2005 CHRYSLER CARAVAN lock

POWER SLIDING DOOR SYSTEM
TABLE OF CONTENTS
page page
POWER SLIDING DOOR SYSTEM
DESCRIPTION.........................40
OPERATION...........................41
DIAGNOSIS AND TESTING
POWER SLIDING DOOR SYSTEM........42
STANDARD PROCEDURE
POWER SLIDING DOOR LEARN CYCLE....48
PUSH-PIN GROMMET REPLACEMENT.....48
POWER SLIDING DOOR ADJUSTMENT....49
LATCH
DESCRIPTION.........................49
OPERATION...........................49
REMOVAL.............................49
INSTALLATION.........................50
SLIDING DOOR MOTOR
DESCRIPTION.........................51
OPERATION...........................51
REMOVAL.............................51
INSTALLATION.........................51
FULL OPEN SWITCH
DESCRIPTION.........................52
OPERATION...........................52
B-PILLAR SWITCH
DESCRIPTION.........................52OPERATION...........................52
REMOVAL.............................52
INSTALLATION.........................52
LOWER DRIVE UNIT
DESCRIPTION.........................53
OPERATION...........................53
REMOVAL.............................53
INSTALLATION.........................54
FLEX DRIVE
DESCRIPTION.........................55
OPERATION...........................55
REMOVAL.............................55
INSTALLATION.........................56
LOWER DRIVE UNIT TRACK & RACK
DESCRIPTION.........................57
OPERATION...........................57
REMOVAL.............................57
INSTALLATION.........................58
WIRING HARNESS
DESCRIPTION.........................59
OPERATION...........................59
REMOVAL.............................59
INSTALLATION.........................59
POWER SLIDING DOOR
SYSTEM
DESCRIPTION
Some vehicles are equipped with a power sliding
door system. Vehicles may be equipped with only a
right side power sliding door or a right and left side
power sliding doors. The components of the power
sliding door system are:
²Door motor assembly
²Latch assembly
²Sliding door control module
²Lower drive unit assembly
²Flex drive assembly
²Wire harness and track
²Lower drive unit track and rack assembly
²Full open switch
²B-pillar switch
²Overhead console switch
²Key fob switches (Fig. 1)
²Pawl switch
²Ratchet switch
²Child lockout and handle switchesEach power sliding door has its own door control
module, 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 sliding 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 sliding 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 sliding 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
sliding door latch assembly. The B-pillar switch is an
open and close command switch located on the inte-
rior B-pillar trim. The overhead console switch, is an
open and close command switch located in the vehi-
cle's overhead console.
Software technology has enabled the power sliding
door control module to detect resistance to door
8N - 40 POWER SLIDING DOOR SYSTEMRS

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 Integrated Power Module (IPM) assembly. The
child lockout switch prevents 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 Programmable Communication Interface
(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 diag-
nose these trouble codes.
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). Refer to the
appropriate wiring information for complete circuit
schematic or connector pin-out information.WARNING: BE CERTAIN TO READ ALL WARNINGS
AND CAUTIONS IN POWER SLIDING DOOR OPER-
ATION BEFORE ATTEMPTING ANY SERVICE OF
THE 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 Programmable Communication Interface (PCI)
Data Bus circuit 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 cycle, if the power sliding door
module detects sufficient resistance to door travel,
such as an obstruction in the door's path, the power
sliding door module will immediately stop door move-
ment 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 detecting 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 complete cycle of the door, using any one of the
command switches or with the DRB IIIt, or equiva-
lent scan tool. (Refer to 8 - ELECTRICAL/POWER
DOORS - STANDARD PROCEDURE - LEARN
CYCLE) 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. The power sliding door system
inhibitors are:
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 transmission must be inpark or neutral
in order for the power sliding door system to start a
cycle.
²The child lockout switch must be in the
ªUNLOCKEDº position in order for the power sliding
door systems B-pillar switches to function.
Fig. 1 KEY FOB
1 - LEFT SLIDING DOOR SWITCH
2 - RIGHT SLIDING DOOR SWITCH
3 - LIFTGATE SWITCH
RSPOWER SLIDING DOOR SYSTEM8N-41
POWER SLIDING DOOR SYSTEM (Continued)

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.
²The fuel tank filler door must be in the closed
position. Due to the sliding door interference with
the open fuel tank filler door, a mechanical linkage
prevents the side door from opening and striking the
fuel door. Refer to the Body section of this manual 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). NEVER PLACE
OBJECTS IN THE POWER SLIDING DOOR WHEN
CINCHING CLOSED. THE OBSTACLE DETECTION
FUNCTION IS INOPERATIVE DURING THE CINCH
PHASE AND DAMAGE TO THE VEHICLE, POWER
SLIDING DOOR SYSTEM OR COMPONENTS
AND/OR PERSONAL INJURY MAY OCCUR.
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.
DIAGNOSIS AND TESTING
POWER SLIDING DOOR SYSTEM
The power sliding door system contains many com-
ponents and modules. In order to obtain conclusive
testing, the Programmable Communications Interface
(PCI) data bus network and all of the electronic mod-
ules 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 - 42 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)

POWER SLIDING DOOR SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
Door opens unexpectedly Inoperative sliding door control module
or Body Control Module (BCM)Disconnect then reconnect battery negative
cable to reset module. Cycle door, if no
function exists check for loose wire
connections, Refer to the Body Diagnostic
Manual for detailed procedures
Inoperative latch assembly Check wiring/cable connections
Check for trouble codes, replace latch if
necessary
Inoperative open/close command
switchCheck for shorted or defective switch
Inoperative striker Striker misaligned or loose
Striker damaged
Replace striker if necessary
Door will not open manually
using inside handleThe child lock out switch is in the
9LOCKED9positionEnsure the child lock out switch is in the
9UNLOCKED9position
Inoperative inside handle assembly
Check for broken inside handle
assembly
Check cable connections at latch and
handle assembly.
Check for binds or kinks in cable.
Check for foreign matter preventing the
operation of handle assembly
Replace the handle if necessary
Inoperative latch assembly Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Replace latch if necessary
Inoperative inside handle cable
assemblyCheck cable for binding
Check cable for broken condition
Replace the cable, if necessary
Binding or sticking of components Check for foreign matter preventing the
operation of door
Establish location of binding
Replace necessary components
Door will not open manually
using outside handleInoperative outside handle assembly Check for broken outside handle assembly
Check cable connections at latch and handle
assembly.
Check for binds or kinks in cable.
RSPOWER SLIDING DOOR SYSTEM8N-43
POWER SLIDING DOOR SYSTEM (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Inoperative fuel filler door lockout
mechanismCheck operation of fuel filler door lockout
mechanism.
Inoperative sliding door control module
or BCMDisconnect then reconnect battery negative
cable to reset module. Cycle door, if no
function exists check for loose wire
connections, see Body Diagnostic Manual for
detailed procedures
Inoperative 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
operate power sliding doorBlown Fuse Check fuse and replace
Battery voltage low Charge or replace battery
Inoperative 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 the appropriate wiring
information
Inoperative BCM Check electrical connections
Refer to the body diagnostic manual for
additional checks
Replace BCM if necessary
Inoperative key fob Verify inoperative key fob by trying other key
fob functions
Replace key fob battery
Reprogram key fob
Replace key fob if necessary
Inoperative sliding door control module Disconnect then reconnect battery negative
cable to reset module. Cycle door, if no
function exists check for loose wire
connections, see Body Diagnostic Manual for
detailed procedures
Inoperative 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
8N - 46 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)

POWER SLIDING DOOR ADJUSTMENT
In order for the power sliding door system to func-
tion properly the door must move freely and
smoothly. The power sliding door system can accom-
modate for some minor changes in the effort required
to move the door. However, in extreme conditions the
door may need to be mechanically adjusted for proper
fit. (Refer to 23 - BODY/DOORS - SLIDING/SLID-
ING DOOR - ADJUSTMENTS).
If a problem exists with the power sliding door and
it is suspected to be extreme effort, check for proper
door alignment and adjustment first, then check the
door tracks and drive unit for free manual operation.
(Refer to 23 - BODY/DOORS - SLIDING/SLIDING
DOOR - ADJUSTMENTS) for detailed instructions.
LATCH
DESCRIPTION
One power latch is used for each power sliding door.
The latch is located on the trailing edge of the sliding
door assembly (Fig. 3). This power latch assembly is com-
prised of many different components which have the abil-
ity to perform the power cinch, release, lock, unlock and
safety related operations. These components are the door
latch, lock/unlock actuator, cinch/release actuator and
child lockout, pawl, ratchet and handle switches. The
pawl and ratchet switches are used to indicate the pri-
mary and secondary latched positions. The cinch latch
also provides a connection point for the interior handle,exterior handle and hold open latch cables. If any of the
components of the latch assembly are inoperative the
complete power latch assembly must be replaced.
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 actua-
tor 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 power sliding
door has reached its secondary latch position (deter-
mined by pawl and ratchet switches). During a power
open cycle, the power release actuator will stop once the
sliding door has moved from the primary latch position.
The power latch uses inputs from the lock/unlock
actuator, power sliding door control module and child
lockout, pawl, ratchet and handle switches to provide
safe power cinch and release operations. (Refer to 8 -
ELECTRICAL/POWER DOORS - OPERATION) for
additional information.
REMOVAL
(1)Disconnect and isolate the battery negative cable.
(2) Remove the appropriate side door trim panel,
(Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - REMOVAL).
(3) Remove the weather shield if necessary.
(4) Open the side door all the way and remove the
door latch retaining bolts (Fig. 4).
Fig. 3 REMOVING/INSTALLING POWER LATCH IN
SLIDING DOOR
1 - POWER LATCH ASSEMBLY
Fig. 4 REMOVING LATCH RETAINING BOLTS
1 - LATCH RETAINING BOLTS
2 - SIDE DOOR
RSPOWER SLIDING DOOR SYSTEM8N-49
POWER SLIDING DOOR SYSTEM (Continued)

(5) Partially close the door and pull the latch
assembly out of the side door inner panel, (Fig. 5).
(6) Disconnect all electrical connectors leading to
the latch assembly.
(7) Disconnect the inside and outside handle cables
from the latch assembly.
(8) Disconnect the hold open latch cable from the
latch assembly.
(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. 6).
(2) Connect the lock actuator link rod on the latch
assembly.
(3) Connect the hold open latch cable on the latch
assembly.
(4) Connect the inside and outside handle cables
on the latch assembly.
(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, (Fig. 7). Torque to 10 - 12 N´m (100 in. lbs.).
(7) Install the weathershield if necessary.(8) Install the appropriate side door trim panel,
(Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - INSTALLATION) for detailed instructions.
(9) Connect the negative battery cable.
Fig. 5 POWER LATCH POSITION & ORIENTATION
1 - POWER LATCH ASSEMBLY
Fig. 6 POWER LATCH POSITION & ORIENTATION
1 - POWER LATCH ASSEMBLY
Fig. 7 REMOVING LATCH RETAINING BOLTS
1 - LATCH RETAINING BOLTS
2 - SIDE DOOR
8N - 50 POWER SLIDING DOOR SYSTEMRS
LATCH (Continued)

SLIDING DOOR MOTOR
DESCRIPTION
The door motor is located in the center of the
power sliding door (Fig. 8) 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 the power and torque
to move the sliding door from the open/closed posi-
tion 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.
OPERATION
With the push of a power sliding door command
switch, the power sliding door control module will
signal the latch assembly to release the door from its
primary locked position. The door motor will then
take over to provide the power to open the door to its
full open or closed position. The gear reduction por-
tion 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 thedoor under power and disengages it so the door can
be moved easily under manual operation.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the door trim panel from the appropri-
ate door, (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - REMOVAL).
(3) Remove the water shield as necessary to gain
access to motor assembly.
(4) Remove retaining clip holding flex drive assem-
bly to the motor (Fig. 9). 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 the door motor.
(7) Remove the door motor assembly from the
vehicle.
INSTALLATION
(1) Position the door motor assembly on the door
inner panel.
(2) Install the push-pin fasteners retaining the
motor assembly to the power sliding door.
Fig. 8 POWER SLIDING DOOR COMPONENTS
1 - POWER 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
Fig. 9 FLEX DRIVE RETAINING CLIP
1 - FLEX DRIVE CABLE RETAINING CLIP
2 - FLEX DRIVE CABLE
3 - DOOR MOTOR ASSEMBLY
RSPOWER SLIDING DOOR SYSTEM8N-51