2003 CHRYSLER CARAVAN door lock

PROGRAMMABLE FEATURES
NOTE: Tire pressure monitoring (TPM) system infor-
mation is not covered in this section of the service
manual. Refer to the tires/wheels section of this
manual for detailed tire pressure monitoring system
information.
²LANGUAGE?- The options include English,
Francaise, Deutsch, Italiana, or Espanol. The default
is English. All EVIC display nomenclature, including
the trip computer functions, warning messages and
the programmable features appear in the selected
language.
²DISPLAY U.S. OR METRIC?- The options
include U.S. and M. The default is U.S. This feature
toggles the trip computer temperature, fuel economy
and odometer display readings between U.S. and
metric units of measure. It also changes the odome-
ter display in the instrument cluster.
²SERVICE INTV. =- The options include from
1000 to 12000 kilometers in 1000 kilometer incre-
ments (2000 to 7500 miles in 500 mile increments).
The default is 12000 kilometers (7500 miles). The
selected distance becomes the interval at which the
Perform Service warning message will be displayed
by the EVIC. If a new distance is selected, a second
programmable feature appears,RESET SERVICE
DISTANCE?- The options include No and Yes. The
default is Yes. When Yes is selected, the accumulated
distance since the last previous Perform Service
warning message will be reset to zero because the
service interval has been changed. When No is
selected, the distance until the next Perform Service
warning message is reduced by the accumulated dis-
tance since the last previous message.
²USE FACTORY SETTINGS?- The options
include Yes and No. The default is Yes. When yes is
selected all the programmable features will return to
there defaults and the rest of the programmable fea-
tures will not be displayed. If No is selected the rest
of the programmable features will be displayed at
there default values. This feature will automatically
return to the Yes default under two conditions. First,
if no programmable features are changed from there
defaults. Second, if all the programmable features
equal there defaults.
²AUTO DOOR LOCKS?- The options include
Yes and No. The default is Yes. When Yes is selected,
all doors and the liftgate lock automatically when
vehicle speed reaches 25 kilometers-per-hour (15
miles-per-hour). If YES is selected, a second program-
mable feature appears,AUTO UNLOCK ON EXIT?
- The options again include Yes and No. The default
is No. When Yes is selected, following each Auto Door
Lock event all doors and the liftgate will automati-
cally unlock when the driver door is opened, if thevehicle is stopped and the transmission gear selector
is in Park or Neutral. The Auto Door Unlock event
will only occur once following each Auto Door Lock
event.
²REMOTE UNLOCK- The options include
Driver Door 1st and All Doors. The default is Driver
Door 1st. When Diver Door 1st is selected, only the
driver door unlocks when the Unlock button of the
Remote Keyless Entry (RKE) transmitter is
depressed once. The Unlock button of the RKE trans-
mitter must be depressed twice to unlock all doors.
When All Doors is selected, all doors unlock when the
Unlock button of the RKE transmitter is depressed
once.
²REMOTE LINKED TO MEMORY?- This pro-
grammable feature only applies to vehicles equipped
with the optional memory / heated system. The
options include Yes and No. The default is No. When
Yes is selected, the memory system will recall the
Driver 1 or Driver 2 memory settings assigned to the
RKE transmitter being used to unlock the vehicle.
When No is selected, the memory system will only
recall memory settings when the Driver 1 or Driver 2
push buttons of the memory switch on the driver side
front door trim panel are depressed.
²SOUND HORN ON LOCK?- The options
include Yes and No. The default is No. When Yes is
selected, a short horn chirp will provide an audible
confirmation when the RKE receiver recognizes a
valid Lock signal from an RKE transmitter. When No
is selected, no horn chirp will occur with the RKE
Lock event. This feature may be selected indepen-
dent of theFLASH LIGHTS WITH LOCKS?pro-
grammable feature.
²FLASH LIGHTS WITH LOCKS?- The options
include Yes and No. The default is Yes. When Yes is
selected, a single flash of the hazard warning lamps
will provide an optical confirmation when the RKE
receiver recognizes a valid Lock signal from an RKE
transmitter, and two flashes of the same lamps will
occur when the RKE receiver recognizes a valid
Unlock signal from an RKE transmitter. When No is
selected, no lamp flash will occur with the RKE Lock
or Unlock event. This feature may be selected inde-
pendent of theSOUND HORN ON LOCK?pro-
grammable feature.
²HEADLAMP DELAY =- The options include
Off, 30 Sec, 60 Sec, and 90 Sec. The default is 90 Sec.
When a time interval is selected, the headlamps will
remain on for that length of time when the head-
lamps are turned off after the ignition is turned off,
or if the Auto mode is selected on vehicles with the
Auto Headlamps option. When Off is selected, the
headlamp delay feature is disabled.
²HEADLAMPS ON WITH WIPERS?- This pro-
grammable feature only applies to vehicles equipped
8M - 8 MESSAGE SYSTEMSRS
ELECTRONIC VEHICLE INFO CENTER (Continued)
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POWER SYSTEMS
TABLE OF CONTENTS
page page
POWER LIFTGATE SYSTEM.................. 1
POWER SLIDING DOOR SYSTEM............ 19
POWER LOCKS........................... 38POWER MIRRORS........................ 45
POWER SEAT SYSTEM..................... 50
POWER WINDOWS........................ 62
POWER LIFTGATE SYSTEM
TABLE OF CONTENTS
page page
POWER LIFTGATE SYSTEM
DESCRIPTION..........................2
OPERATION............................3
DIAGNOSIS AND TESTING - POWER
LIFTGATE SYSTEM.....................4
STANDARD PROCEDURE
STANDARD PROCEDURE - LIFTGATE
ADJUSTMENT.........................9
STANDARD PROCEDURE - POWER
LIFTGATE LEARN CYCLE................9
SPECIFICATIONS
SPECIFICATIONS TABLE................9
CHIME/THERMISTOR
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL.............................10
INSTALLATION.........................10
ENGAGE ACTUATOR
DESCRIPTION.........................10
OPERATION...........................11
REMOVAL.............................11
INSTALLATION.........................11
EXTERIOR HANDLE SWITCH
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................11
INSTALLATION.........................12
FULL OPEN SWITCH
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL.............................13INSTALLATION.........................13
LATCH
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL.............................13
INSTALLATION.........................14
LATCH ACTUATOR
DESCRIPTION.........................14
OPERATION...........................14
REMOVAL.............................14
INSTALLATION.........................14
LIFTGATE MOTOR
DESCRIPTION.........................15
OPERATION...........................15
REMOVAL.............................15
INSTALLATION.........................15
LIFT GEAR & LINK ROD
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................16
INSTALLATION.........................16
PINCH SENSOR
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL.............................17
INSTALLATION.........................17
TRANSVERSE BRACKET
DESCRIPTION.........................18
OPERATION...........................18
REMOVAL.............................18
INSTALLATION.........................18
RSPOWER SYSTEMS8N-1
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gate control module, telling the module that the lift-
gate has reached the full open position.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the lift gear and link rod assembly
from the vehicle(Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - REMOVAL).
(3) Cut the two wires leading to the full open
switch or back the wires out of the electrical connec-
tor (Fig. 8). Refer to the Wiring section of the service
manual for detailed instructions.
(4) Remove the full open switch retaining screw
and remove the full open switch from the gear motor
housing assembly.
INSTALLATION
(1) Perform a wiring repair on the full open switch
wires following the approved procedure in the Wiring
section of the service manual. Or install new termi-
nals on the wire ends and reinstall in the main lift-
gate motor electrical connector.
(2) Position and install the full open switch retain-
ing screw.
(3) Install the power liftgate lift gear and link rod
assembly. (Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - INSTALLATION)
(4) Connect the negative battery cable.
(5) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
(6) Verify power liftgate system and full open
switch operation. Cycle the power liftgate through
one complete open and close cycle, this will allow the
power liftgate control module to relearn its cycle with
the new components.
LATCH
DESCRIPTION
Vehicles equipped with a power liftgate, utilize a
power cinch/release latch. This latch performs the
same features as a manual liftgate latch as well as
the power cinch and / or release capability. A second
type of power latch can also be found on some RS
models, this latch is designed to perform a power
release only. The power cinch and release capability
is accomplished by an actuator mounted to the lead-
ing edge of the latch assembly. The latch is located in
the lower center of the liftgate assembly (Fig. 9) and
contains integral pawl and ratchet switches. The
ratchet switch acts as a liftgate ajar switch.
The power latch assembly can be serviced as a
complete assembly, latch without actuator or just theactuator. Consult your Mopar parts catalog for spe-
cific part numbers.
OPERATION
On the power cinch/release latch, the latch
mounted actuator provides the torque required to
close the power liftgate from the secondary to the pri-
mary closed and latched position. On the power
cinch/release latch and the power release only latch,
the actuator releases the liftgate from the primary
closed and latched position to the fully unlatched and
movable position.
REMOVAL
(1) Open the hood, disconnect and isolate the neg-
ative battery cable.
(2) Open the liftgate and remove the liftgate trim
panel. Refer to Body for the procedure.
(3) Disconnect the power latch electrical connector
(Fig. 9).
(4) Remove the power latch retaining bolts.
(5) Disconnect the liftgate lock cylinder link rod
from the key cylinder or latch assembly. To discon-
nect from latch, rotate the plastic retaining clip 90 É
to unsnap clip from linkrod. Then pull link rod
straight out of latch arm.
Fig. 9 POWER LATCH ORIENTATION
1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
RSPOWER LIFTGATE SYSTEM8N-13
FULL OPEN SWITCH (Continued)
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INSTALLATION
(1) Connect the liftgate lock cylinder link rod on
the cinch latch assembly. Rotate the plastic retaining
clip 90 É to lock retaining clip on linkrod.
(2) Connect the link rod on the lock cylinder.
(3) Install three new power latch retaining bolts.
Torque to 10 N´m (90 in. lbs.).
(4) Connect the power latch electrical connector
and secure push pin retainers.
(5) Connect the negative battery cable.
(6) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes related to the power latch.
(7) Verify power liftgate system and power cinch /
release latch operation. Cycle the power liftgate
through one complete open and close cycle, this will
allow the power liftgate control module to relearn its
cycle with the new components.
(8) Verify power liftgate manual operation. Using
liftgate key rotate the lock cylinder to verify door
operation. Pull door open using exterior liftgate han-
dle / switch.
(9) Install the liftgate trim panel. Refer to Body for
the procedure.
LATCH ACTUATOR
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
power cinch latch or power release latch (Fig. 10).
The power cinch and/or power release is made possi-
ble by a latch actuator attached to the leading edge
of the power latch assembly. This 12 volt latch actua-
tor contains a small drive gear that meshes with the
latch assemblies internal gears to perform the power
cinch close / power release operations. Refer to the
Latch assembly for more information.
The power cinch/release actuator is serviceable
component. Consult your MoparŸ parts catalog for
specific part numbers.
OPERATION
During a power close cycle, the power cinch actua-
tor provides the torque required to close the power
liftgate from the secondary to the primary closed and
latched position. During a power open cycle, the
power release actuator releases the liftgate from the
primary closed and latched position to the fully
unlatched and movable position.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Open the liftgate and remove the lower liftgate
trim panel. Refer to Body for the procedure.
(3) Disconnect the power latch electrical connector
(Fig. 10).
(4) Remove the three latch retaining bolts.
(5) Grab the latch assembly and unhook the key
cylinder link rod from the key cylinder (Fig. 10).
(6) Place the latch assembly on a bench and locate
the three wires leading from the actuator portion of
the latch assembly.
(7) Disengage the main connector retaining push
pins from the latch actuator housing.
(8) Back the three wires out of the main latch elec-
trical connector. Refer to the wiring section of the
service manual for detailed instructions.
(9) Flip the latch assembly over and remove the
latch actuator retaining screw(s).
(10) Remove the latch actuator from the latch
assembly.
INSTALLATION
(1) Install the latch actuator on the latch assem-
bly.
(2) Install the three latch actuator retaining
screws. Torque the screws to 4 in. lbs.
(3) Install the three wires in the main latch elec-
trical connector. Refer to the wiring section of the
service manual for detailed instructions.
Fig. 10 POWER LATCH ORIENTATION
1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
8N - 14 POWER LIFTGATE SYSTEMRS
LATCH (Continued)
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POWER SLIDING DOOR SYSTEM
TABLE OF CONTENTS
page page
POWER SLIDING DOOR SYSTEM
DESCRIPTION.........................19
OPERATION...........................21
DIAGNOSIS AND TESTING - POWER SLIDING
DOOR SYSTEM.......................22
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER DOOR
LEARN CYCLE.......................28
STANDARD PROCEDURE - PUSH-PIN
GROMMET REPLACEMENT.............28
STANDARD PROCEDURE - SLIDING DOOR
ADJUSTMENT........................28
SPECIFICATIONS
SPECIFICATIONS TABLE...............29
LATCH
DESCRIPTION.........................29
OPERATION...........................29
REMOVAL.............................29
INSTALLATION.........................29
SLIDING DOOR MOTOR
DESCRIPTION.........................30
OPERATION...........................30
REMOVAL.............................30
INSTALLATION.........................31
FULL OPEN SWITCH
DESCRIPTION.........................31
OPERATION...........................31
LEFT B-PILLAR SWITCH
DESCRIPTION.........................32OPERATION...........................32
REMOVAL.............................32
INSTALLATION.........................32
RIGHT B-PILLAR SWITCH
DESCRIPTION.........................32
OPERATION...........................32
REMOVAL.............................32
INSTALLATION.........................32
LOWER DRIVE UNIT
DESCRIPTION.........................32
OPERATION...........................32
REMOVAL.............................33
INSTALLATION.........................33
LOWER DRIVE UNIT TRACK & RACK
DESCRIPTION.........................34
OPERATION...........................34
REMOVAL.............................34
INSTALLATION.........................34
WIRING HARNESS
DESCRIPTION.........................35
OPERATION...........................35
REMOVAL.............................35
INSTALLATION.........................36
FLEX DRIVE
DESCRIPTION.........................36
OPERATION...........................36
REMOVAL.............................37
INSTALLATION.........................37
POWER SLIDING DOOR
SYSTEM
DESCRIPTION
Some vehicles are equipped with a power opening
and closing sliding door system (Fig. 1). Depending
on how the vehicle is ordered it may be equipped
with only a right side power door or right and left
side power doors. This power sliding door system is a
complex system consisting of many components.
Some of these components are the door motor, latch
assembly, sliding door control module, lower drive
unit, flex drive assembly, wire harness and track,
lower drive unit track and rack assembly, full open
switch, B-pillar switch, overhead console switch, key
fob switches (Fig. 2), pawl switch, ratchet switch and
child lockout and handle switches.Each power side door has its own door control mod-
ule, located in the center of the door behind the door
trim panel. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/DOOR CONTROL
MODULE - DESCRIPTION) The power side door
motor is located in the front portion of the door, on
the inner door panel sheet metal. The latch assembly
is located in the rear of the power side door, near the
body line. The lower drive unit is attached to the
lower door hinge. The flex drive assembly connects
the door motor to the lower drive unit. The wire har-
ness and track and the lower drive unit track are vis-
ible with the door open in the lower door sill area.
The power side door full open switch is located under
the lower drive unit and is part of the hold open
latch assembly. The pawl, ratchet, handle and child
lockout switches are all located on the power side
door latch assembly. The B-pillar switch, as it will be
referred to, is an open and close command switch
RSPOWER SLIDING DOOR SYSTEM8N-19
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located on the vehicles interior body side B-pillar
trim. The overhead console switch, is an open and
close command switch located in the vehicle's over-
head console. More detailed information can be found
on these components later in this section.
Safety is of the utmost concern with the power
sliding door system. Software technology has enabled
the power sliding door control module to detect resis-
tance to door travel. This allows the power sliding
door to stop and reverse direction any time an
obstruction is felt or any of the command switches
are operated (while closing only). Battery voltage is
supplied to the power sliding door system through a
40 amp fuse, located in the Intelligent Power Module
(IPM) assembly (Fig. 3). The child lockout switch pre-
vents children from opening or actuating the power
sliding door system when desired. In the unlikely
event that the power sliding door system develops a
fault, the power sliding door can still be operated
manually from the interior or exterior door handle,
just like a standard manual sliding door.
The power sliding door control module communi-
cates on the J1850 PCI Data Bus Circuit. Therefore,
the power sliding door control module can generate
and store its own diagnostic trouble codes (DTC). A
diagnostic scan tool, such as the DRB IIItis used to
read and diagnose these trouble codes. Refer to the
Fig. 1 Power Sliding Door Introduction
Fig. 2 Key Fob
1 - Left Sliding Door Switch
2 - Right Sliding Door Switch
3 - Liftgate Switch
8N - 20 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)
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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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