2003 CHRYSLER CARAVAN wiring

CONDITION POSSIBLE CAUSES CORRECTION
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
assemblyTroubleshoot 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
8N - 24 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
Power loss during power
door operationWiring problems (system or
vehicle)Troubleshoot using electrical schematics.
Refer to wiring diagrams
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
RSPOWER SLIDING DOOR SYSTEM8N-25
POWER SLIDING DOOR SYSTEM (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
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
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
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 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
8N - 26 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
High inside/outside opening
effortFailure 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 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
RSPOWER SLIDING DOOR SYSTEM8N-27
POWER SLIDING DOOR SYSTEM (Continued)
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NOTE: Take care to locate the lower hinge assem-
bly on the door in its original position (ie. match
screw washer with rings left on hinge). Adjust door
fit if required.
(4) Remove the floor jack.
(5) Install the hold-open striker. Refer to the Body
section for the procedure.
(6) Install the side door sill plate on the lower of
the door opening. Refer to the Body section for the
procedure.
(7) Connect the negative battery cable.
WIRING HARNESS
DESCRIPTION
The wire harness supplies power (12v), ground and
various electrical signals to the side sliding door for
various power door functions. A plastic chain or wir-
ing track covers the wire harness assembly (Fig. 16)
and is used to protect the wire harness from abrasion
and/or tangling. This wiring track is replaced with
the wire harness assembly.
The wire harness assembly is a replaceable compo-
nent. Consult your Mopar parts catalog for specific
part numbers.
OPERATION
The wire harness and plastic wiring track provide
a safe and reliable means of supplying power, groundand other various electrical connections to the side
sliding door. During sliding door movement the wir-
ing track folds and unfolds like the links in a chain.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate door trim panel from
the sliding side door. Refer to the Body section for
the procedure.
(3) Remove the lower drive unit cover retaining
screws and remove the cover (Fig. 17).
(4) Disconnect the power side door electrical con-
nector, located just behind the lower drive unit
assembly.
(5) Disengage retaining pushpin and pull wire har-
ness away from its power side door mounting loca-
tion (Fig. 16).
(6) Using a flat bladed screwdriver, unsnap the
wire harness retaining clip from the lower drive unit.
(7) Slide the wire harness off the forward lower
drive unit stud.
(8) Using a pushpin removal tool, unsnap wire
harness retaining pushpins from the rocker panel.
(9) Remove side door lower sill plate. Refer to
Body for the procedure.
(10) Pull back the rearward edge of the B-pillar
trim to access the wire harness connector and discon-
nect connector.
Fig. 15 Lower Track Retaining Nuts
1 - Lower Track Retaining Nuts
2 - Lower Door Track
Fig. 16 Wire Harness Position and Orientation
1 - Lower Door Track and Rack Assembly
2 - Wire Harness
3 - Rack Access Hole Sealing Patches
4 - Lower Drive Unit Cover
RSPOWER SLIDING DOOR SYSTEM8N-35
LOWER DRIVE UNIT TRACK & RACK (Continued)
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(11) Remove the wire harness assembly from the
vehicle.
INSTALLATION
(1) Position the wire harness assembly in the vehi-
cle.
(2) Connect the wire harness connector located at
the rearward edge of the B-pillar.
(3) Install the side door lower sill plate. Refer to
the Body section for the procedure.
(4) Snap the wire harness retaining pushpins in
the rocker panel.
(5) Slide the wire harness on the lower drive unit
stud.
(6) Install the wire harness retaining clip on the
lower drive unit stud.
(7) Connect the power side door electrical connec-
tor, located just behind the lower drive unit.
(8) Install the lower drive unit cover and retaining
screws.
(9) Install the appropriate door trim panel on the
sliding side door. Refer to the Body section for the
procedure.
(10) Connect the negative battery cable.
FLEX DRIVE
DESCRIPTION
Vehicles equipped with a power sliding side door
utilize a flex drive assembly. The flex drive assembly
is located in the lower portion of the door (Fig. 18)
and is used to connect the door motor to the lower
drive unit. An E-clip is used to secure the flexdrive to
the motor assembly, while the flex drive collar is
used to secure the drive to the lower drive unit. The
flex drive assembly is basically a flexible drive shaft
for the power side door system.
The flex drive assembly is a replaceable compo-
nent. Consult your Mopar parts catalog for specific
part numbers.
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.
Fig. 17 Lower Hinge/Drive Assembly
1 - Lower Drive Unit Cover
2 - Lower Drive Unit Cover Retaining Screws
3 - Sliding Door
4 - Lower Hinge Arm Bracket
Fig. 18 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
8N - 36 POWER SLIDING DOOR SYSTEMRS
WIRING HARNESS (Continued)
ProCarManuals.com

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
RSPOWER LOCKS8N-41
DOOR CYLINDER LOCK SWITCH (Continued)
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STANDARD PROCEDURE - RKE TRANSMITTER
PROGRAMING
(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 indicate that the transmitter program-
ming mode has been entered (allow 3 seconds for
chime to sound).
(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 button on the same transmitter and a chime will
sound after successfully programming the transmit-
ter.
(7) Repeat steps 5 and 6 for all transmitters that
will be used with this vehicle (up to 4 total).
(8) Turn ignition to the OFF position. Transmitter
programming mode will discontinue after 60 seconds.
All transmitter programming must be com-
pleted within time specified.
SPECIFICATIONS
RANGE
Normal operation range is up to a distance of 7
meters (23 ft.) of the vehicle. Range may be better or
worse depending on the environment around the
vehicle. Closeness to a radio frequency transmitter
such as a radio station tower that is broadcasting on
105 MHz FM or a 156 MHz 2±way communication
station, may degrade operational range, while range
in an open field will be enhanced.
BATTERY
The batteries can be removed without special tools
and are readily available at local retail stores. Therecommended battery is Duracell DL 2016 or equiva-
lent, TWO cells are required. Battery life is about
three years minimum.
CAUTION: Do not touch the battery terminals or
handle the batteries any more than necessary.
Hands must be clean and dry.
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
systems groups within this manual:
²Vehicle Theft Security System
²Power Seats
²Power Mirrors
RSPOWER LOCKS8N-43
KEYLESS ENTRY TRANSMITTER (Continued)
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