2002 CHRYSLER CARAVAN battery location

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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LOWER DRIVE UNIT TRACK &
RACK
DESCRIPTION
Vehicles equipped with a power sliding side door
utilize a lower drive unit track or door track and
rack assembly. This track provides a mating rack
gear (Fig. 13) for the lower drive unit to engage. The
track also accepts the lower hinge rollers, which
helps support the weight of the side door as well as
providing a smooth surface for the hinge rollers to
move upon.
The lower door track is a replaceable component.
Consult your Mopar parts catalog for specific part
numbers.
OPERATION
With the start of a power door open cycle, the door
motor drives the flex drive assembly. The flex drive
assembly drives the lower drive unit. A metal drive
gear which is part of the lower drive unit, meshes
with the door track rack teeth and moves the door
into the full open position. The same operation
repeats itself, during a power close cycle only the sys-
tem rotates in the opposite direction.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the side door sill plate from the lower
of the door opening. Refer to the Body section for the
procedure.
(3) Remove the hold-open striker. Refer to Body for
the procedure.
(4) Position a floor jack, with a block of wood
under the leading edge of the side door to support it
(Fig. 14).
(5) Remove the lower hinge assembly from the
door. Refer to the Body section of the service manual
for the procedure.
(6) Position the wire harness assembly out of door
opening (Fig. 13), this will allow sufficient room to
remove the door track.
(7) Pull back the sealing patches (Fig. 13) and
remove the lower track retaining nuts (Fig. 15).
(8) Carefully remove the lower door track from the
vehicle.
INSTALLATION
(1) Carefully position the lower door track in the
vehicle.
(2) Install the lower track retaining nuts (Fig. 15)
and install the sealing patches. Torque the fasteners
to 70 in. lbs.
(3) Install the lower hinge assembly on the door.
Refer to the Body section of the service manual for
the procedure.
Fig. 13 Rack Access Hole Locations
1 - Lower Door Track and Rack Assembly
2 - Wire Harness
3 - Rack Access Hole Sealing Patches
4 - Lower Drive Unit Cover
Fig. 14 Supporting Side Door
RSPOWER SLIDING DOOR SYSTEM8N-33
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CAUTION: Do not disconnect the switch from the
rear of the door key cylinder. This switch is a one
time use switch. Once it is removed from the rear of
the switch, it is not reusable and must be replaced.
Test the switch at the harness connector.
DOOR CYLINDER LOCK SWITCH RESISTANCE
SWITCH POSITION RESISTANCE VALUE
COUNTERCLOCKWISE 5.4K OHMS
NEUTRAL 18.4K OHMS
CLOCKWISE 2K OHMS
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the door trim panel of the effected door
cylinder lock switch (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - REMOVAL).
(3) Close the door window.
(4) Disconnect the door cylinder lock switch wire
connector from the door harness, and wiring clip
from the impact beam.
(5) Remove the outer door handle from the door.
(6) Remove the switch from the key cylinder in the
door handle and remove from vehicle.
INSTALLATION
(1) Install the switch on the key cylinder in the
door handle.
(2) Install the door handle.
(3) Connect the door cylinder lock switch wire con-
nector to the door harness, and the wiring clip to the
impact beam.
(4) Install the door trim panel of the affected door
cylinder lock switch (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION).
(5) Connect the battery negative cable.
(6) Verify system operation.
DOOR LOCK MOTOR
DIAGNOSIS AND TESTING - DOOR LOCK
MOTOR
Verify battery condition before testing door lock
motor(s) (Refer to 8 - ELECTRICAL/BATTERY SYS-
TEM/BATTERY - DIAGNOSIS AND TESTING).
To determine which motor is faulty, check each
individual door for electrical lock and unlock or dis-
connect the motor connectors one at a time, while
operating the door lock switch. In the event that
none of the motors work, the problem may be caused
by a shorted motor or a bad switch. Disconnecting
the defective motor will allow the others to work.To test an individual door lock motor, disconnect
the electrical connector from the motor. To lock the
door, connect a 12 volt power source to the positive
pin of the lock motor and a ground wire to the other
pin. Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, further details
on wire harness routing and retention, as well as
pin-out and location views for the various wire har-
ness connectors, splices and grounds. To unlock the
door reverse the wire connections at the motor pin
terminals. If these results are NOT obtained, replace
the motor.
DOOR LOCK SWITCH
DIAGNOSIS AND TESTING - DOOR LOCK
SWITCH
(1) Remove door trim panel. Refer to Body, Door -
Front, Trim Panel, Removal and Installation.
(2) Disconnect wire connector from back of door
lock switch.
(3) Depress switch to LOCK position.
(4) Using an ohmmeter, test switch resistance
between Pins 2 and 3. Refer to the DOOR LOCK
SWITCH CONTINUITY test and (Fig. 2).
(5) Depress switch to UNLOCK position.
(6) Test resistance between Pins 2 and 3.
(7) Test resistance between pins 2 and 3 while
switch is in its normal unactuated mode.
(8) If resistance values are not within the param-
eters shown replace the door lock switch.
DOOR LOCK SWITCH CONTINUITY
SWITCH
POSITIONCONTINUITY
BETWEENRESISTANCE
VALUE
LOCK 2 and 3 5.3K Ohm   5%
UNLOCK 2 and 3 2.0K Ohm   5%
UNACTUATED 2 and 3 18.3K Ohms  
5%
Fig. 2 DOOR LOCK SWITCH
8N - 42 POWER LOCKSRS
DOOR CYLINDER LOCK SWITCH (Continued)
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REMOTE KEYLESS ENTRY
MODULE
DESCRIPTION
The RKE module is capable of retaining up to four
different Vehicle Access Codes.
OPERATION
Whenever the vehicle battery power is interrupted
the RKE Module will retain all vehicle access codes
in its memory. When replacing or adding a key fob
transmitter (maximum 4) a DRB IIItscan tool is
required to program the RKE Module to accept the
new Vehicle Access Code if a customer owned trans-
mitter is not available. Refer to Electrical, Remote
Keyless Entry Module, Standard Procedure - Pro-
gramming RKE Module or the Proper Body Diagnos-
tic Procedures manual.
DIAGNOSIS AND TESTING - REMOTE KEYLESS
ENTRY MODULE
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, further details
on wire harness routing and retention, as well as
pin-out and location views for the various wire har-
ness connectors, splices and grounds. Refer to the
proper Body Diagnostic Procedures Manual for test-
ing the Remote Keyless Entry system using a DRB
IIItscan tool. Also refer to other interrelated sys-
tems groups within this manual:
²Vehicle Theft Security System
²Power Seats
²Power Mirrors
STANDARD PROCEDURE - PROGRAMMING
RKE MODULE
(1) Using a functional key fob transmitter, unlock
the vehicle and disarm the Vehicle Theft Security
System.
(2) Insert ignition key into the ignition switch.
(3) Turn the ignition switch to RUN position with-
out starting engine.
(4) Using a functional key fob transmitter, press
and hold the UNLOCK button for a minimum five
seconds (maximum ten seconds).
(5) While still holding UNLOCK button, and
before ten seconds passes, press the PANIC button
and release both at the same time. A single chime
will sound to verify that the RKE module is set to
receive the new Vehicle Access Code(s).
(6) Within 30 seconds of the chime, press and
release the ªLOCKº and ªUNLOCKº buttons on the
transmitter at the same time. Then press and release
any one of the buttons. The BCM will sound anabbreviated chime to acknowledge that the program-
ming of the transmitter has been completed and was
successful.
(7) Repeat step 6 for all transmitters that will be
used with this vehicle (up to 4 total).
(8) Programming mode will last for 30 seconds. To
get out of programming mode sooner, turn the igni-
tion OFF. A single chime will sound to verify that the
RKE module will no longer accept additional Vehicle
Access Code(s).
(9) When Vehicle Access Code(s) programming is
complete, turn the ignition switch to the OFF posi-
tion and verify RKE system operation using each key
fob.
NOTE:
Only the two key fob transmitters that have been
programmed to the memory seat and mirror system
will operate it. If any key fob is replaced, the mem-
ory seat and mirror module will require program-
ming. (Refer to 8 - ELECTRICAL/POWER SEATS -
DIAGNOSIS AND TESTING).
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove instrument panel top cover (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP PAD - REMOVAL).
(3) Remove screws holding RKE module to instru-
ment panel.
(4) Disconnect wire connector from RKE module
(Fig. 4).
(5) Remove the RKE module from vehicle.
Fig. 4 RKE MODULE
1 - REMOTE KEYLESS ENTRY MODULE
2 - INSTRUMENT PANEL
3 - DEMISTER DUCT
8N - 44 POWER LOCKSRS
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