electr CHRYSLER VOYAGER 2002 Service Manual

CONDITION POSSIBLE CAUSES CORRECTION
Replace the handle if necessary
Failure of latch assembly Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Replace latch assembly, if necessary
Failure of outside 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
Sliding door will not
open/close manuallyBinding or sticking of components Establish location of binding. Disconnect
flex drive and recheck. Replace necessary
components
Failure of latch assembly Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Replace latch assembly, if necessary
Sliding door will not
open/close under powerFailure 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 latch assembly Check wire connections and for blown fuse
Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
Failure of motor assembly Troubleshoot using body diagnostic manual
Failure of full open switch assembly Troubleshoot using body diagnostic manual
Failure of flex drive assembly Disconnect flex drive and check for broken
condition
Failure of lower drive unit assembly Remove lower drive unit and check for
broken condition
Binding or sticking of components Establish location of binding and replace
necessary components
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Power loss during power
door operationWiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
RSPOWER SLIDING DOOR SYSTEM8N-23
POWER SLIDING DOOR SYSTEM (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
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 module Disconnect 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
High inside/outside opening
effortFailure of latch assembly Check wire connections and for blown fuse
Check cable connections
RSPOWER SLIDING DOOR SYSTEM8N-25
POWER SLIDING DOOR SYSTEM (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
Failure of inside/outside handle
assemblyGo to that9POSSIBLE CAUSE9and review
9CORRECTIONS9
Binding or sticking of components Establish location of binding and replace
necessary components
Door continues to cinch
closed during power modeFailure of latch assembly Check wire connections and for blown fuse
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
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
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Door continues to open
during power mode
(runaway motor)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 hold open latch assembly Check wire/cable connections
Replace hold open latch, if necessary
Failure of drive assembly Remove lower drive unit and check for no
drive condition
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Door opens very slowly Failure of door motor assembly Check wire/cable connections
Replace motor assembly, if necessary
Binding or sticking of components Establish location of binding and replace
necessary components
Squeaks, Noises and rattles Foreign material in door
compartmentRemove foreign material
Loose components Check and tighten loose components
Poor door track lubrication Lubricate the front portions of the side door
tracks with9Door EaseT9or equivalent
8N - 26 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)
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STANDARD PROCEDURE
STANDARD PROCEDURE - WELLNUT
REPLACEMENT
Vehicles equipped with a power sliding door utilize
wellnuts. These wellnuts are used to hold and isolate
the power sliding door motor to and from the door
inner panel. The wellnut functions like a expandable
rubber core plug, as the screw fastener is threaded
into the wellnut and tightened the wellnuts diameter
increases. This secures the door motor assembly to
the inner panel and keeps the audible motor vibra-
tions to a minimum. If a wellnut shows signs of wear,
it must be replaced. Follow the procedure below if
replacement is necessary.
(1) Remove the door motor from the door inner
panel. (Refer to 8 - ELECTRICAL/POWER DOORS/
MOTOR - REMOVAL).
(2) Remove the wellnuts from the inner panel by
pulling them straight out (Fig. 4). If a wellnut is dif-
ficult to remove, use a high leverage cutting tool to
cut the wellnut in half and remove the two halves
from the door assembly.
(3) Install the replacement wellnuts in the inner
panel and install the door motor(Refer to 8 - ELEC-
TRICAL/POWER DOORS/MOTOR - INSTALLA-
TION) .CAUTION: Be certain to use the correct torque
specification (35 in.lbs.) when installing the door
motor retaining screws.STANDARD PROCEDURE - POWER DOOR
LEARN CYCLE
Any time a power side door component is removed,
replaced, door adjustment is performed or diagnostic
trouble codes are addressed and erased, a learn cycle
mustbe performed. This learn cycle enables the
power side door control module to learn or relearn its
critical information (travel limits, resistance to door
travel, etc.) which allows it to perform properly and
safely. It also tells the technician that the system is
performing properly and is able to be returned to ser-
vice. To perform a power door learn cycle do the fol-
lowing:
(1) Obtain a DRB IIItscan tool.
Connect the DRB IIItto the vehicle and check for
any power side door system stored diagnostic trouble
codes, erase any stored codes. Operate the system
and check to see if any trouble codes return. If any
diagnostic trouble codes return, diagnose, correct and
erase the codes before performing the learn cycle. If a
DRB IIItscan tool is not available, the learn cycle
can be performed by opening and closing the power
side door using any of the normal open/close com-
mand switches. Be certain to cycle the side door
through a complete openandclose cycle or the pro-
cedure will not be complete.
(2) Using the DRB IIIt, Go into Test Routine
Menu and select a power open command.
(3) Select a power close command.
(4) The power side door learn cycle is complete.
NOTE: If the power side door will not complete a
full cycle, a problem exists with the power side
door system. Refer to Power Side Door Diagnosis
and Testing.
STANDARD PROCEDURE - 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.
Fig. 4 Side Door Motor Wellnuts
1 - Wellnuts
2 - Side Door Inner Panel
RSPOWER SLIDING DOOR SYSTEM8N-27
POWER SLIDING DOOR SYSTEM (Continued)
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(5) Partially close the door and pull the latch
assembly out of the side door inner panel.
(6) Disconnect all electrical connectors leading to
the latch assembly.
(7) Disconnect the inside and outside handle cables
from the latch assembly. Refer to the Body Section of
the service manual for the procedure.
(8) Disconnect the hold open latch cable from the
latch assembly. Refer to the Body Section of the ser-
vice manual for the procedure.
(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.
(2) Connect the lock actuator link rod on the latch
assembly.
(3) Connect the hold open latch cable on the latch
assembly. Refer to the procedure in this section for
detailed instructions.
(4) Connect the inside and outside handle cables
on the latch assembly. Refer to the procedure in the
Body section for detailed instructions.
(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. Torque to 10 - 12 N´m (100 in. lbs.).
(7) Install the weathershield if necessary. Refer to
the procedure in the Body section for detailed
instructions.
(8) Install the appropriate side door trim panel.
Refer to the procedure in the Body section for
detailed instructions.
(9) Connect the negative battery cable.
SLIDING DOOR MOTOR
DESCRIPTION
Vehicles equipped with a power sliding door utilize
a door motor assembly. The door motor is located in
the center of the side door (Fig. 7) 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 position to full closed/open position, after
the power latching mechanism has released.
Special wellnuts and screws are used in the side
door inner panel to retain the door motor to the doorpanel. Refer to Standard Procedures in this section
for additional wellnut information.
The door motor is replaced as a complete assembly,
which includes the DC motor, gear reduction and
clutch assemblies. Consult your Mopar parts catalog
for specific part numbers.
OPERATION
With the push of a Power Side Door (PSD) com-
mand switch, the PSD control module will signal the
latch assembly to release the door from its primary
locked position. The drive motor will then take over
to provide the power to open the door to its full open
or closed position. The gear reduction portion 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 the door under
power and disengages it so the door can be moved
easily under manual operation.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
Fig. 7 Side Door Components
1 - 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
RSPOWER SLIDING DOOR SYSTEM8N-29
LATCH (Continued)
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(2) Remove the door trim panel from the appropri-
ate side door. Refer to the Body section for the pro-
cedure.
(3) Remove water shield as necessary to gain
access to motor assembly.
(4) Remove retaining clip holding flex drive assem-
bly to the motor (Fig. 8). Pull flex drive cable straight
out of the motor assembly.
(5) Disconnect door motor electrical connector.
(6) Remove the 4 screws holding the motor to the
inner door panel.
(7) Remove the motor assembly from the vehicle.
INSTALLATION
(1) Position the motor assembly on the door inner
panel.
(2) Install the 4 screws holding the motor to the
inner door panel. Torque to 35 in. lbs.
(3) Install the flex shaft by lining up the square
shaped drive shaft with corresponding hole in motor
drive unit and push straight in.
(4) Install the E-clip to secure flex-shaft.
(5) Connect the negative battery cable.
(6) Install the weather shield. Refer to the Body
section of the service manual for the procedure.
(7) Install the door trim panel on the side door.
Refer to Body for the procedure.
FULL OPEN SWITCH
DESCRIPTION
Vehicles equipped with a power sliding door utilize
a full open switch. This switch is located in the hold
open latch (Fig. 9) under the side door lower hinge.
When the power side door module receives a ground
signal input from the full open switch, and as long as
the cinching latch actuator is not in power mode or
the handle switch is open, the signal indicates that
the door is at the full open position.
The full open switch is incorporated into the hold
open latch. If the full open switch proves faulty, the
entire hold open latch assembly must be replaced.
OPERATION
The full open switch is triggered by a pawl lever in
the hold open latch. When the full open switch is
closed (circuit to ground) the ratchet has engaged on
the hold open striker and the pawl lever has engaged
on the ratchet, locking the latch from opening and
holding the door in the full open position.
Fig. 8 Flex Drive Retaining Clip
1 - Flex Drive Cable Retaining Clip
2 - Flex Drive Cable
3 - Side Door Motor Assembly
Fig. 9 Full Open Switch Position & Orientation
1 - Hold Open Latch Assembly
2 - Hold Open Latch Cable
3 - Full Open Switch
8N - 30 POWER SLIDING DOOR SYSTEMRS
SLIDING DOOR MOTOR (Continued)
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LEFT B-PILLAR SWITCH
DESCRIPTION
Vehicles equipped with power sliding side door/s
utilize B-pillar switches. These switches are located
on the interior of the vehicle, on the B-pillar trim
panels. These switches serve as an open and close
command switch for the appropriate power side door.
The B-pillar switches are replaceable. Consult your
Mopar parts catalog for a specific part number.
OPERATION
When the Pillar switch is depressed a signal is
sent to the Body Control Module (BCM), this signal
is then sent to the Power Sliding Door Module, tell-
ing it to start a power open or close cycle. The child
lockout feature must be disabled and the side door
must be unlocked in order for the Pillar switch to
function.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Using a trim stick or other small flat-bladed
pry tool, gently pry the leading upper edge of the
B-pillar switch away from the B-pillar trim.
(3) Once the upper edge is free from pillar trim,
rock the switch out of the switch opening.
(4) Disconnect the B-pillar switch electrical con-
nector. First, slide the connector lock away from the
switch then, depress connector retaining tab while
pulling straight apart.
(5) Remove the B-pillar switch from the vehicle.
INSTALLATION
(1) Connect the B-pillar switch electrical connector.
Slide connector lock toward the switch to lock in
place.
(2) Hook the lower edge of the B-pillar switch on
the B-pillar trim and then push the switch firmly
into position.
(3) Connect the negative battery cable.
RIGHT B-PILLAR SWITCH
DESCRIPTION
Vehicles equipped with power sliding side door/s
utilize B-pillar switches. These switches are located
on the interior of the vehicle, on the B-pillar trim
panels. These switches serve as an open and close
command switch for the appropriate power side door.
The B-pillar switches are replaceable. Consult your
Mopar parts catalog for a specific part number.
OPERATION
When the Pillar switch is depressed a signal is
sent to the Body Control Module (BCM), this signal
is then sent to the Power Sliding Door Module, tell-
ing it to start a power open or close cycle. The child
lockout feature must be disabled and the side door
must be unlocked in order for the Pillar switch to
function.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Using a trim stick or other small flat-bladed
pry tool, gently pry the leading upper edge of the
B-pillar switch away from the B-pillar trim.
(3) Once the upper edge is free from pillar trim,
rock the switch out of the switch opening.
(4) Disconnect the B-pillar switch electrical con-
nector. First, slide the connector lock away from the
switch then, depress connector retaining tab while
pulling straight apart.
(5) Remove the B-pillar switch from the vehicle.
INSTALLATION
(1) Connect the B-pillar switch electrical connector.
Slide connector lock toward the switch to lock in
place.
(2) Hook the lower edge of the B-pillar switch on
the B-pillar trim and then push the switch firmly
into position.
(3) Connect the negative battery cable.
LOWER DRIVE UNIT
DESCRIPTION
Vehicles equipped with a power sliding side door
utilize a lower drive unit. The lower drive unit is
located on the sliding door lower hinge assembly
(Fig. 10). This drive unit is used to transfer the lat-
eral rotation of the flex drive assembly into longitu-
dinal movement via the drive unit gear and door
track rack teeth (Fig. 10).
The lower drive unit is a replaceable component.
Consult your Mopar parts catalog for specific part
numbers.
OPERATION
During a power open or close cycle, the power drive
unit is driven by the flex drive assembly. The lower
drive units main gear engages the lower door tracks
rack teeth, this moves the side door assembly accord-
ingly.
RSPOWER SLIDING DOOR SYSTEM8N-31
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NOTE: Take care to locate the lower hinge assem-
bly on the door in its original position (ie. match
screw washer with rings left on hinge). Adjust door
fit if required.
(4) Remove the floor jack (Fig. 14).
(5) Install the hold-open striker. Refer to the Body
section for the procedure.
(6) Install the side door sill plate on the lower of
the door opening. Refer to the Body section for the
procedure.
(7) Connect the negative battery cable.
WIRING HARNESS
DESCRIPTION
The wire harness supplies power (12v), ground and
various electrical signals to the side sliding door for
various power door functions. A plastic chain or wir-
ing track covers the wire harness assembly (Fig. 16)
and is used to protect the wire harness from abrasion
and/or tangling. This wiring track is replaced with
the wire harness assembly.
The wire harness assembly is a replaceable compo-
nent. Consult your Mopar parts catalog for specific
part numbers.
OPERATION
The wire harness and plastic wiring track provide
a safe and reliable means of supplying power, ground
and other various electrical connections to the side
sliding door. During sliding door movement the wir-
ing track folds and unfolds like the links in a chain.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate door trim panel from
the sliding side door. Refer to the Body section for
the procedure.
(3) Remove the lower drive unit cover retaining
screws and remove the cover (Fig. 17).
(4) Disconnect the power side door electrical con-
nector, located just behind the lower drive unit
assembly.
(5) Disengage retaining pushpin and pull wire har-
ness away from its power side door mounting loca-
tion (Fig. 16).
(6) Using a flat bladed screwdriver, unsnap the
wire harness retaining clip from the lower drive unit.
(7) Slide the wire harness off the forward lower
drive unit stud.
(8) Using a pushpin removal tool, unsnap wire
harness retaining pushpins from the rocker panel.
Fig. 15 Lower Track Retaining Bolts
1 - Lower Track Retaining Bolts
2 - Lower Door Track
Fig. 16 Wire Harness Position and Orientation
1 - Lower Door Track and Rack Assembly
2 - Wire Harness
3 - Rack Access Hole Sealing Patches
4 - Lower Drive Unit Cover
8N - 34 POWER SLIDING DOOR SYSTEMRS
LOWER DRIVE UNIT TRACK & RACK (Continued)
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(9) Remove side door lower sill plate. Refer to
Body for the procedure.
(10) Pull back the rearward edge of the B-pillar
trim to access the wire harness connector and discon-
nect connector.
(11) Remove the wire harness assembly from the
vehicle.
INSTALLATION
(1) Position the wire harness assembly in the vehi-
cle.
(2) Connect the wire harness connector located at
the rearward edge of the B-pillar.
(3) Install the side door lower sill plate. Refer to
the Body section for the procedure.
(4) Snap the wire harness retaining pushpins in
the rocker panel.
(5) Slide the wire harness on the lower drive unit
stud.
(6) Install the wire harness retaining clip on the
lower drive unit stud.
(7) Connect the power side door electrical connec-
tor, located just behind the lower drive unit.
(8) Install the lower drive unit cover and retaining
screws.(9) Install the appropriate door trim panel on the
sliding side door. Refer to the Body section for the
procedure.
(10) Connect the negative battery cable.
FLEX DRIVE
DESCRIPTION
Vehicles equipped with a power sliding side door
utilize a flex drive assembly. The flex drive assembly
is located in the lower portion of the door (Fig. 18)
and is used to connect the door motor to the lower
drive unit. An E-clip is used to secure the flexdrive to
the motor assembly, while the flex drive collar is
used to secure the drive to the lower drive unit. The
flex drive assembly is basically a flexible drive shaft
for the power side door system.
The flex drive assembly is a replaceable compo-
nent. Consult your Mopar parts catalog for specific
part numbers.
Fig. 17 Lower Hinge/Drive Assembly
1 - Lower Drive Unit Cover
2 - Lower Drive Unit Cover Retaining Screws
3 - Sliding Door
4 - Lower Hinge Arm Bracket
Fig. 18 Side Door Components
1 - 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
RSPOWER SLIDING DOOR SYSTEM8N-35
WIRING HARNESS (Continued)
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SLIDING DOOR MODULE
DESCRIPTION
Vehicles equipped with a power sliding door utilize
a sliding door control module. The sliding door con-
trol module is located behind the sliding door trim
panel in the center of the door, just above the sliding
door motor (Fig. 22). This module controls the opera-
tion of the door through the Programmable Commu-
nication Interface (PCI) J1850 data bus circuit and
the Body Control Module. The sliding door control
module contains software technology which enables it
to detect resistance to door travel and to reverse door
travel in order to avoid damage to the door or to
avoid possible personal injury if the obstruction is a
person. This feature functions in both the opening
and closing cycles. If the power sliding door system
develops any problems the control module will store
and recall Diagnostic Trouble Codes (DTC). The use
of a diagnostic scan tool, such as the DRB IIItis
required to read and troubleshoot these trouble
codes. The sliding door control module can be
reflashed if necessary. Refer to the latest Technical
Service Bulletin (TSB) Information for any updates.
The power door control module is a replaceable
component and cannot be repaired, if found to be
faulty it must be replaced. Consult your MoparŸ
parts catalog for a specific part number.OPERATION
The power sliding door control module serves as
the main computer for the power sliding side door
system. All power door functions are processed
through the power door control module and/or the
vehicles body control module (BCM). At the start of a
power open command, a signal is sent to the BCM
and then to the power door control module via the
J1850 data bus circuit. This signal, generated by any
of the power door command switches, tells the power
door control module to activate a power latch release,
engage the clutch assembly and drive the door into
the full open position. If an obstacle is felt during
this power open cycle, the module will reverse direc-
tion and close the door. This process is also enabled
during a power close cycle. This process will repeat
three times, and if a fourth obstacle is detected, the
door will go into full manual mode. Once the full
open position is obtained, a hold open latch assembly
mounted full open switch tells the control module
that the door has reached the full open position. If
the power sliding door system develops any problems
the control module will store and recall Diagnostic
Trouble Codes (DTC). The use of a diagnostic scan
tool, such as the DRB IIItis required to read and
troubleshoot these trouble codes.
Fig. 21 Flex Drive Cable
1 - Door Motor
2 - Flex Drive Collar
3 - Flex Drive Inner Shaft
Fig. 22 Side Door Components
1 - 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
RSPOWER SLIDING DOOR SYSTEM8N-37
FLEX DRIVE (Continued)
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