
wire cavities. Failure to do so could result in dam-
age to the latch actuator. Refer to Wiring Diagrams
if previous notes were not made.
(4) Secure the main connector retaining push pins
on the latch actuator housing.
(5) Grab the latch assembly and hook the key cyl-
inder link rod on the key cylinder.
(6) Position the latch and install the three latch
retaining bolts. Torque to 10 N´m (90 in. lbs.).
(7) Connect the power latch electrical connector.
(8) Install the lower liftgate trim panel. Refer to
Body for the procedure.
(9) Connect the negative battery cable.
EXTERIOR HANDLE SWITCH
DESCRIPTION
Vehicles equipped with a power liftgate or power
locks utilize a exterior handle switch. The exterior
handle switch is a electronic release switch mounted
to the rear license plate lamp housing assembly,
located just above the license plate. This switch con-
trols the power liftgate release function and is also
capable of reversing the power liftgate when it is in
motion. A full power open cycle cannot be performed
using this switch, only one of the power open com-
mand switches (key fob and overhead console
mounted) can be used to perform a full power open
cycle.The exterior handle switch is a serviceable compo-
nent. Consult your MoparŸ parts catalog for a spe-
cific part number.
OPERATION
When the exterior handle switch is depressed, with
the liftgate in the closed position. A message is sent
to the Body Control Module (BCM). The Body Con-
trol Module then sends a signal to the power liftgate
control module via the J1850 PCI data bus circuit.
The power liftgate control module then sends a sig-
nal to the power latch mounted actuator, which
moves the liftgate from the primary closed and
latched position to the open and movable position. If
the liftgate is not pulled open once the latch releases
within a few seconds, the latch will cinch closed
again.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Open the liftgate and remove the liftgate trim
panel. Refer to the Body section of the service man-
ual for the procedure.
(3) Remove the rear lamp bar assembly from the
vehicle. Refer to the Body section of the service man-
ual for the procedure.
(4) Locate the two wires going to the exterior han-
dle switch. Cut the tie strap and trace the wires to
the large electrical connector and back the wires out
of the large connector and through the grommet.
Refer to the Wiring section of the service manual for
detailed instructions.
(5) Depress the two exterior handle switch retain-
ing tabs and roll the switch out of the light bar
assembly (Fig. 14).
INSTALLATION
(1) Install the handle switch in the light bar
assembly.
(2) Locate the two wires going to the exterior han-
dle switch. Install the wires through the grommet
and in the large connector. Secure with a tie strap.
Refer to the Wiring section of the service manual for
detailed instructions.
NOTE: Be certain wires are reinstalled in the correct
wire cavities. Failure to do so could result in dam-
age to the handle switch. Refer to Wiring Diagrams
if previous notes were not made.
(3) Install the rear light bar. Refer to the Body sec-
tion of the service manual for the procedure.
(4) Install the liftgate trim panel. Refer to the
Body section of the service manual for the procedure.
(5) Connect the negative battery cable.
8N - 16 POWER LIFTGATE SYSTEMRS
LATCH ACTUATOR (Continued)
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CHRYSLER CARAVAN 2002 Service Manual (6) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
(7) Verify power liftgate system and handle switch
operation. Cycle the power liftgate t

(6) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
(7) Verify power liftgate system and handle switch
operation. Cycle the power liftgate through one com-
plete open and close cycle, this will allow the power
liftgate control module to relearn its cycle with the
new components.
CHIME/THERMISTOR
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
chime/thermistor assembly. The chime/thermistor
assembly is a small capacitor shaped electrical com-
ponent mounted to the rear license plate lamp hous-
ing assembly (Fig. 15) , located just above the license
plate. The chime portion of the assembly controls the
audible chime sound heard at the rear of the vehicle
when the power liftgate is in motion. The thermistor
portion of the assembly is a temperature sensor, used
by the power liftgate module.
The chime/thermistor assembly is a serviceable
component. Consult your MoparŸ parts catalog for a
specific part number.
OPERATION
The chime/thermistor assembly performs two dif-
ferent functions for the power liftgate system. First,
the chime portion provides an audible chime sound
which is controlled by the power liftgate module. Thechime/thermistor assembly is hardwired to the power
liftgate module. Second the thermistor provides a
outside temperature reading by way of a resistance
reading (V- ohms) supplied to the power liftgate
module. As temperature increases the resistance
reading (V- ohms) increases , as temperature
decreases the resistance reading (V- ohms)
decreases.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the rear light bar assembly from the
vehicle. Refer to Body for the procedure.
(3) Using your hands, grasp the light bar at its
sides next to thermistor/chime assembly and gently
pull the two sides of the light bar apart until the
thermistor/chime assembly can be removed.
INSTALLATION
(1) Gently pull the two sides of the light bar apart
until the thermistor/chime assembly can be installed.
(2) Install the rear light bar assembly on the vehi-
cle. Refer to the Body section of the service manual
for the procedure.
(3) Connect the negative battery cable.
Fig. 14 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
Fig. 15 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
RSPOWER LIFTGATE SYSTEM8N-17
EXTERIOR HANDLE SWITCH (Continued)
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CHRYSLER CARAVAN 2002 Service Manual POWER SLIDING DOOR SYSTEM
TABLE OF CONTENTS
page page
POWER SLIDING DOOR SYSTEM
DESCRIPTION.........................18
OPERATION...........................20
DIAGNOSIS AND TESTING - POWER SLIDING
DOOR

POWER SLIDING DOOR SYSTEM
TABLE OF CONTENTS
page page
POWER SLIDING DOOR SYSTEM
DESCRIPTION.........................18
OPERATION...........................20
DIAGNOSIS AND TESTING - POWER SLIDING
DOOR SYSTEM.......................21
STANDARD PROCEDURE
STANDARD PROCEDURE - WELLNUT
REPLACEMENT.......................27
STANDARD PROCEDURE - POWER DOOR
LEARN CYCLE.......................27
STANDARD PROCEDURE - SLIDING DOOR
ADJUSTMENT........................27
LATCH
DESCRIPTION.........................28
OPERATION...........................28
REMOVAL.............................28
INSTALLATION.........................29
SLIDING DOOR MOTOR
DESCRIPTION.........................29
OPERATION...........................29
REMOVAL.............................29
INSTALLATION.........................30
FULL OPEN SWITCH
DESCRIPTION.........................30
OPERATION...........................30
LEFT B-PILLAR SWITCH
DESCRIPTION.........................31
OPERATION...........................31
REMOVAL.............................31
INSTALLATION.........................31RIGHT B-PILLAR SWITCH
DESCRIPTION.........................31
OPERATION...........................31
REMOVAL.............................31
INSTALLATION.........................31
LOWER DRIVE UNIT
DESCRIPTION.........................31
OPERATION...........................31
REMOVAL.............................32
INSTALLATION.........................32
LOWER DRIVE UNIT TRACK & RACK
DESCRIPTION.........................33
OPERATION...........................33
REMOVAL.............................33
INSTALLATION.........................33
WIRING HARNESS
DESCRIPTION.........................34
OPERATION...........................34
REMOVAL.............................34
INSTALLATION.........................35
FLEX DRIVE
DESCRIPTION.........................35
OPERATION...........................36
REMOVAL.............................36
INSTALLATION.........................36
SLIDING DOOR MODULE
DESCRIPTION.........................37
OPERATION...........................37
REMOVAL.............................38
INSTALLATION.........................38
POWER SLIDING DOOR
SYSTEM
DESCRIPTION
Some vehicles are equipped with a power opening
and closing sliding door system (Fig. 1). Depending
on how the vehicle is ordered it may be equipped
with only a right side power door or right and left
side power doors. This power sliding door system is a
complex system consisting of many components.
Some of these components are the door motor, latch
assembly, sliding door control module, lower drive
unit, flex drive assembly, wire harness and track,
lower drive unit track and rack assembly, full open
switch, B-pillar switch, overhead console switch, key
fob switches (Fig. 2), pawl switch, ratchet switch and
child lockout and handle switches.Each power side door has its own door control mod-
ule, located in the center of the door behind the door
trim panel. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/DOOR CONTROL
MODULE - DESCRIPTION) The power side door
motor is located in the front portion of the door, on
the inner door panel sheet metal. The latch assembly
is located in the rear of the power side door, near the
body line. The lower drive unit is attached to the
lower door hinge. The flex drive assembly connects
the door motor to the lower drive unit. The wire har-
ness and track and the lower drive unit track are vis-
ible with the door open in the lower door sill area.
The power side door full open switch is located under
the lower drive unit and is part of the hold open
latch assembly. The pawl, ratchet, handle and child
lockout switches are all located on the power side
door latch assembly. The B-pillar switch, as it will be
8N - 18 POWER SLIDING DOOR SYSTEMRS
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CHRYSLER CARAVAN 2002 Service Manual referred to, is an open and close command switch
located on the vehicles interior body side B-pillar
trim. The overhead console switch, is an open and
close command switch located in the vehicles ove

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