instrument panel CHRYSLER CARAVAN 2002 Service Manual

(5) Install the mounting plate with the multi-func-
tion switch.
(6) Install the clockspring (Refer to 8 - ELECTRI-
CAL/RESTRAINTS/CLOCKSPRING - INSTALLA-
TION).
(7) Install the steering column to the vehicle.
(8) Install the two upper mounting nuts
(9) Tighten the two lower mounting nuts and the
two upper mounting nuts. Tighten to 12 N´m (105 in.
lbs.).
(10) Install the coupling onto the intermediate
shaft and install the pinch bolt. Tighten the pinch
bolt to 28 N´m (250 in. lbs.).
(11) Install the cable from the bracket on the col-
umn, then install the pinch side clips.
(12) Reconnect the shift cable at the lever.
(13) Reconnect the wiring harness connectors to
the clockspring, multi-function switch, halo lamp,
SKIM module, ignition switch and BTSI solenoid.
(14) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(15) Install the vibration damper weight.
(16) Install the steering wheel retaining nut.
Tighten the nut to 61 N´m (45 ft. lbs.)
(17) Install the airbag (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(18) Install the knee blocker reinforcement (Refer
to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - INSTALLATION).(19) Install the parking brake handle link.
(20) Install the knee blocker (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - INSTALLATION).
(21) Install the cluster trim bezel (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
INSTALLATION).
(22) Install the upper shroud (Refer to 19 -
STEERING/COLUMN/LOWER SHROUD - INSTAL-
LATION).
(23) Install the traction off switch.
(24) Install the lower shroud.
SPECIFICATIONS
COLUMN TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Steering Wheel Retaining
Nut61 45 Ð
Steering Column Mounting
Bracket Attaching Nuts12 Ð 105
Steering Column Coupling
Pinch Bolt28 Ð 250
Steering Column Airbag
Module Attaching Nuts11 Ð 100
19 - 14 COLUMNRS
COLUMN (Continued)
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(3) Carefully install the ignition switch. The
switch will snap over the retaining tabs (Fig. 16) .
Install mounting screw (Fig. 12).
(4) Install upper and lower shrouds.
(5) Install key cylinder (cylinder retaining tab will
depress only in the RUN position).
(6) Connect negative cable to battery.(7) Check for proper operation of ignition switch
and key-in warning switch.
LOCK CYLINDER HOUSING
DESCRIPTION - IGNITION INTERLOCK
All vehicles equipped with automatic transaxles
have an interlock system. The system prevents shift-
ing the vehicle out of Park unless the ignition lock
cylinder is in the Unlock, Run or Start position. In
addition, the operator cannot rotate the key to the
lock position unless the shifter is in the park posi-
tion. On vehicles equipped with floor shift refer to
the - Transaxle for Automatic Transmission Shifter/
Ignition Interlock.
REMOVAL
(1) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(2) Remove the screws attaching the lower steer-
ing column cover to the instrument panel (Fig. 17),
then remove the cover from the lower instrument
panel.
Fig. 15 Ignition Switch Connectors
1 - KEY IN SWITCH
2 - PRNDL SWITCH
3 - IGNITION SWITCH
Fig. 16 Ignition Switch Installation
1 - IGNITION SWITCH
2 - ACTUATOR SHAFT
3 - RETAINING TABS
Fig. 17 Lower Steering Column Cover Attachment
1 - PARK BRAKE RELEASE HANDLE
2 - STEERING COLUMN COVER
3 - STEERING COLUMN
4 - ATTACHING CLIP
5 - ATTACHING SCREWS
6 - HOOD RELEASE LEVER
7 - ATTACHING SCREWS
RSCOLUMN19-17
IGNITION SWITCH (Continued)
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(3) Remove the parking brake release cable from
the parking brake release lever (Fig. 18), then move
the lower steering column cover out of the way.
(4)
Remove the 10 bolts attaching the lower steering
column cover liner to the instrument panel (Fig. 19),
then remove the lower steering column cover liner.
(5) Remove the 3 screws attaching the upper and
lower shrouds to the steering column (Fig. 20), then
separate and remove both shrouds.(6) Remove the trim bezel on the instrument panel
above the steering column. The trim bezel is
mounted to the instrument panel using 2 screws (one
on each side of the column) and retaining clips.
(7) Remove the 2 screws securing the steering col-
umn fixed shroud to the steering column (Fig. 21),
then remove the shroud.
Fig. 18 Parking Brake Release Cable Attachment To
Release Lever
1 - PARK BRAKE PEDAL RELEASE CABLE
2 - PARK BRAKE RELEASE LEVER
3 - LOWER STEERING COLUMN COVER
Fig. 19 Liner Attachment
1 - STEERING COLUMN COVER LINER
2 - ATTACHING BOLTS
3 - ATTACHING BOLTS
4 - STEERING COLUMN
5 - ATTACHING BOLTS
6 - ATTACHING BOLTS
Fig. 20 Steering Column Shroud Screws
1 - STEERING WHEEL
2 - SCREWS
3 - LOWER STEERING COLUMN SHROUD
Fig. 21 Fixed Shroud Mounting
1 - SCREWS
2 - SHROUD
19 - 18 COLUMNRS
LOCK CYLINDER HOUSING (Continued)
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(5) Carefully install the ignition switch over the
actuator shaft (Fig. 30) . The switch will snap over
the retaining tabs on the housing.
(6) Install the ignition switch mounting screw (Fig.
26) .
(7) Install the key cylinder halo lamp on the lock
cylinder housing.
(8) Install the vehicle wiring harness connector
onto the key cylinder halo lamp (Fig. 25) .
(9) Install the key cylinder (with key in it turned
to the ON position) by sliding it straight into the lock
cylinder housing aligning the retaining tab on the
key cylinder with the hole in the lock cylinder hous-
ing.
(10) Turn the key to the OFF position and remove
the key.
(11) Connect the shifter/ignition interlock link to
the lever on the lock cylinder housing by aligning the
retaining tab on the lever with the ramp on the link
(Fig. 23) , then pushing the two together.
(12) Install the metal cover in place below the
shifter/ignition interlock linkage using the two
screws (Fig. 22) .
(13) Install the steering column fixed shroud on
the steering column (Fig. 21) using its 2 mounting
screws.
(14) Install the trim bezel on the instrument panel
above the steering column. The trim bezel is
mounted to the instrument panel using 2 screws (one
on each side of the column) and retaining clips.
(15) Install the lower steering column shroud on
the steering column. Install and securely tighten the
center screw attaching the lower shroud to the tilt
head on the column (Fig. 20) .(16) Install the upper steering column shroud over
the tilt head of the steering column snapping it into
place on the lower shroud. Install and securely
tighten the 2 remaining screws attaching the upper
shroud to the lower shroud (Fig. 20) .
(17) Install the steering column cover liner on the
instrument panel below the steering column (Fig. 19)
. Install and securely tighten the 10 bolts attaching
the steering column cover liner to the instrument
panel.
(18) Install the parking brake pedal release cable
on the parking brake release lever in the lower steer-
ing column cover (Fig. 18) .
(19) Install the lower steering column trim cover
on the instrument panel below the steering column.
Install and securely the screws attaching the lower
steering column cover to the instrument panel (Fig.
17) .
(20) Connect the negative (ground) cable on the
battery terminal.
KEY/LOCK CYLINDER
DESCRIPTION
The lock cylinder is inserted in the end of the
housing opposite the ignition switch.
OPERATION
The ignition key rotates the cylinder to 5 different
detents (Fig. 31) :
²Accessory
²Off (lock)
²Unlock
²On/Run
²Start
Fig. 30 Ignition Switch Installation
1 - IGNITION SWITCH
2 - ACTUATOR SHAFT
3 - RETAINING TABS
Fig. 31 Ignition Lock Cylinder Detents
RSCOLUMN19-21
LOCK CYLINDER HOUSING (Continued)
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REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove steering column cover retaining
screws.
(3) Remove screws holding steering column
shrouds and remove lower shroud.
(4) Place key cylinder in RUN position. Depress
lock cylinder retaining tab on the bottom of the lock
housing and remove key cylinder.
INSTALLATION
(1) Install key in lock cylinder. Turn key to run
position (retaining tab on lock cylinder can be
depressed).
(2) The shaft at the end of the lock cylinder aligns
with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the socket is
in the Run position (Fig. 32) .
(3) Align the lock cylinder with the grooves in the
housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the hous-
ing.
(4) Turn the key to the Off position. Remove the
key.
(5) Install lower steering column shroud.
(6) Install steering column cover.
(7) Connect negative cable to battery.
GEAR SHIFT LEVER
REMOVAL
(1) Remove the knee blocker (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - REMOVAL).(2) Remove the knee blocker reinforcement (Refer
to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(3) Remove the upper and lower shrouds (Refer to
19 - STEERING/COLUMN/LOWER SHROUD -
REMOVAL).
(4) Remove the cluster trim bezel (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
REMOVAL).
(5) Remove the fixed shroud from the column.
(6) Disconnect the electrical connector to the BTSI.
(7) Remove the two screws securing the BTSI to
the steering column. (Fig. 33)
(8) Disconnect the SKIM electrical wire connector.
(9) Remove the SKIM from the steering column.
(10) Disconnect the autostick wiring connector (if
equipped with autostick).
(11) Disconnect the shifter cable at the shifter.
(12) Remove the three screws securing the shifter
to the steering column. (Fig. 34)
(13) Remove the shift lever from the column.
INSTALLATION
(1) Install the shifter cable to the shifter.
(2) Install the three screws securing the shifter to
the steering column.
(3) Install the shifter cable at the handle.
(4) Install the SKIM to the steering column.
(5) Reconnect the SKIM electrical wire connector.
(6) Reconnect the autostick wiring connector (if
equipped with autostick).
(7) Install the two screws securing the BTSI to the
steering column.
(8) Reconnect the electrical connector to the BTSI.
(9) Install the fixed shroud to the column.
Fig. 32 Socket in Lock Cylinder Housing
1 - LOCK CYLINDER HOUSING
2 - SOCKET
Fig. 33 SHIFT LEVER / B.T.S.I
1 - B.T.S.I.
2 - SHIFT LEVER
19 - 22 COLUMNRS
KEY/LOCK CYLINDER (Continued)
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(10) Install the cluster trim bezel (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
INSTALLATION).
(11) Install the upper and lower shrouds (Refer to
19 - STEERING/COLUMN/LOWER SHROUD -
INSTALLATION).
(12) Install the knee blocker reinforcement (Refer
to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - INSTALLATION).
(13) Install the knee blocker (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - INSTALLATION).
SHROUD
REMOVAL
(1) Remove the three screws from the lower
shroud.
(2) Unsnap and remove the lower shroud.
(3) Lift off upper shroud from the steering column.
(Fig. 35)
INSTALLATION
(1) Install the upper shroud in place over the
steering column.
(2) Snap the lower shroud to the upper shroud.
(3) Install and tighten the three retaining screws.
Tighten the screws to 11 N´m (100 in. lbs.). (Fig. 35)
STEERING WHEEL
REMOVAL
NOTE: Before proceeding, (Refer to 19 - STEERING/
COLUMN - WARNING).(1) Rotate key cylinder to the lock position and
remove key. Rotate the steering wheel a half turn to
the left until the steering column lock engages keep-
ing the steering column in the locked position (Fig.
36).
(2) Remove the 3 bolts (one in each spoke of the
steering wheel) attaching the airbag module to the
steering wheel. Lift the airbag module from the
steering wheel.
(3) Disconnect wiring connectors from the airbag,
horn switch wire, and speed control switches (Fig.
37). Remove the wiring harness routing clip from the
airbag module studs.
Fig. 34 SHIFT LEVERFig. 35 UPPER AND LOWER SHROUDS
1 - FIXED SHROUD
2 - UPPER SHROUD
3 - CLOCKSPRING
4 - LOWER SHROUD
5 - STEERING COLUMN
Fig. 36 Steering Wheel In Locked Position
1 - STEERING WHEEL
RSCOLUMN19-23
GEAR SHIFT LEVER (Continued)
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GEAR SHIFT CABLE
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect gear shift cable at manual valve
lever (Fig. 169).
(3) Disconnect gear shift cable from upper mount
bracket (Fig. 169).
(4) Remove instrument panel lower silencer (Fig.
170).(5) Remove knee bolster (Fig. 171).
(6) Disconnect PRNDL cable from gear shift lever
(Fig. 172).
Fig. 169 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 170 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 171 Knee Bolster
1 - KNEE BOLSTER
Fig. 172 PRNDL Cable
1 - PRNDL CABLE
2 - GEAR SHIFT LEVER
RS31TH AUTOMATIC TRANSAXLE21 - 101
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(4) Connect PRNDL cable to gear shift lever (Fig.
177). Adjust if necessary.
(5) Install knee bolster (Fig. 178).
(6) Install instrument panel lower silencer (Fig.
179).
(7) Install gear shift cable to transaxle upper
mount bracket (Fig. 180). An audible ªclickº should
be heard.
(8) Connect gear shift cable end to transaxle man-
ual valve lever (Fig. 180).(9) Adjust gearshift cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 31TH/GEAR
SHIFT CABLE - ADJUSTMENTS)
Fig. 177 PRNDL Cable
1 - PRNDL CABLE
2 - GEAR SHIFT LEVER
Fig. 178 Knee Bolster
1 - KNEE BOLSTER
Fig. 179 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 180 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
RS31TH AUTOMATIC TRANSAXLE21 - 103
GEAR SHIFT CABLE (Continued)
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DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK SOLENOID
For intended BTSI system operation, refer to the
following chart:
ACTION EXPECTED RESPONSE
1. Turn key to the9OFF9
position.1. Shifter CAN be shifted
out of park with brake
pedal applied.
2. Turn key to the
9ON/RUN9position.2. Shifter CANNOT be
shifted out of park.
3. Turn key to the
9ON/RUN9position and
depress the brake pedal.3. Shifter CAN be shifted
out of park.
4. Leave shifter in any
gear and try to return key
to the9LOCK9or9ACC9
position.4. Key cannot be
returned to the9LOCK9or
9ACC9position.
5. Return shifter to
9PARK9and try to remove
the key.5. Key can be removed
(after returning to9LOCK9
position).
6. With the key removed,
try to shift out of9PARK9.6. Shifter cannot be
shifted out of9PARK9.
NOTE: Any failure to meet these expected
responses requires system repair. Refer to the
appropriate Diagnostic Information.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove instrument panel lower shroud (Fig.
214).(3) Remove knee bolster (Fig. 215).
(4) Remove steering column lower shroud.
(5) Disconnect brake/transmission shift interlock
(BTSI) solenoid connector (Fig. 216).
Fig. 214 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 215 Knee Bolster
1 - KNEE BOLSTER
Fig. 216 BTSI Solenoid Connector
1 - BTSI SOLENOID
2 - SOLENOID CONNECTOR
RS31TH AUTOMATIC TRANSAXLE21 - 117
SHIFT INTERLOCK SOLENOID (Continued)
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(5) Install instrument panel lower silencer (Fig.
221).
(6) Connect battery negative cable.
(7) Verify proper shift interlock system operation.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/SHIFT INTERLOCK SOLENOID -
OPERATION)
SOLENOID - TCC
DESCRIPTION
The torque converter clutch (TCC) solenoid is fas-
tened to the transaxle valve body, and its connector
protrudes through the transaxle case (Fig. 222).
OPERATION
The torque converter clutch solenoid is responsible
for controlling application of the torque converter
clutch. It is controlled by the Powertrain Control
Module (PCM), which determines when conditions
are acceptable for torque converter lock-up.
REMOVAL
(1) Remove valve body from transaxle. (Refer to 21
- TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/VALVE BODY - REMOVAL)
(2) Remove three (3) torque converter clutch sole-
noid-to-valve body screws (Fig. 223).
(3) Remove torque converter clutch solenoid (Fig.
223). Note orientation of plug and spring.
Fig. 221 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 222 Torque Converter Clutch Solenoid
1 - TCC SOLENOID WIRING CONNECTOR
RS31TH AUTOMATIC TRANSAXLE21 - 119
SHIFT INTERLOCK SOLENOID (Continued)
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