2003 CHRYSLER CARAVAN Service Manual

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Page 1769 of 2177

CHRYSLER CARAVAN 2003 Service Manual (5) Install bolts attaching upper hinge to sliding
door.
(6) Remove padded block from between sliding
door and roof rail.
(7) Place stop bracket in position on vehicle.
(8) Install screw attaching upp

(5) Install bolts attaching upper hinge to sliding
door.
(6) Remove padded block from between sliding
door and roof rail.
(7) Place stop bracket in position on vehicle.
(8) Install screw attaching upper stop bracket to
upper roller bracket (Fig. 23).
(9) Verify sliding door alignment and operation.
Adjust as necessary. (Refer to 23 - BODY/DOORS -
SLIDING/SLIDING DOOR - ADJUSTMENTS)
OUTSIDE HANDLE CABLE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - REMOVAL).
(3) Remove the appropriate side door trim panel.
(Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - REMOVAL)
(4) Peel watershield away from adhesive around
perimeter of inner door panel.
CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
(5) Trace the outside handle cable along its routing
path and disconnect from its retaining clips.(6) Disconnect the outside handle cable from the
latch assembly. Gently pry cable sleeve retainer out
of the latch mounting bracket and then unhook
swedged cable end from the latch link.
(7) Disconnect the outside handle cable from the
handle assembly. Gently pry cable sleeve retainer out
of the handle bracket and then unhook swedged
cable end from the handle link.
(8) Remove the outside handle cable from the side
door.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Match the replacement cable up against the old
cable to verify the correct part.
(2) Position the outside handle cable on the side
door.
(3) Connect the outside handle cable on the handle
assembly. Hook the swedged cable end on the handle
link and gently push the cable sleeve retainer in the
handle bracket.
NOTE: The outside handle cable is marked with red
tape. It must be attached to the latch at the lowest
point. This is marked with a ªRº on the latch.
(4) Connect the outside handle cable on the latch
assembly. Hook the swedged cable end on the latch
link and gently push the cable sleeve retainer in the
latch bracket.
(5) Trace the outside handle cable along its routing
path and install on its retaining clips and position
foam insulators. Use previously made schematic as a
guide or remove the opposite side door trim panel
and use that door as a guide.
CAUTION: Be certain replacement cable is routed
and retained correctly and foam insulators are
properly positioned.
(6) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(7) Install the appropriate side door trim panel on
the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - INSTALLATION)
(8) Install stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - INSTALLA-
TION).
(9) Connect the negative battery cable.
Fig. 24 SLIDING DOOR UPPER HINGE
1 - SLIDING DOOR UPPER HINGE
2 - SLIDING DOOR
23 - 36 DOORS - SLIDINGRS
UPPER HINGE (Continued)
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Page 1770 of 2177

CHRYSLER CARAVAN 2003 Service Manual INSIDE HANDLE CABLE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove th

INSIDE HANDLE CABLE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate side door trim panel
from the vehicle. (Refer to 23 - BODY/DOORS -
SLIDING/TRIM PANEL - REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
(4) Remove the inside handle assembly from the
side door. (Refer to 23 - BODY/DOORS - SLIDING/
INSIDE LATCH HANDLE - REMOVAL)
(5) Disconnect the inside handle cable from the
handle assembly. Gently pry cable sleeve retainer out
of the handle bracket and then unhook swedged
cable end from the handle link.
(6) Open the side door and remove the latch
assembly. Refer to the Power Side Doors section for
the procedure.
CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
(7) Trace the inside handle cable along its routing
path and disconnect from its retaining clips.
(8) Disconnect the inside handle cable from the
latch assembly. Gently pry cable sleeve retainer out
of the latch mounting bracket and then unhook
swedged cable end from the latch link.
(9) Remove the inside handle cable from the side
door.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Match the replacement cable up against the old
cable to verify the correct part.
(2) Position the inside handle cable on the side
door.
(3) Connect the inside handle cable on the handle
assembly. Hook the swedged cable end on the handle
link and gently push the cable sleeve retainer in the
handle bracket.
(4) Install the inside handle assembly on the side
door. (Refer to 23 - BODY/DOORS - SLIDING/IN-
SIDE LATCH HANDLE - INSTALLATION)NOTE: The inside handle cable is marked with blue
tape and must be attached to the latch at the center
(just above the lower cable). This position is
marked with a ªBº on the latch.
(5) Connect the inside handle cable on the latch
assembly. Hook the swedged cable end on the latch
link and gently push the cable sleeve retainer in the
latch bracket.
(6) Trace the inside handle cable along its routing
path and install on its retaining clips and position
foam insulators. Use previously made schematic as a
guide or remove the opposite side door trim panel
and use that door as a guide.
CAUTION: Be certain replacement cable is routed
and retained correctly and foam insulators are
properly positioned.
(7) Install the latch assembly. Refer to the Power
Side Doors section for the procedure.
(8) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(9) Install the appropriate side door trim panel on
the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - INSTALLATION)
(10) Connect the negative battery cable.
HOLD OPEN LATCH CABLE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate side door trim panel
from the vehicle. (Refer to 23 - BODY/DOORS -
SLIDING/TRIM PANEL - REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
(4) Open the side door and remove the latch
assembly. (Refer to 8 - ELECTRICAL/POWER
DOORS/LATCH - REMOVAL)
CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
(5) Trace the hold open latch cable along its rout-
ing path and disconnect from its retaining clips.
(6) Disconnect the hold open latch cable from the
latch assembly. Gently pry cable sleeve retainer out
RSDOORS - SLIDING23-37
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Page 1771 of 2177

CHRYSLER CARAVAN 2003 Service Manual of the latch mounting bracket and then unhook
swedged cable end from the latch link.
(7) Remove the hold open latch from the side door.
(Refer to 23 - BODY/DOORS - SLIDING/HOLD
OPEN LATCH - REMOVAL)
(

of the latch mounting bracket and then unhook
swedged cable end from the latch link.
(7) Remove the hold open latch from the side door.
(Refer to 23 - BODY/DOORS - SLIDING/HOLD
OPEN LATCH - REMOVAL)
(8) Disconnect the hold open latch cable from the
hold open latch. Gently pry cable sleeve retainer out
of the handle bracket and then unhook swedged
cable end from the latch link.
(9) Remove the hold open latch cable from the side
door.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Match the replacement cable up against the old
cable to verify the correct part.
(2) Position the hold open latch cable on the side
door.
NOTE: The hold open latch cable is marked with
white tape. It must be attached to the upper most
cable attachment at the latch. This position is
marked with a ªWº on the latch.
(3) Connect the hold open latch cable on the hold
open latch assembly. Hook the swedged cable end onthe latch link and gently push the cable sleeve
retainer in the latch bracket.
(4) Install the hold open latch on the side door.(Re-
fer to 23 - BODY/DOORS - SLIDING/HOLD OPEN
LATCH - INSTALLATION)
(5) Connect the hold open latch cable on the latch
assembly. Hook the swedged cable end on the latch
link and gently push the cable sleeve retainer in the
latch bracket.
(6) Trace the outside handle cable along its routing
path and install on its retaining clips and position
foam insulators. Use previously made schematic as a
guide or remove the opposite side door trim panel
and use that door as a guide.
CAUTION: Be certain replacement cable is routed
and retained correctly and foam insulators are
properly positioned.
(7) Install the latch assembly. (Refer to 8 - ELEC-
TRICAL/POWER DOORS/LATCH - INSTALLATION)
(8) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(9) Install the appropriate side door trim panel on
the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - INSTALLATION)
(10) Connect the negative battery cable.
23 - 38 DOORS - SLIDINGRS
HOLD OPEN LATCH CABLE (Continued)
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Page 1772 of 2177

CHRYSLER CARAVAN 2003 Service Manual DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL.............................39
INSTALLATION.........................39
HINGE
REMOVAL.............................39

DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL.............................39
INSTALLATION.........................39
HINGE
REMOVAL.............................39
INSTALLATION.........................39
LATCH
REMOVAL.............................40
INSTALLATION.........................40
LATCH STRIKER
REMOVAL.............................40
INSTALLATION.........................40
LIFTGATE
REMOVAL.............................41
INSTALLATION.........................41
LIFTGATE SPOILER
REMOVAL.............................41INSTALLATION.........................41
LOCK CYLINDER
REMOVAL.............................41
INSTALLATION.........................41
SUPPORT CYLINDER
REMOVAL.............................42
INSTALLATION.........................42
TRIM PANEL
REMOVAL.............................42
INSTALLATION.........................43
SLAM BUMPER
REMOVAL
REMOVAL...........................43
REMOVAL - LIFTGATE SIDE.............43
INSTALLATION
INSTALLATION.......................43
INSTALLATION - LIFTGATE SIDE.........43
EXTERIOR HANDLE
REMOVAL
(1) Remove liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the exterior handle electrical con-
nectors.
(3) Remove the two outer screws and the two inner
screws.
(4) Remove the exterior handle/license plate light
assembly.
INSTALLATION
(1) Route the exterior handle electrical connector
through the door and position handle.
(2) Install the two out screws and tighten to 20
N´m (15 ft. lbs.).
(3) Install the two inner bolts and tighten to 40
N´m (30 ft. lbs.).
(4) Connect the electrical connector.
(5) Install the trim panel. (Refer to 23 - BODY/
DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM
PANEL - INSTALLATION)
HINGE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device in
the full open position.
(3) Apply several layers of duct tape on the outside
of to roof across the gap to the lift gate to hold the
liftgate in position.
(4) Remove bolts attaching liftgate hinge to roof
header.
(5) Disconnect VTSS switch from the body har-
ness.
(6) Remove bolts attaching hinge to liftgate (Fig.
1).
(7) Remove hinge from vehicle.
INSTALLATION
(1) If necessary, paint replacement hinge before
installation.
(2) Place hinge in position on vehicle.
(3) Align hinge to marks on liftgate.
(4) Install bolts attaching hinge to liftgate (Fig. 1).
Tighten bolts to 33 N´m (24 ft. lbs.) torque.
(5) Align hinge to marks on roof header.
(6) Install bolts attaching liftgate hinge to roof
header. Tighten outer two bolts to 33 N´m (24 ft. lbs.)
torque. The sheet medal screw at center 12 N´m (105
in. lbs.)
(7) Remove duct tape from roof and liftgate.
RSDECKLID/HATCH/LIFTGATE/TAILGATE23-39
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Page 1773 of 2177

CHRYSLER CARAVAN 2003 Service Manual (8) Verify liftgate alignment. Refer to Liftgate
Remove and Installation for proper gap measure-
ments.
LATCH
REMOVAL
(1) Remove liftgate trim panel.
(2) Disengage outside handle link from clip on
lat

Page 1774 of 2177

CHRYSLER CARAVAN 2003 Service Manual LIFTGATE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Remove screws attaching liftgate wire connec-
tor to rear header.
(3) Disconnect liftgate wire harness from body
wire harness.
(4) Re

LIFTGATE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Remove screws attaching liftgate wire connec-
tor to rear header.
(3) Disconnect liftgate wire harness from body
wire harness.
(4) Remove liftgate upper frame molding.
(5) Disconnect rear window washer hose from
spray nozzle.
(6) Support liftgate on a suitable lifting device.
(7) Remove screws attaching support cylinders to
liftgate.
(8) Remove bolts attaching liftgate hinge to roof
header (Fig. 4).
(9) With assistance, remove liftgate from vehicle.
INSTALLATION
(1) With assistance, place liftgate in position on
vehicle.
(2) Install bolts attaching liftgate hinge to roof
header. Tighten bolts to 33 N´m (24 ft. lbs.) torque.
(3) Install screws attaching support cylinders to
liftgate. Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(4) Remove lifting device from under liftgate.
(5) Connect liftgate wire harness into body wire
harness.
(6) Install screws attaching wire connector to rear
header.
(7) Connect rear window washer hose onto spray
nozzle.
(8) Install liftgate upper frame molding.
(9) Verify liftgate alignment. The liftgate should
have a gap to adjacent panels and fit flush across the
gaps. The gap is;²7 mm (0.280 in.) to the fascia,
²6 mm (0.240 in.) to the roof,
²4 mm (0.160 in.) to the aperture.
LIFTGATE SPOILER
REMOVAL
(1) Remove nuts (Fig. 5).
(2) Remove spoiler from vehicle.
INSTALLATION
(1) Place liftgate spoiler in position and install
nuts.
(2) Tighten nuts to 9 N´m (80 in. lbs.) torque.
LOCK CYLINDER
REMOVAL
(1) Remove the liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the electrical connector.
(3) Disconnect the latch rod.
(4) Rotate plastic lock cylinder nut one quarter
turn and remove nut and spring washer.
(5) Remove the lock cylinder from the liftgate.
INSTALLATION
(1) Install lock cylinder into liftgate.
(2) Install the plastic lock cylinder lock nut, spring
washer and rotate one quarter turn.
(3) Connect the electrical connector.
Fig. 4 LIFTGATE
1 - HINGE
2 - ROOF
3 - NET HOLE OR SLOT
Fig. 5 LIFTGATE SPOILER
1 - RETAINER SEALER WASHER
2 - LIFT GATE SPOILER
RSDECKLID/HATCH/LIFTGATE/TAILGATE23-41
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Page 1775 of 2177

CHRYSLER CARAVAN 2003 Service Manual (4) Connect the latch rod.
(5) Install the trim panel. (Refer to 23 - BODY/
DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM
PANEL - INSTALLATION)
(6) Verify lock cylinder operation.
SUPPORT CYLINDER
REMOVAL
(1)

Page 1776 of 2177

CHRYSLER CARAVAN 2003 Service Manual INSTALLATION
(1) Place liftgate trim panel in position on vehicle.
(2) Engage hidden clips to hold trim panel to lift-
gate and fasteners around perimeter of liftgate (Fig.
8).
(3) Connect wire connec

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