2003 CHRYSLER CARAVAN lock

Body Diagnostic Manual for a complete list of diag-
nostic routines.
NOTE: It may be possible to generate Sliding Door
Diagnostic Trouble Codes during normal power
sliding door operation. Refer to the Body Diagnos-
tic Manual for a complete list of diagnostic routines.
For additional information, (Refer to 8 - ELECTRI-
CAL/POWER DOORS - OPERATION). For a com-
plete power sliding door system wiring schematic,
refer to Wiring Diagrams. For power sliding door sys-
tem operation instructions, refer to the vehicle owner
manual.
WARNING: BE CERTAIN TO READ ALL WARNINGS
AND CAUTIONS IN POWER SLIDING DOOR OPER-
ATION BEFORE ATTEMPTING ANY SERVICE OF
POWER SLIDING DOOR SYSTEM OR COMPO-
NENTS.
OPERATION
With the push of a power sliding door open/close
command switch (key fob, overhead console or B-pil-
lar mounted) a signal is sent out to the Body Control
Module (BCM). The BCM then sends a signal out on
the PCI Data Bus circuit (J1850) to the power sliding
door module. The power sliding door module then
signals the power sliding door latch to release the
door to the unlatched and movable position. The
motor then starts an open cycle.
During the door open cycle, if the power sliding
door module detects sufficient resistance to doortravel, such as an obstruction in the door's path, the
power sliding door module will immediately stop door
movement and reverse door travel to the full open or
closed position. The ability for the power sliding door
module to detect resistance to door travel is accom-
plished by hall effect sensors and the door motor
speed.
The power sliding door control module has the abil-
ity to learn. Anytime a door is opened or closed using
the power sliding door system the module learns
from its cycle. If a replacement power sliding door
component is installed or a door adjustment is made,
the module must re-learn the effort required to open
or close the door. A learn cycle can be performed with
a Diagnostic Scan Tool, such as the DRB IIIt, or with
a complete cycle of the door, using any one of the
command switches. Refer to Standard Procedures in
this section for detailed instructions.
The power sliding door system is designed with a
number of system inhibitors. These inhibitors are
necessary for safety and/or feasibility of the power
sliding door system. See the power sliding door sys-
tem inhibitors noted below:
POWER SLIDING DOOR SYSTEM INHIBITORS
²The power sliding door must be in thefullopen
or closed position in order for the power sliding door
system to start a cycle. If the door is not in this posi-
tion (based on the input from the full open, pawl or
ratchet switches) the door control module will not
respond to command switch inputs.
²The vehicles transmission must be inpark or
neutralin order for the power sliding door system to
start a cycle.
²The vehicles child lockout switch must be in the
ªUNLOCKEDº position in order for the power sliding
door systems B-pillar switches to function.
²If multiple obstacles are detected during the
same power open or close cycle the power sliding
door may go into full manual mode.
²If severe Diagnostic Trouble Codes (DTC) are
stored in the power sliding door control module the
power sliding door may go into full manual mode.
²Due to the high pressure created in the passen-
ger compartment with the blower motor on high, the
power sliding door may not complete a power close
cycle unless a window is cracked, allowing the pres-
sure to escape. This situation will only be experi-
enced on some vehicles, or vehicles with brand new
side door weather seals installed. Refer to the Side
Door Adjustment procedure in the Standard Proce-
dures section of this group.
²The vehicles fuel tank filler door must be in the
closed position. Due to the sliding door interference
with the open fuel tank filler door, mechanical link-
age prevents the side door from opening and striking
Fig. 3 Power Side Door Fuse Location
RSPOWER SLIDING DOOR SYSTEM8N-21
POWER SLIDING DOOR SYSTEM (Continued)
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the fuel door. Refer to the Body section of this man-
ual for detailed information on the fuel door lockout
feature.
POWER SLIDING DOOR SYSTEM WARNINGS
WARNING: ALWAYS DISCONNECT THE NEGATIVE
BATTERY CABLE BEFORE ATTEMPTING ANY
POWER SLIDING DOOR SYSTEM SERVICE.
WARNING: EXTREME CARE MUST BE TAKEN TO
PREVENT OBJECTS FROM ENTERING THE DOORS
PATH ONCE THE DOOR REACHES THE CINCH
MOTOR CONTACT (APPROXIMATELY 1 INCH
BEFORE FULLY CLOSED).
WARNING: NEVER ATTEMPT TO ENTER OR EXIT
THE VEHICLE WHILE THE POWER SLIDING DOOR
IS IN MOTION. YOU COULD DAMAGE THE POWER
SLIDING DOOR SYSTEM OR COMPONENTS
AND/OR CAUSE PERSONAL INJURY.
WARNING: NEVER ATTEMPT TO DRIVE AWAY WITH
THE POWER SLIDING DOOR IN MOTION. YOU
COULD DAMAGE THE POWER SLIDING DOOR SYS-
TEM OR COMPONENTS AND/OR CAUSE PER-
SONAL INJURY.
WARNING: NEVER PLACE OBJECTS IN THE
POWER SLIDING DOOR WHEN CINCHING CLOSED.
YOU COULD DAMAGE THE VEHICLE, POWER SLID-
ING DOOR SYSTEM OR COMPONENTS AND/OR
CAUSE PERSONAL INJURY.
DIAGNOSIS AND TESTING - POWER SLIDING
DOOR SYSTEM
The power opening and closing power sliding door
system 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 sliding door system must be checked.
The power sliding door system was designed to be
diagnosed with an appropriate diagnostic scan tool,
such as the DRB IIIt. The most reliable, efficient,
and accurate means to diagnose the power sliding
door 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
statuses throughout the power sliding door system to
help the technician diagnose a defective switch or
component. The DRB IIItcan also be used to actuate
various components throughout the power sliding
door system to help the technician diagnose a defec-
tive component.
Before any testing of the power sliding door system
is attempted, the battery should be fully charged, all
built-in power sliding door system inhibitors read
and understood (Refer to 8 - ELECTRICAL/POWER
DOORS - OPERATION) and all wire harness and
ground connections inspected around the affected
areas on the vehicle.
The following are quick reference diagnostic tables
to help when diagnosing and testing the power slid-
ing door system.
8N - 22 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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SPECIFICATIONS
SPECIFICATIONS TABLE
TORQUE SPECIFICATIONS
DESCRIPTION N´m In. Lbs.
Door Latch 12 100
Lower Drive Unit
Allen Head980
Lower Drive Unit
Screw328
Lower Track Nuts 8 70
LATCH
DESCRIPTION
Vehicles equipped with a power side door or doors
utilize a power latch. One power latch is used for
each power door. The latch is located on the trailing
edge of the side door assembly (Fig. 5). This power
latch assembly is comprised of many different compo-
nents which have the ability to perform the power
cinch, release, lock, unlock and safety related opera-
tions. These components are the door latch, lock/un-
lock actuator, cinch/release actuator and child
lockout, pawl, ratchet and handle switches. The pawl
and ratchet switches are used to indicate the primaryand secondary latched positions. The cinch latch also
provides a connection point for the interior handle,
exterior handle and hold open latch cables.
The power latch is a replaceable component. Con-
sult your Mopar parts catalog for specific part num-
bers.
OPERATION
The power latch performs the same operation as a
full manual door latch as well as power cinch,
release, lock and unlock operations. The power latch
mounted actuator cinches the door closed and latches
it in its primary latched position. During a power
close cycle, the power cinch actuator will not operate
until the side door has reached its secondary latch
position (determined by pawl and ratchet switches).
During a power open cycle, the power release actua-
tor will stop once the side door has moved from pri-
mary latch position.
The power latch uses inputs from the lock/unlock
actuator, power side door control module and child
lockout, pawl, ratchet and handle switches to provide
safe power cinch and release operations. Refer to
Power Side Door Operation for additional informa-
tion.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate side door trim panel.
Refer to the Body section for the procedure.
(3) Remove the weather shield if necessary. Refer
to the Body section for the procedure.
(4) Open the side door all the way and remove the
door latch retaining bolts (Fig. 6).
(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.
Fig. 5 Removing/Installing Power Latch in Sliding
Door
1 - Power Latch Assembly
RSPOWER SLIDING DOOR SYSTEM8N-29
POWER SLIDING DOOR SYSTEM (Continued)
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(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 thepower and torque to move the sliding door from the
open/closed position to full closed/open position, after
the power latching mechanism has released.
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. 6 Removing Latch Retaining Bolts
1 - Latch Retaining Bolts
2 - Side Door
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
8N - 30 POWER SLIDING DOOR SYSTEMRS
LATCH (Continued)
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(2) Remove the door trim panel from the appropri-
ate side door. Refer to the Body section for the pro-
cedure.
(3) Remove water shield as necessary to gain
access to motor assembly.
(4) Remove retaining clip holding flex drive assem-
bly to the motor (Fig. 8). Pull flex drive cable straight
out of the motor assembly.
(5) Disconnect door motor electrical connector.
(6) Using a trim stick (special tool #C-4755) or
equivalent, gently pry out push-pin fasteners retain-
ing motor.
(7) Remove the motor assembly from the vehicle.
INSTALLATION
(1) Position the motor assembly on the door inner
panel.
(2) Install the push-pin fasteners retaining the
motor assembly to the sliding door.
NOTE: Push in on the push-pins at the clutch hous-
ing (plastic side) until you hear one click. Push in
on the push-pin fasteners at the motor mount
(sheet metal side) until you hear two clicks. This
assures proper installation/attachment of the motor
to the sliding door.
(3) Install the flex shaft by lining up the square
shaped drive shaft with corresponding hole in motor
drive unit and push straight in.(4) Install the E-clip to secure flex-shaft.
(5) Connect the negative battery cable.
(6) Install the weather shield. Refer to the Body
section of the service manual for the procedure.
(7) Install the door trim panel on the side door.
Refer to Body for the procedure.
FULL OPEN SWITCH
DESCRIPTION
Vehicles equipped with a power sliding door utilize
a full open switch. This switch is located in the hold
open latch (Fig. 9) under the side door lower hinge.
When the power side door module receives a ground
signal input from the full open switch, and as long as
the cinching latch actuator is not in power mode or
the handle switch is open, the signal indicates that
the door is at the full open position.
The full open switch is incorporated into the hold
open latch. If the full open switch proves faulty, the
entire hold open latch assembly must be replaced.
OPERATION
The full open switch is triggered by a pawl lever in
the hold open latch. When the full open switch is
closed (circuit to ground) the ratchet has engaged on
the hold open striker and the pawl lever has engaged
on the ratchet, locking the latch from opening and
holding the door in the full open position.
Fig. 8 Flex Drive Retaining Clip
1 - Flex Drive Cable Retaining Clip
2 - Flex Drive Cable
3 - Side Door Motor Assembly
Fig. 9 Full Open Switch Position & Orientation
1 - Hold Open Latch Assembly
2 - Hold Open Latch Cable
3 - Full Open Switch
RSPOWER SLIDING DOOR SYSTEM8N-31
SLIDING DOOR MOTOR (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.
8N - 32 POWER SLIDING DOOR SYSTEMRS
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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, this will allow sufficient room to remove the
door track.
(7) Pull back the sealing patches 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 and
install the sealing patches. Torque the nuts 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
8N - 34 POWER SLIDING DOOR SYSTEMRS
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