2003 CHRYSLER CARAVAN Service Manual

low beam roof rack radiator overheating alternator belt wheel

Page 1761 of 2177

CHRYSLER CARAVAN 2003 Service Manual LOWER HINGE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Open sliding door.
(2) Mark outline of roller arm on sliding door to
aid

LOWER HINGE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Open sliding door.
(2) Mark outline of roller arm on sliding door to
aid installation (Fig. 7).
(3) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(4) Remove screws attaching open latch to lower
roller arm.
(5) Remove open latch from lower arm.
(6) Support sliding door on a suitable lifting device
with a padded upper surface. The door must be
moveable with lifting device in place.
(7) Remove hold open latch striker.
(8) Remove bolts attaching lower roller arm to
sliding door.
(9) Remove roller arm from sliding door.
(10) Disengage roller arm from lower channel.
(11) Remove roller arm from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.(1) Place roller arm into position (Fig. 7).
(2) Engage roller arm to lower channel.
(3) Install roller arm to sliding door.
(4) Install bolts attaching lower roller arm to slid-
ing door.
(5) Install hold open latch striker.
(6) Install screws attaching open latch to lower
roller arm.
(7) Install sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(8) Check sliding door for proper operation.
REAR LATCH STRIKER
REMOVAL
(1) Open sliding door.
(2) Mark outline of striker on C-pillar door jamb
face to aid installation.
(3) Remove screws attaching striker to C-pillar
(Fig. 8).
(4) Remove striker from vehicle.
INSTALLATION
(1) Place striker in position on vehicle.
(2) Align striker to outline marks on C-pillar.
(3) Install screws attaching striker to C-pillar.
Tighten screws to 28 N´m (21 ft. lbs.) torque.
(4) Verify sliding door alignment and operation.
Fig. 7 SLIDING DOOR LOWER ROLLER ARM
1 - POWER LOWER ROLLER ARM
2 - MANUAL LOWER ROLLER ARM
Fig. 8 SLIDING DOOR LATCH STRIKER
1 - LATCH STRIKER
2 - SLIDING DOOR
23 - 28 DOORS - SLIDINGRS
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Page 1762 of 2177

CHRYSLER CARAVAN 2003 Service Manual SLIDING DOOR
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Apply masking tape to outside surface of quar-
ter panel below the cent

SLIDING DOOR
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Apply masking tape to outside surface of quar-
ter panel below the center roller channel, rearward of
the door opening.
(2) Release sliding door latch and open door.
(3) Apply masking tape to door jamb area, rear-
ward of the upper roller channel.
(4) Remove screw attaching upper stop bumper to
upper roller arm (Fig. 9).
(5) Remove upper stop from upper roller arm.
(6) Remove center stop from sliding door. (Refer to
23 - BODY/DOORS - SLIDING/STOP BUMPER -
REMOVAL)
(7) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(8) Remove hold open latch striker (Refer to 23 -
BODY/DOORS - SLIDING/HOLD OPEN LATCH
STRIKER - REMOVAL).
(9) Open quarter glass.
(10) Remove center roller channel end cover (Fig.
10).
(11) Support sliding door on a suitable lifting
device with a padded upper surface. The door must
be moveable with lifting device in place.
CAUTION: Do not allow the center hinge roller to
contact the quarter glass. Glass can break.
(12) Slide door rearward until the upper sliding
door hinge roller disengages from the upper channel
(Fig. 11).
(13) Continue moving the door rearward until the
lower rollers exit the lower track.
(14) Continue moving door rearward till center
hinge roller exits the channel (Fig. 12)
(15) Remove sliding door from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Place sliding door in position on lifting device.
(2) Engage center hinge roller into channel and
move door forward (Fig. 12).
(3) Position door rearward of the sliding door open-
ing.CAUTION: Do not allow the center hinge roller to
contact the quarter glass. Glass can break.
(4) Engage the center hinge roller into the channel
(Fig. 12).
(5) Roll door forward until lower roller engage into
rear of the track.
(6) Engage the upper sliding door hinge into the
upper channels (Fig. 11).
(7) Install hold open latch striker(Refer to 23 -
BODY/DOORS - SLIDING/HOLD OPEN LATCH
STRIKER - INSTALLATION).
(8) Install sliding door sill plate.
(9) Install center roller channel end cover (Fig. 10).
Fig. 9 SLIDING DOOR UPPER STOP
1 - UPPER STOP PLATE
2 - SLIDING DOOR
3 - UPPER SLIDING DOOR HINGE
Fig. 10 CENTER CHANNEL END COVER
1 - CENTER CHANNEL
2 - CENTER CHANNEL END COVER
3 - PLASTIC NUT
RSDOORS - SLIDING23-29
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Page 1763 of 2177

CHRYSLER CARAVAN 2003 Service Manual (10) Install center stop on sliding door. (Refer to 23
- BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(11) Place upper roller stop bumper in position on
upper roller arm.
(12) Install screw attach

(10) Install center stop on sliding door. (Refer to 23
- BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(11) Place upper roller stop bumper in position on
upper roller arm.
(12) Install screw attaching upper roller arm stop
bumper to upper roller arm (Fig. 9).
(13) Remove masking tape from body surfaces.
(14) Verify door operation and fit. Adjust as neces-
sary. (Refer to 23 - BODY/DOORS - SLIDING/SLID-
ING DOOR - ADJUSTMENTS)
ADJUSTMENTS
SLIDING DOOR ADJUSTMENTS
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
PRELIMINARY CHECKS
(1) Close the sliding door, visually checking C-post
striker alignment entry into latch. Striker at this
point must not affect alignment. Striker should go
straight into the latching mechanism.
(2) On vehicles with left sliding doors, check the
fuel door blocker striker entry into latch. Striker at
this point must not affect alignment.
(3) Check C-post and B-post for door to aperture
gaps and door to door gaps. All gaps should be 5 mm
1 mm.
(4) Check door for height using character lines as
a reference. Also check roof contour as a controlling
factor.
Using the procedures noted below, adjust the side
door in the order the individual steps are called out.
DOOR FLUSHNESS ADJUSTMENT
(1) Check sliding door flushness at the C-pillar
striker.
(2) Adjust the C-pillar striker in or out until the
door is flush.
(3) Check upper B-pillar flushness to A-pillar
cover.
(4) Loosen one nut on upper hinge and adjust door
in or out until the door is flush.
(5) Check flushness at upper C-pillar.
(6) If upper C-pillar flushness is out of specifica-
tion use a heavy rubber mallet on the door assembly
until door is in specifications.
DOOR GAP ADJUSTMENT - UP/DOWN
(1) Visually inspect the sliding door for fitting low
at the top of the door by checking the alignment of
the top contour of the door to the quarter panel.
(2) Fully open the sliding door.
(3) Verify that all center hinge bolts are tight.
(4) Adjust the rear of the sliding door up by turn-
ing the center hinge bolt clockwise (Fig. 13).
(5) Close the door and check the sliding door align-
ment.
(6) Adjust the front of the sliding door up by
adjusting lower hinge bolts.
(7) Open door half way and remove lower hinge
bolt access plug.
(8) Loosen bolts as necessary to move the front of
door up or down.
Fig. 11 SLIDING DOOR UPPER ROLLER
1 - SLIDING DOOR
2 - UPPER HINGE
3 - UPPER CHANNEL
Fig. 12 SLIDING DOOR CENTER ROLLER
1 - SLIDING DOOR
2 - QUARTER GLASS
3 - CENTER HINGE ROLLERS
4 - CENTER HINGE
23 - 30 DOORS - SLIDINGRS
SLIDING DOOR (Continued)
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Page 1764 of 2177

CHRYSLER CARAVAN 2003 Service Manual (9) Check the upper hinge for possible bind, adjust
as necessary.
(10) Close the door and check the sliding door
alignment.
(11) Fully open door and apply thread lock nut
onto the center hinge bolt. T

(9) Check the upper hinge for possible bind, adjust
as necessary.
(10) Close the door and check the sliding door
alignment.
(11) Fully open door and apply thread lock nut
onto the center hinge bolt. Tighten nut until till it
butts up against the welded nut on the center hinge.
Tighten nut to 15 N´m (130 in. lbs.). It may be nec-
essary to hold the center hinge bolt to prevent it
from turning while tightening nut.
(12) Verify alignment, adjust as necessary.
DOOR GAP ADJUSTMENT - FORE/AFT
(1) Check height of sliding door at the B-post and
C-post to determine which area is contributing the
greatest to the incorrect gaps.
(2) If the sliding door is high at the C-post;
(a) Open the door to mid-point of travel.
(b) Mark outline of center hinge on sliding door
to assist in making adjustments.
(c) Loosen center hinge bolts (Fig. 13).
(d) Move hinge fore or aft to position the sliding
door into the correct location.
(e) Tighten center hinge bolts.
(f) Verify alignment, adjust as necessary.
(3) If the sliding door is low at the B-post;
(a) Remove access plug in the sliding door trim
panel.
(b) Open the door to mid-point of travel.
(c) Mark outline of lower roller arm bracket on
sliding door to assist in making adjustments.
(d) Loosen lower roller arm bracket bolts (Fig.
14).
(e) Move hinge downward to raise the door.(f) Tighten lower roller arm bracket bolts.
(g) Verify alignment, adjust as necessary.
(4) If the sliding door is low at the C-post;
(a) Open the door to mid-point of travel.
(b) Mark outline of center hinge on sliding door
to assist in making adjustments.
(c) Adjust the adjustment bolt up or down to
move the door position. (Fig. 13).
(d) Move hinge downward to raise the door.
(e) Tighten center hinge bolts.
(f) Verify alignment adjust as necessary.
(5) If the sliding door is high at the B-post;
(a) Remove access plug in the sliding door trim
panel.
(b) Open the door to mid-point of travel.
(c) Mark outline of lower roller arm bracket on
sliding door to assist in making adjustments.
(d) Loosen lower roller arm bracket bolts (Fig.
14).
(e) Move hinge upward to raise the door.
(f) Tighten lower roller arm bracket bolts.
(g) Verify alignment, adjust as necessary.
DOOR SEAL COMPRESSION
(1) First check Gap & Flush (Refer to 23 - BODY/
BODY STRUCTURE/GAP AND FLUSH - SPECIFI-
CATIONS). Check seal compression near the middle
of the door even with the latch assembly. Using a
piece of paper, place it across door seal and close
door. Pull paper out of door opening. If paper tears
setting is to tight, if paper slides thought to easily
the compression is insufficient and needs to be
adjusted.
(2) Adjust seal compression at the top of the
B-post seal;
Fig. 13 SLIDING DOOR CENTER HINGE
1 - ADJUSTING BOLT
2 - WELD NUT
Fig. 14 SLIDING DOOR LOWER ROLLER ARM
1 - LOWER ROLLER ARM BRACKET
2 - BOLTS
3 - SLIDING DOOR
RSDOORS - SLIDING23-31
SLIDING DOOR (Continued)
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Page 1765 of 2177

CHRYSLER CARAVAN 2003 Service Manual (a) Open door to mid-point of travel.
(b) Mark outline of upper roller arm on door to
assist in making adjustments.
(c) Loosen bolts attaching upper roller arm to
door (Fig. 9).
(d) Decrease the lengt

(a) Open door to mid-point of travel.
(b) Mark outline of upper roller arm on door to
assist in making adjustments.
(c) Loosen bolts attaching upper roller arm to
door (Fig. 9).
(d) Decrease the length of the upper roller arm
to increase seal compression.
(e) Increase the length of the upper roller arm to
decrease seal compression.
(f) Tighten all upper roller arm bolts.
(g) Verify door alignment, adjust as necessary.
(3) Adjust seal compression at the bottom of B-post
seal.
(a) Open door to mid-point of travel.
(b) Mark outline of lower roller arm on lower
roller arm bracket to assist in making adjustments
(Fig. 15).
(c) Loosen bolts holding lower roller arm to
lower roller arm bracket.
(d) Pivot lower roller arm toward center of vehi-
cle to decrease seal compression.
(e) Pivot lower roller arm outward to increase
seal compression.
(f) Tighten lower roller arm bolts.
(g) Verify alignment, adjust as necessary.
NOTE: Adjusting seal compression at the B-post
can affect door flushness the C-post.
STABILIZER ADJUSTMENT - UPPER/LOWER
(1) Open sliding door.
(2) Loosen the bolts holding the male stabilizers to
the sliding door enough that the stabilizers can move
with some effort.
(3) Close and then reopen sliding door.
(4) Tighten all stabilizers bolts.
STABILIZER
REMOVAL
(1) Open sliding door.
(2) Remove screws attaching stabilizer to door end
frame (Fig. 16).
(3) Remove stabilizer from vehicle.
INSTALLATION
(1) Place stabilizer in position on vehicle.
NOTE: Loose install screws first. Fit should be
snug but free to move when closing door to align to
body half stabilizer.
(2) Install screws attaching stabilizer to door end
frame.
(3) Open door and final tighten screws.
(4) Verify sliding door operation.
STABILIZER SOCKET
REMOVAL
(1) Open sliding door.
(2) Remove screws holding stabilizer socket to
B-pillar (Fig. 17).
(3) Remove stabilizer socket from vehicle.
INSTALLATION
(1) Place stabilizer socket in position on vehicle.
(2) Install screws to hold stabilizer socket to B-pil-
lar. Tighten nuts to 5 N´m (45 in. lbs.) torque.
(3) Close sliding door and verify operation.
Fig. 15 Sliding Door Lower Roller Arm
1 - POWER LOWER ROLLER ARM
2 - MANUAL LOWER ROLLER ARM
Fig. 16 SLIDING DOOR STABILIZER
1 - SLIDING DOOR
2 - STABILIZER
23 - 32 DOORS - SLIDINGRS
SLIDING DOOR (Continued)
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Page 1766 of 2177

CHRYSLER CARAVAN 2003 Service Manual TRIM PANEL
REMOVAL
(1) Remove sliding door upper frame molding.
(2) If removing the left sliding door trim panel,
remove screw from inside ash receiver bezel.
(3) Remove screw from pull cup.
(4) Disen

TRIM PANEL
REMOVAL
(1) Remove sliding door upper frame molding.
(2) If removing the left sliding door trim panel,
remove screw from inside ash receiver bezel.
(3) Remove screw from pull cup.
(4) Disengage push-in fasteners holding trim to
door panel around perimeter and upper edge of door
(Fig. 18).
(5) Remove sliding door trim panel from vehicle.
INSTALLATION
(1) Place sliding door trim panel in position on
vehicle.
(2) Align locating pins on backside of trim panel to
mating holes in the inner door panel.
(3) Engage push-in fasteners to hold trim to door
panel around perimeter and upper edge of door (Fig.
18).
(4) Install pull cup screw.
(5) If necessary, install screw from inside ash
receiver bezel on left sliding door trim panel.
(6) Install sliding door upper frame molding.
INSIDE LATCH HANDLE
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)(2) Remove screws attaching bottom of inside latch
handle to sliding door (Fig. 19).
(3) Remove two screw attaching top of inside latch
handle to sliding door.
(4) Remove latch handle from sliding door.
(5) Disengage cable end from clip on release han-
dle mechanism.
(6) Disengage cable end from release handle mech-
anism.
(7) Remove push pin fastener attaching cable end
to release handle.
(8) Disengage cable casing end from release handle
(Fig. 20).
(9) Disengage cable end from latch handle.
(10) Remove handle from vehicle.
INSTALLATION
(1) Place inside latch handle in position on vehicle.
(2) Engage cable end into latch handle.
(3) Engage cable casing end into release handle.
(4) Install push pin fastener to hold cable into
release handle.
(5) Engage cable end into release handle mecha-
nism.
(6) Engage clip to hold cable end into release han-
dle mechanism.
(7) Place latch handle in position on sliding door.
Fig. 17 SLIDING DOOR STABILIZER SOCKET
1 - B-PILLAR
2 - STABILIZER SOCKET
Fig. 18 SLIDING DOOR TRIM PANEL
1 - PUSH-IN FASTENERS
2 - SLIDING DOOR UPPER FRAME MOLDING
3 - SLIDING DOOR TRIM PANEL
4 - PUSH-IN FASTENERS
5 - PUSH-IN FASTENERS
6 - SLIDING DOOR
RSDOORS - SLIDING23-33
STABILIZER SOCKET (Continued)
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Page 1767 of 2177

CHRYSLER CARAVAN 2003 Service Manual (8) Install screw to hold top of inside release han-
dle to sliding door.
(9) Install screws to hold bottom of inside latch
handle to sliding door.
(10) Verify sliding door operation. Adjust as neces-

Page 1768 of 2177

CHRYSLER CARAVAN 2003 Service Manual OUTSIDE HANDLE
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPE

OUTSIDE HANDLE
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel as necessary to access
outside release handle fasteners.
(4) Disengage clip attaching outside door handle
linkage to door cable.
(5) Remove linkage from outside door handle.
(6) Remove three nuts attaching outside door han-
dle to outer door panel (Fig. 22).
(7) Remove outside door handle from vehicle.
INSTALLATION
(1) Position outside door handle on vehicle.
(2) Install nuts attaching outside door handle to
outer door panel.
(3) Engage clip attaching linkage to outside door
handle.
(4) Engage rigging cam to latch/lock control mech-
anism.
(5) Move clip on latch/lock control to bottom of slot
and engage linkage to latch/lock control.
(6) Verify sliding door operation. Adjust as neces-
sary.(7) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(8) Install sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(9) Install sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
UPPER HINGE
REMOVAL
(1) Open sliding door, do not latch open.
(2) Remove screw attaching upper stop bracket to
upper roller bracket (Fig. 23).
(3) Remove stop bracket from vehicle.
(4) Place a padded block between the open sliding
door and the roof rail.
(5) Mark outline of upper hinge bracket on sliding
door.
(6) Remove bolts attaching upper roller to sliding
door (Fig. 24).
(7) Remove upper hinge from door.
(8) Slide roller out of rear end of roof upper chan-
nel.
(9) Remove upper hinge from vehicle.
INSTALLATION
(1) Place upper hinge in position on vehicle (Fig.
24).
(2) Slide roller into rear end of roof upper channel.
(3) Place upper hinge in position on door.
(4) Align outline marks on sliding door to upper
roller bracket
Fig. 22 SLIDING DOOR OUTSIDE LATCH RELEASE
HANDLE
1 - OUTSIDE DOOR PANEL
2 - LOCK LINK
3 - LATCH LINK
4 - LOCKING LINK AND SLEEVE LINK
5 - BELLCRANK
6 - KEY CYLINDER LOCK LINK (IF EQUIPPED)
7 - KEY CYLINDER (IF EQUIPPED)
Fig. 23 SLIDING DOOR UPPER STOP
1 - UPPER STOP PLATE
2 - SLIDING DOOR
3 - UPPER SLIDING DOOR HINGE
RSDOORS - SLIDING23-35
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