lock CHRYSLER CARAVAN 2002 Service Manual

(15) Disconnect the shift cable at the lever. (Fig. 4)
(16) Remove the pinch side clip, then remove the
cable from the bracket on the column.
(17) Remove the pinch bolt coupling. (Fig. 5)
(18) Loosen the two lower mounting nuts.
(19) Remove the two upper mounting nuts
(20) Remove the steering column.
(21) Remove the clockspring (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/CLOCKSPRING - REMOV-
AL). (Fig. 6)
(22) Remove the mounting plate with the multi-
function switch.
(23) Remove the halo-lamp.(24) Remove the ignition key cylinder (Refer to 19
- STEERING/COLUMN/KEY/LOCK CYLINDER -
REMOVAL).
(25) Remove the BTSI.
INSTALLATION
To service the steering wheel components or the
airbag (Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL). Follow all WARN-
INGS AND CAUTIONS.
(1) Make sure the front wheels of the vehicle are
still in the STRAIGHT AHEAD position before begin-
ning the column installation procedure.
(2) Install the BTSI.
(3) Install the ignition key cylinder (Refer to 19 -
STEERING/COLUMN/KEY/LOCK CYLINDER -
INSTALLATION).
(4) Install the halo-lamp.
Fig. 3 STEERING WHEEL REMOVAL
1 - STEERING WHEEL
2 - PULLER
Fig. 4 SHIFT CABLE MOUNTING
1 - SHIFT CABLE MOUNT
2 - SHIFT LEVER
Fig. 5 PINCH BOLT
1 - PINCH BOLT
2 - STEERING COLUMN
Fig. 6 CLOCKSPRING
RSCOLUMN19-13
COLUMN (Continued)
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(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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IGNITION SWITCH
REMOVAL
The ignition switch attaches to the lock cylinder
housing on the end opposite the lock cylinder (Fig. 7).
For ignition switch terminal and circuit identifica-
tion, refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, further details
on wire harness routing and retention, as well as
pin-out and location views for the various wire har-
ness connectors, splices and grounds.
(1) Disconnect negative cable from battery.
(2) Remove steering column cover retaining screws
(Fig. 8).(3) Remove parking brake release cable from han-
dle (Fig. 9).
(4) Remove screws holding steering column
shrouds (Fig. 10)and remove lower shroud.
Fig. 7 Ignition SwitchÐViewed From Below Column
1 - IGNITION SWITCH
2 - LOCK CYLINDER HOUSING
3 - RETAINING TABS
Fig. 8 Steering Column Cover
1 - SCREWS
2 - STEERING COLUMN COVER
Fig. 9 Parking Brake Release Cable
1 - PARKING BRAKE CABLE
2 - PARKING BRAKE HANDLE
Fig. 10 Steering Column Shroud Screws
1 - STEERING WHEEL
2 - SCREWS
3 - LOWER STEERING COLUMN SHROUD
RSCOLUMN19-15
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(5) Place key cylinder in RUN position. Depress
lock cylinder retaining tab and remove key cylinder
(Fig. 11).
(6) Remove ignition switch mounting screw (Fig.
12) with a #10 Torxttamper proof bit.
(7) Depress retaining tab (Fig. 8) or (Fig. 13) and
gently pry ignition switch from steering column (Fig.
14).
(8) Disconnect electrical connectors from ignition
switch and remove switch (Fig. 15).
INSTALLATION
The ignition switch attaches to the lock cylinder
housing on the end opposite the lock cylinder (Fig. 7)
. For ignition switch terminal and circuit identifica-
tion, refer to the Wiring Diagrams section.
(1) Ensure the ignition switch is in the RUN posi-
tion and the actuator shaft in the lock housing is in
the RUN position.
(2) Install electrical connectors to ignition switch.
Fig. 11 Lock Cylinder Retaining Tab
1 - IGNITION SWITCH
2 - RETAINING TAB
Fig. 12 Ignition Switch Mounting Screw
1 - MOUNTING SCREW
2 - IGNITION SWITCH
Fig. 13 Ignition Switch Retaining Tab
1 - IGNITION SWITCH
2 - RETAINING TAB
Fig. 14 Removing Ignition Switch
1 - IGNITION SWITCH
2 - RETAINING TAB
19 - 16 COLUMNRS
IGNITION SWITCH (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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(8) Remove the two screws holding the metal cover
in place below the shifter/ignition interlock linkage
(Fig. 22), then remove the cover.
(9) Disconnect the shifter/ignition interlock link
from the lever on the lock cylinder housing (Fig. 23).
(10) Remove the key cylinder. To do this:
²Turn the key placing the key cylinder in the ON
position.²Depress and hold the retaining tab on the bot-
tom of the lock cylinder housing (Fig. 24).
²Pull the key cylinder straight out of the lock cyl-
inder housing.
(11) Remove the vehicle wiring harness connector
from the key cylinder halo lamp (Fig. 25).
(12) Remove the key cylinder halo lamp from the
lock cylinder housing.
Fig. 22 Cover Removal/Installation
1 - IGNITION SWITCH
2 - SCREW
3 - COVER
Fig. 23 Shifter/Ignition Interlock Linkage
Disconnected
1 - LEVER
2 - LINK
3 - LOCK CYLINDER HOUSING
Fig. 24 Cylinder Retaining Tab
1 - IGNITION SWITCH
2 - RETAINING TAB
Fig. 25 Wiring Harness Connection To Halo Lamp
1 - IGNITION SWITCH
2 - STEERING COLUMN ASSEMBLY
3 - WIRING HARNESS CONNECTOR
4 - IGNITION SWITCH HALO LIGHT
RSCOLUMN19-19
LOCK CYLINDER HOUSING (Continued)
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(13) Remove the ignition switch mounting screw
(Fig. 26).
(14) Depress the two retaining tabs (Fig. 27), then
remove the ignition switch from the lock cylinder
housing.
(15) Disconnect both tilt mechanism springs from
their mounting posts on the tilt housing (Fig. 28),
then move them to the side out of the way (Fig. 29).
(16) While supporting the lock cylinder housing,
remove both mounting screws securing the lock cyl-
inder housing to the column (Fig. 29).
(17) Remove the lock cylinder housing from the
bottom of the steering column.
INSTALLATION
(1) Install the lock cylinder housing in the bottom
of the steering column lining up the mounting holes.
(2) Install the self-tapping lock cylinder housing
mounting screws through the top of the column into
the housing (Fig. 29) . Tighten the two mounting
screws to a torque of 11 N´m (100 in. lbs.).
(3) Connect both tilt mechanism springs back onto
their mounting posts making sure the spring hooks
engage the grooves in the posts (Fig. 28) .
(4) Ensure that the ignition switch and the actua-
tor shaft in the lock cylinder housing are in the ON
position.
Fig. 26 Ignition Switch Mounting Screw
1 - MOUNTING SCREW
2 - IGNITION SWITCH
Fig. 27 Ignition Switch Retaining Tabs
1 - IGNITION SWITCH
2 - LOCK CYLINDER HOUSING
3 - RETAINING TABS
Fig. 28 Tilt Mechanism Spring Removal/Installation
1 - SPRINGS
2 - POST
3 - GROOVE
Fig. 29 Lock Cylinder Housing Mounting Screw
Location
1 - SPRINGS
2 - MOUNTING SCREWS
19 - 20 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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