2003 CHRYSLER CARAVAN key fob

POWER LIFTGATE SYSTEM
DESCRIPTION
Some vehicles are equipped with an automatic
opening and closing power liftgate system (Fig. 1).
This power liftgate system is a complex system con-
sisting of many components. Some of these compo-
nents are the liftgate gear motor assembly, latch
assembly, lift gear and rod, liftgate control module,
chime/thermistor, full open switch, engage actuator,
pinch sensor, liftgate handle switch, overhead console
switch, key fob switches (Fig. 2), pawl switch and
ratchet switch.
The power liftgate system has its own door control
module, located on the vehicles left body D-pillar
behind the trim panel. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/DOOR CON-
TROL MODULE - DESCRIPTION) The power
liftgate gear motor assembly is located just above the
control module. The latch assembly is located in the
bottom center of the power liftgate, below the exte-
rior liftgate handle switch. The power liftgate full
open switch, engage actuator, lift gear and rod are
part of the liftgate gear motor assembly. The pawl
and ratchet switches are part of the latch assembly.
The pinch sensor or sensors are located along theright and left sides of the power liftgate, just above
the body line. The liftgate handle switch is an power
release switch and is located in the rear light bar
assembly, just above the license plate. The overhead
console switch is an power open and close command
switch located in the vehicles overhead console.
Safety is of the utmost concern with the power lift-
gate system. Software technology has enabled the
power liftgate control module to detect resistance to
liftgate travel, which allows the power liftgate to stop
and reverse direction anytime an obstruction is felt
or any of the command switches are operated (only in
closing direction). Battery voltage is supplied to the
power liftgate system through a 40 amp fuse, located
in the Intelligent Power Module (IPM) assembly (Fig.
3). In the unlikely event that the power liftgate sys-
tem develops a fault the power liftgate can still be
operated manually with a key, just like a standard
manual liftgate.
The power liftgate control module communicates
on the J1850 Programmable Communication Inter-
face (PCI) Bus Circuit. Therefore, the power liftgate
control module can generate and store its own Diag-
nostic Trouble Codes (DTC). The vehicles Body Con-
trol Module (BCM) receives and supplies messages to
the power liftgate control module via the PCI bus cir-
cuit. A diagnostic scan tool, such as the DRB IIItis
Fig. 1 POWER LIFTGATE INTRODUCTION
8N - 2 POWER LIFTGATE SYSTEMRS
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used to read and troubleshoot these Diagnostic Trou-
ble Codes (DTC). Refer to the Body Diagnostic Man-
ual for a complete list of diagnostic routines.
For additional information refer to Power Liftgate
Operation. For a complete system wiring schematic
refer to Wiring Diagrams. For system operationinstructions refer to the vehicles owner manual.
Refer to the Body section of the service manual
for additional information on liftgate components
such as the prop rods, hinges, door alignment and
striker alignment.
WARNING: BE CERTAIN TO READ ALL WARNINGS
AND CAUTIONS (NOTED BELOW) IN POWER LIFT-
GATE SYSTEM OPERATION BEFORE ATTEMPTING
ANY SERVICE OF THE POWER LIFTGATE SYSTEM
OR COMPONENTS.
OPERATION
With the push of a power liftgate open/close com-
mand switch (key fob or overhead console mounted) a
signal is sent out on the J1850 PCI Data Bus circuit.
This signal is detected at the body control module
(BCM). The BCM then sends a signal out on the
J1850 PCI Data Bus circuit to the power liftgate
module. The power liftgate module then signals the
power liftgate motor to start an open or close cycle,
depending on what position the liftgate is in open or
closed.
During a liftgate open or close cycle, if the power
liftgate module detects sufficient resistance to liftgate
travel, such as an obstruction in the liftgates path,
the power liftgate control module will immediately
stop the liftgate movement and reverse travel to the
full open or closed position. The ability for the power
liftgate module to detect resistance to liftgate travel
is accomplished by hall effect sensors, drive motor
speed and pinch sensors (tape switches).
The power liftgate control module has the ability to
learn. Anytime the liftgate is opened or closed using
the power liftgate system the module learns from its
cycle. If a replacement power liftgate component is
installed or a liftgate adjustment is made, the mod-
ule will relearn the effort and/or time required to
open or close the door. This learn cycle can be per-
formed with a Diagnostic Scan Tool, such as the
DRB IIItor with a complete cycle of the liftgate,
using any one of the command switches. Refer to
Standard Procedures in this section for detailed
instructions.
The power liftgate system is designed with a num-
ber of system inhibitors. These inhibitors are neces-
sary for safety and / or feasibility of the power
liftgate system. Refer to power liftgate system inhib-
itors noted below:
POWER LIFTGATE SYSTEM INHIBITORS
²The Power Liftgate may not operate in extreme
temperatures. These extreme temperatures will be
approximately -12É F (-24.4É C) on the low side and
143É F (61.6É C) for the high side. A chime/thermister
Fig. 2 KEY FOB
1 - Left Sliding Door Switch
2 - Right Sliding Door Switch
3 - Liftgate Switch
Fig. 3 LIFTGATE FUSE LOCATION
RSPOWER LIFTGATE SYSTEM8N-3
POWER LIFTGATE SYSTEM (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
Key fob, Outside Handle or
overhead console switches
do not power operate
liftgateBlown Fuse Check fuse and replace
Battery voltage low Charge or replace battery in key fob or
vehicle
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
(BCM)Check electrical connections
Refer to the Body electrical troubleshooting
guide for additional checks
Replace BCM if necessary
Failure of key fob Reprogram key fob
Replace key fob if necessary
Failure of Power Liftgate Module Disconnect then reconnect battery to reset
module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Failure of liftgate motor assembly Check for foreign matter preventing the
operation of gear motor assembly
Check wire connections
Motor clutch does not engage, replace
assembly
Full open switch inoperative, replace
switch, if necessary
Troubleshoot using Body Diagnostic
Manual Replace motor, if necessary
Liftgate does not stay open Failure of liftgate prop rods Replace prop rods, if necessary
Check for broken attachments
High inside/outside opening
effortFailure of liftgate prop rods Replace prop rods, if necessary
Check for broken attachments
Gear motor did not disengage Troubleshoot using Body Diagnostic
Manual Replace components, if necessary
Binding or sticking of components Establish location of binding and replace
necessary components
RSPOWER LIFTGATE SYSTEM8N-7
POWER LIFTGATE SYSTEM (Continued)
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The engage actuator is a serviceable component
and cannot be repaired, if found to be faulty it must
be replaced.
OPERATION
The engage actuators normal position is disen-
gaged. When a power liftgate open or close command
is generated from any of the command switches, the
power liftgate control module signals the engage
actuator to move its lever to the engaged position.
This engages the gear motor to the lift gear, so when
the motor turns the lift gate moves upward or down-
wards depending on its current position.
During a manual liftgate open or close cycle the
engage actuator is disengaged, allowing unrestricted
liftgate movement.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the left rear D-pillar trim from the
vehicle. Refer to Body for the procedure.
(3) Using your hand manually engage the actuator
link rod, this must be done to access one of the
engage actuator retaining screws.
(4) Remove the two engage actuator retaining
screws (Fig. 6).
(5) Disconnect the engage actuator electrical con-
nector and remove the engage actuator from the
vehicle.
INSTALLATION
(1) Position the engage actuator and connect the
engage actuator electrical connector.
(2) Install the two engage actuator retaining
screws.
(3) Manually disengage the actuator.
(4) Install the left rear D-pillar trim on the vehi-
cle. Refer to Body for the procedure.
(5) Connect the negative battery cable.
(6) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes.
(7) Verify power liftgate system and engage actua-
tor operation. Cycle the power liftgate through one
complete open and close cycle.
EXTERIOR HANDLE SWITCH
DESCRIPTION
Vehicles equipped with a power liftgate or power
locks utilize a exterior handle switch. The exterior
handle switch is a electronic release switch mounted
to the rear license plate lamp housing assembly,
located just above the license plate. This switch con-
trols the power liftgate release function and is also
capable of reversing the power liftgate when it is in
motion. A full power open cycle cannot be performed
using this switch, only one of the power open com-
mand switches (key fob and overhead console
mounted) can be used to perform a full power open
cycle.
The exterior handle switch is a serviceable compo-
nent. Consult your MoparŸ parts catalog for a spe-
cific part number.
OPERATION
When the exterior handle switch is depressed, with
the liftgate in the closed position. A message is sent
to the Body Control Module (BCM). The Body Con-
trol Module then sends a signal to the power liftgate
control module via the J1850 PCI data bus circuit.
The power liftgate control module then sends a sig-
nal to the power latch mounted actuator, which
moves the liftgate from the primary closed and
latched position to the open and movable position. If
the liftgate is not pulled open once the latch releases
within a few seconds, the latch will cinch closed
again.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Open the liftgate and remove the liftgate trim
panel. Refer to the Body section of the service man-
ual for the procedure.
Fig. 6 LIFTGATE GEAR MOTOR ASSEMBLY
1 - ENGAGE ACTUATOR RETAINING SCREWS
2 - LIFT GEAR RETAINING BOLTS
RSPOWER LIFTGATE SYSTEM8N-11
ENGAGE ACTUATOR (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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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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