torque CHRYSLER VOYAGER 2003 Service Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2003, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2003Pages: 2177, PDF Size: 59.81 MB
Page 405 of 2177
REMOVAL
When replacing the spark plugs and spark plug
cables, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise, cross ignition of the spark plugs orshort cir-
cuit the cables to ground.
Always remove cables by grasping at the boot,
rotating the boot 1/2 turn, and pulling straight back
in a steady motion.
(1) Prior to removing the spark plug, spray com-
pressed air around the spark plug hole and the area
around the spark plug.
(2) Remove the spark plug using a quality socket
with a foam insert.
(3) Inspect the spark plug condition.
INSTALLATION
When replacing the spark plugs and spark plug
cables, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise, cross ignition of the spark plugs orshort cir-
cuit the cables to ground.
(1) Coat threads of spark plug with anti-seize. Be
sure not to get anti-seizeANTWHERE BUT ON
THE THREADS OF THE SPARK PLUG as
shown in (Fig. 13).
(2) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(3) Tighten spark plugs to 17.5 N´m (13 ft. lbs.)
torque.
(4) Install spark plug cables over spark plugs. A
click will be heard and felt when the cable properly
attaches to the spark plug.
SPARK PLUG CABLE
DESCRIPTION
Spark Plug cables are sometimes referred to as
secondary ignition wires. The wires transfer electri-
cal current from the ignition coil pack to individual
spark plugs at each cylinder. The resistive spark plug
cables are of nonmetallic construction. The cables
provide suppression of radio frequency emissions
from the ignition system.
Check the spark plug cable connections for good
contact at the coil, and spark plugs. Terminals should
be fully seated. The insulators should be in good con-
dition and should fit tightly on the coil, and spark
plugs. Spark plug cables with insulators that are
cracked or torn must be replaced.
Clean Spark Plug cables with a cloth moistened
with a non-flammable solvent. Wipe the cables dry.
Check for brittle or cracked insulation. The spark
plug cables and spark plug boots are made from high
temperature materials.
REMOVAL - 2.0/2.4L
Failure to route the cables properly could cause the
radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
Remove spark plug cable from coil first.
Always remove the spark plug cable by grasping
the top of the spark plug insulator, turning the boot
1/2 turn and pulling straight up in a steady motion.
INSTALLATION - 2.0/2.4L
Failure to route the cables properly could cause the
radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
Install spark plug insulators over spark plugs.
Ensure the top of the spark plug insulator covers the
upper end of the spark plug tube, then connect the
other end to coil pack.
8I - 10 IGNITION CONTROLRS
SPARK PLUG (Continued)
ProCarManuals.com
Page 449 of 2177
US/Mpush button to step through the zone numbers,
until the zone number for your geographic location
appears in the display.
(6) On Electronic Vehicle Information Center
(EVIC) and Compass Mini-Trip Computer (CMTC)
equipped vehicles momentarily depress and release
theRESETpush button to enter the displayed zone
number into the EVIC/CMTC module memory. On
Compass Temperature Module (CT) equipped vehicles
depress theC/Tpush button to enter the displayed
zone number into the electronic module memory.
(7) Confirm that the correct directions are now
indicated by the compass.
REMOVAL - OVERHEAD CONSOLE
(1) Disconnect and isolate the remote negative bat-
tery cable.
(2) Remove the overhead console retaining screw,
located in the front of console.
(3) Using your fingertips, grasp the sides of the
overhead console and pull straight down evenly to
disengage the two snap clips at the rear of the unit.
(4) Lower the overhead console far enough to
access the wire harness connectors.
(5) Disconnect the EVIC, CMTC or CT electronic
module and the reading/courtesy lamps electrical
connector.
(6) Remove the overhead console from the vehicle.
INSTALLATION
(1) Position the overhead console in the vehicle.
(2) Connect the EVIC, CMTC or CT electronic
module and the reading/courtesy lamps electrical
connector.
(3) Using your fingertips, grasp the sides of the
overhead console and push straight up evenly to
engage the two snap clips at the rear of the unit.
CAUTION: DO NOT PRESS ON THE SUNGLASS
STORAGE BIN DOOR. DAMAGE TO THE DOOR MAY
RESULT.
(4) Install the overhead console retaining screw,
located in the front of console. Torque the screw to
1.2 N´m (10 in. lbs.).
(5) Connect the remote negative battery cable.
SPECIAL TOOLS
OVERHEAD CONSOLE
ELECTRONIC VEHICLE INFO
CENTER
DESCRIPTION
The Electronic Vehicle Information Center (EVIC)
is a module located in the overhead console on some
models. The EVIC module features a large Vacuum
Fluorescent Display (VFD) screen for displaying
information, and back-lit push button switches
labeled C/T (compass/thermometer), RESET, STEP,
and MENU.
The EVIC module contains a central processing
unit and interfaces with other electronic modules in
the vehicle over the Programmable Communications
Interface (PCI) J1850 data bus circuit. The PCI data
bus circuit allows the sharing of sensor information.
This helps to reduce wire harness complexity, reduce
internal controller hardware, and reduce component
sensor current loads. At the same time, this system
provides increased reliability, enhanced diagnostics,
and allows the addition of many new feature capabil-
ities.
The EVIC ªMenuº push button provides the vehicle
operator with a user interface, which allows the
selection of several optional customer programmable
electronic features to suit individual preferences.
Refer toELECTRONIC VEHICLE INFORMA-
TION CENTER PROGRAMMINGin the Standard
Procedures section of this group for more information
on the customer programmable feature options.
If the vehicle is equipped with the optional univer-
sal transmitter transceiver, the EVIC will also dis-
play messages and an icon indicating when the
universal transmitter transceiver is being trained,
which of the three transmitter buttons is transmit-
ting, and when the transceiver is cleared.
Data input for all EVIC functions, including VFD
dimming level, is received through the J1850 PCI
data bus circuit. The EVIC module uses its internal
programming and all of its data inputs to calculate
and display the requested data. If the data displayed
is incorrect, perform the self-diagnostic tests as
described in this group. If these tests prove inconclu-
DEGAUSSING TOOL #6029
8M - 6 MESSAGE SYSTEMSRS
OVERHEAD CONSOLE (Continued)
ProCarManuals.com
Page 464 of 2177
STANDARD PROCEDURE
STANDARD PROCEDURE - LIFTGATE
ADJUSTMENT
In order for the power liftgate system to function
properly the liftgate must move freely and smoothly.
The power liftgate system can acommodate for some
minor changes in the effort required to move the lift-
gate. However, in extreme conditions the liftgate may
need to be mechanicaly adjusted for proper fit and
finish. Refer to the Liftgate Adjustment procedure in
the Body section of the service manual for detailed
instructions.
If a problem exists with the power liftgate and it is
suspected to be extreme effort check the liftgate prop
rods and hinges for free movement. Use a known
good vehicle for liftgate effort comparison.
NOTE: Routine application of Mopar MP-50Tor
equivalent on the chrome prop rod shafts and lift-
gate latch and hinges will help keep the liftgate in
good working order.
STANDARD PROCEDURE - POWER LIFTGATE
LEARN CYCLE
Any time a power liftgate component is removed,
replaced or a liftgate adjustment is performed a learn
cycle must be performed. This learn cycle enables the
power liftgate control module to learn or relearn
information (travel limits, resistance to door travel,
etc.) which allows it to perform properly and safely.
To perform a learn cycle do the following:
(1) Obtain a DRBIIItscan tool.
(2) Connect the DRBIIItto the vehicle and check
for any power liftgate system stored trouble codes,
correct and erase any stored codes.
(3) Using the DRBIIIt, Go into Test Routine Menu
and select the power open command.
(4) Select the power close command.
(5) The liftgate learn cycle is complete.
If a DRBIIItscan tool is not available, the learn
cycle can be performed by actuating the liftgate using
any of the normal command switches. Be certain to
cycle the liftgate through a complete open and close
cycle before returning the vehicle to service.
NOTE: If the power liftgate will not complete a full
cycle a problem exists with the power liftgate sys-
tem. (Refer to 8 - ELECTRICAL/POWER DOORS -
DIAGNOSIS AND TESTING).
SPECIFICATIONS
SPECIFICATIONS TABLE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Liftgate Motor 10 7 85
Pinch Sensor 3 2 25
Transverse Bracket 10 7 85
Lift Gear Bolts 8 6 71
Link Rod to Liftgate 28 21 250
Liftgate Latch 10 8 90
RSPOWER LIFTGATE SYSTEM8N-9
POWER LIFTGATE SYSTEM (Continued)
ProCarManuals.com
Page 468 of 2177
gate control module, telling the module that the lift-
gate has reached the full open position.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the lift gear and link rod assembly
from the vehicle(Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - REMOVAL).
(3) Cut the two wires leading to the full open
switch or back the wires out of the electrical connec-
tor (Fig. 8). Refer to the Wiring section of the service
manual for detailed instructions.
(4) Remove the full open switch retaining screw
and remove the full open switch from the gear motor
housing assembly.
INSTALLATION
(1) Perform a wiring repair on the full open switch
wires following the approved procedure in the Wiring
section of the service manual. Or install new termi-
nals on the wire ends and reinstall in the main lift-
gate motor electrical connector.
(2) Position and install the full open switch retain-
ing screw.
(3) Install the power liftgate lift gear and link rod
assembly. (Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - INSTALLATION)
(4) Connect the negative battery cable.
(5) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
(6) Verify power liftgate system and full open
switch operation. Cycle the power liftgate through
one complete open and close cycle, this will allow the
power liftgate control module to relearn its cycle with
the new components.
LATCH
DESCRIPTION
Vehicles equipped with a power liftgate, utilize a
power cinch/release latch. This latch performs the
same features as a manual liftgate latch as well as
the power cinch and / or release capability. A second
type of power latch can also be found on some RS
models, this latch is designed to perform a power
release only. The power cinch and release capability
is accomplished by an actuator mounted to the lead-
ing edge of the latch assembly. The latch is located in
the lower center of the liftgate assembly (Fig. 9) and
contains integral pawl and ratchet switches. The
ratchet switch acts as a liftgate ajar switch.
The power latch assembly can be serviced as a
complete assembly, latch without actuator or just theactuator. Consult your Mopar parts catalog for spe-
cific part numbers.
OPERATION
On the power cinch/release latch, the latch
mounted actuator provides the torque required to
close the power liftgate from the secondary to the pri-
mary closed and latched position. On the power
cinch/release latch and the power release only latch,
the actuator releases the liftgate from the primary
closed and latched position to the fully unlatched and
movable position.
REMOVAL
(1) Open the hood, disconnect and isolate the neg-
ative battery cable.
(2) Open the liftgate and remove the liftgate trim
panel. Refer to Body for the procedure.
(3) Disconnect the power latch electrical connector
(Fig. 9).
(4) Remove the power latch retaining bolts.
(5) Disconnect the liftgate lock cylinder link rod
from the key cylinder or latch assembly. To discon-
nect from latch, rotate the plastic retaining clip 90 É
to unsnap clip from linkrod. Then pull link rod
straight out of latch arm.
Fig. 9 POWER LATCH ORIENTATION
1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
RSPOWER LIFTGATE SYSTEM8N-13
FULL OPEN SWITCH (Continued)
ProCarManuals.com
Page 469 of 2177
INSTALLATION
(1) Connect the liftgate lock cylinder link rod on
the cinch latch assembly. Rotate the plastic retaining
clip 90 É to lock retaining clip on linkrod.
(2) Connect the link rod on the lock cylinder.
(3) Install three new power latch retaining bolts.
Torque to 10 N´m (90 in. lbs.).
(4) Connect the power latch electrical connector
and secure push pin retainers.
(5) Connect the negative battery cable.
(6) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes related to the power latch.
(7) Verify power liftgate system and power cinch /
release latch operation. Cycle the power liftgate
through one complete open and close cycle, this will
allow the power liftgate control module to relearn its
cycle with the new components.
(8) Verify power liftgate manual operation. Using
liftgate key rotate the lock cylinder to verify door
operation. Pull door open using exterior liftgate han-
dle / switch.
(9) Install the liftgate trim panel. Refer to Body for
the procedure.
LATCH ACTUATOR
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
power cinch latch or power release latch (Fig. 10).
The power cinch and/or power release is made possi-
ble by a latch actuator attached to the leading edge
of the power latch assembly. This 12 volt latch actua-
tor contains a small drive gear that meshes with the
latch assemblies internal gears to perform the power
cinch close / power release operations. Refer to the
Latch assembly for more information.
The power cinch/release actuator is serviceable
component. Consult your MoparŸ parts catalog for
specific part numbers.
OPERATION
During a power close cycle, the power cinch actua-
tor provides the torque required to close the power
liftgate from the secondary to the primary closed and
latched position. During a power open cycle, the
power release actuator releases the liftgate from the
primary closed and latched position to the fully
unlatched and movable position.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Open the liftgate and remove the lower liftgate
trim panel. Refer to Body for the procedure.
(3) Disconnect the power latch electrical connector
(Fig. 10).
(4) Remove the three latch retaining bolts.
(5) Grab the latch assembly and unhook the key
cylinder link rod from the key cylinder (Fig. 10).
(6) Place the latch assembly on a bench and locate
the three wires leading from the actuator portion of
the latch assembly.
(7) Disengage the main connector retaining push
pins from the latch actuator housing.
(8) Back the three wires out of the main latch elec-
trical connector. Refer to the wiring section of the
service manual for detailed instructions.
(9) Flip the latch assembly over and remove the
latch actuator retaining screw(s).
(10) Remove the latch actuator from the latch
assembly.
INSTALLATION
(1) Install the latch actuator on the latch assem-
bly.
(2) Install the three latch actuator retaining
screws. Torque the screws to 4 in. lbs.
(3) Install the three wires in the main latch elec-
trical connector. Refer to the wiring section of the
service manual for detailed instructions.
Fig. 10 POWER LATCH ORIENTATION
1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
8N - 14 POWER LIFTGATE SYSTEMRS
LATCH (Continued)
ProCarManuals.com
Page 470 of 2177
NOTE: Be certain wires are reinstalled in the correct
wire cavities. Failure to do so could result in dam-
age to the latch actuator. Refer to Wiring Diagrams
if previous notes were not made.
(4) Secure the main connector retaining push pins
on the latch actuator housing.
(5) Grab the latch assembly and hook the key cyl-
inder link rod on the key cylinder.
(6) Position the latch and install three new latch
retaining bolts. Torque to 10 N´m (90 in. lbs.).
(7) Connect the power latch electrical connector.
(8) Install the lower liftgate trim panel. Refer to
Body for the procedure.
(9) Connect the negative battery cable.
LIFTGATE MOTOR
DESCRIPTION
Vehicles equipped with a power liftgate, utilize a
liftgate gear/motor assembly (Fig. 11). The gear
motor assembly consists of a DC motor, hall effect
sensor, engage actuator, full open switch, lift gear,
aluminum housing, drive gears and wire harness.
The gears and motor portion of the assembly pro-
vides the power and torque required to open or close
the liftgate under the worst case conditions. The hall
effect sensor is used to provide the liftgate control
module with a speed reading, which is used to mon-itor the resistance of liftgate travel. This speed read-
ing also allows the power liftgate control module to
detect obstructions and move the liftgate accordingly.
The engage actuator is used to toggle between power
open/close mode and full manual mode when desired.
The full open switch is used to let the power liftgate
control module know when the liftgate is approach-
ing the full open position.
Serviceable components of the power liftgate gear/
motor assembly are the complete gear/motor assem-
bly, motor and wire harness, lift gear and control rod,
engage actuator, full open switch and the transverse
bracket. Refer to additional information in this group
for more component details.
OPERATION
With the push of a power liftgate command switch
(liftgate closed), the power liftgate control module
will signal the latch assembly to release the door
from its primary closed and latched position to the
released and movable position. The liftgate motor-
mounted engage actuator then engages the liftgate
motor assembly, which moves the liftgate into the
open position. The liftgate motor provides the torque
and power to move the door to its full open or closed
position(Refer to 8 - ELECTRICAL/POWER DOORS -
OPERATION) for additional information.
REMOVAL
The power liftgate gear/motor assembly is serviced
in two ways: the complete gear/motor assembly, or
the motor, aluminum housing, drive gears and wire
harness assembly. To perform this service, use the
following procedure to remove the gear/motor assem-
bly from the vehicle. Then refer to the other proce-
dures called out this section to transfer the
remaining components (engage actuator, full open
switch, transverse bracket and lift gear and rod) to
the replacement gear/motor assembly.
(1) Disconnect and isolate the negative battery
cable.
(2)
Remove the left rear D-pillar trim panel from the
vehicle. Refer to the Body section for the procedure.
(3) Disconnect the wire harness connector from the
motor assembly (Fig. 11).
(4) Remove the two bolts from the motor housing
and the one bolt from the transverse mount bracket.
(5) Grab the liftgate motor assembly and lift
upward and out to unhook the motor assembly from
the D-pillar.
(6) Remove the liftgate motor assembly from the
vehicle.
INSTALLATION
(1) Using the motor housing tab, hook the liftgate
motor assembly on the D-pillar.
Fig. 11 POWER LIFTGATE COMPONENTS
1 - POWER LIFTGATE GEAR MOTOR/ASSEMBLY
2 - POWER LIFTGATE CONTROL MODULE
3 - ELECTRICAL GROUND LOCATION
RSPOWER LIFTGATE SYSTEM8N-15
LATCH ACTUATOR (Continued)
ProCarManuals.com
Page 471 of 2177
(2) Install the three motor assembly retaining
bolts. Torque the two rear most bolts first to 9.5 N´m
(85 in. lbs.). Torque the remaining bolt next to the
window actuator to 9.5 N´m (85 in. lbs.).
(3) Connect the liftgate motor assembly electrical
connector.
(4) Install the D-pillar trim panel on the vehicle.
Refer to Body for the procedure.
(5) Connect the negative battery cable.
(6) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes related to the door motor assembly.
(7) Verify power liftgate system operation. Cycle
the power liftgate through one complete open and
close cycle, this will allow the power liftgate control
module to relearn its cycle with the new components.
LIFT GEAR & LINK ROD
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
lift gear and rod assembly. This lift gear and rod
assembly are located in the left rear of the vehicle
and are visible without removing the D-pillar trim
(Fig. 12). The lift gear provides the leverage to move
the liftgate from the closed to the open position. The
lift gear attaches to a bearing on the gear motor
assembly with four bolts. On the outboard side of thelift gear are riveted on teeth, which mesh with the
gear motor assembly drive gears during a open or
close operation. The rod assembly is a steel shaft,
equipped with two spherical rod ends which attaches
the lift gear to the liftgate.
The lift gear and rod assembly are serviceable com-
ponents. Consult your MoparŸ parts catalog for a
part number.
OPERATION
One end of the rod assembly is attached to the lift-
gate, the other attached to the lift gear. When the lift
gear is driven by the gear motor assembly the lift-
gate is moved to the open or closed position.
REMOVAL
(1) Remove the left rear D-pillar trim from the
vehicle. Refer to Body for the procedure.
(2) Remove the lift gear retaining bolts (Fig. 13).
(3) Remove the lift gear and rod from the vehicle.
INSTALLATION
(1)Position the lift gear assembly and install the
retaining bolts. Torque the bolts to 8 N´m (71 in. lbs.).
(2) Install the left rear D-pillar trim on the vehi-
cle. Refer to Body for the procedure.
CAUTION: Torque link rod to liftgate attachment
bolt to 250 in. lbs. Care must be taken not to over-
torque link rod bolt.
Fig. 12 LIFTGATE GEAR/MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Fig. 13 LIFTGATE GEAR MOTOR ASSEMBLY
1 - ENGAGE ACTUATOR RETAINING SCREWS
2 - LIFT GEAR RETAINING BOLTS
8N - 16 POWER LIFTGATE SYSTEMRS
LIFTGATE MOTOR (Continued)
ProCarManuals.com
Page 472 of 2177
PINCH SENSOR
DESCRIPTION
Vehicles equipped with a power liftgate utilize two
pinch sensors, one is located on each side of the lift-
gate (Fig. 14). These sensors look like weather-strips,
however they consist of pieces of electrically conduc-
tive rubber (tapeswitch), wires, resistor, double sided
tape, and a plastic carrier. They are used to indicate
an obstruction during a power close cycle.
OPERATION
During a power liftgate close cycle, if either of the
two conductive rubber strips (tapeswitch) of thepinch sensor come in contact with an obstacle, the
pinch sensor circuit is completed. This tells the
power liftgate control module that a obstruction is
felt. The control module will stop the liftgate imme-
diately and return it to the full open position.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove trim panel from liftgate. Refer to Body
for the procedure.
(3) Disconnect the pinch sensor wire harness con-
nector (Fig. 14).
(4) Remove screws holding the pinch sensor to lift-
gate.
(5) Feed the pinch sensor wire harness out of the
liftgate and remove the sensor from the vehicle.
INSTALLATION
WARNING: USE EXTREME CAUTION WHEN TEST-
ING PINCH SENSOR OPERATION.
(1) Position the pinch sensor and install screws
holding the sensor to the liftgate. Torque screws to
25 in. lbs.
(2) Install wire harness grommet in liftgate flange
and route, connect the pinch sensor wire harness
connector.
(3) Install the trim panel on the liftgate. Refer to
the Body section for the procedure.
(4) Connect the negative battery cable.
(5) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes related to the pinch sensor.
(6) Verify power liftgate system and pinch sensor
operation. Cycle the power liftgate through one com-
plete open and close cycle, during the final close cycle
press the pinch sensor to verify the power liftgate
detects an obstruction and returns to the full open
position.
Fig. 14 PINCH SENSOR LOCATION
1 - LIFTGATE
2 - PINCH SENSOR ASSEMBLY
3 - LIFTGATE PROP ROD
4 - PINCH SENSOR WIRE HARNESS CONNECTOR
5 - PINCH SENSOR WIRE HARNESS
RSPOWER LIFTGATE SYSTEM8N-17
ProCarManuals.com
Page 473 of 2177
TRANSVERSE BRACKET
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
transverse bracket (Fig. 15) to support and secure
the power liftgate gear/motor assembly to the left
rear body D-pillar.
The transverse bracket is a serviceable power lift-
gate component. Consult your MoparŸ parts catalog
for a specific part number.
OPERATION
The power liftgate transverse bracket supports the
gear motor assembly by supplying an additional
attachment point. Located on the leading edge of the
gear motor assembly, one end of the transverse
bracket attaches to the motor assembly the other to
the leading edge of the vehicles D-pillar.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the left D-pillar trim from the vehicle.
Refer to Body for the procedure.
(3) Disconnect the gear motor assembly electrical
connector and disengage retaining pushpin.
(4) Loosen the gear motor assembly retaining bolts
to allow room for transverse bracket to be removed.
(5) Remove the transverse bracket retaining bolts
(Fig. 12).
(6) Remove the transverse bracket from the vehi-
cle.
INSTALLATION
(1) Position the transverse bracket in the vehicle.
Be certain the transverse bracket is properly posi-
tioned. The bracket should just touch the engage
actuator arm and be positioned between the actuator
arm and the motor housing.
(2) Torque the transverse bracket retaining bolts
to the gear motor assembly to 9.5 N´m (85 in. lbs.).
Do not tighten the transverse bracket retaining bolt,
located under the window actuator at this time.
(3) Torque the gear motor assembly retaining bolts
to 9.5 N´m (85 in. lbs.).
(4) Torque the final transverse bracket retaining
bolt to 9.5 N´m (85 in. lbs.).
(5) Connect the gear motor assembly electrical con-
nector and engage retaining pushpin.
(6) Install the appropriate D-pillar trim from the
vehicle. Refer to Body for the procedure.
Fig. 15 LIFTGATE GEAR/MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
8N - 18 POWER LIFTGATE SYSTEMRS
ProCarManuals.com
Page 484 of 2177
SPECIFICATIONS
SPECIFICATIONS TABLE
TORQUE SPECIFICATIONS
DESCRIPTION N´m In. Lbs.
Door Latch 12 100
Lower Drive Unit
Allen Head980
Lower Drive Unit
Screw328
Lower Track Nuts 8 70
LATCH
DESCRIPTION
Vehicles equipped with a power side door or doors
utilize a power latch. One power latch is used for
each power door. The latch is located on the trailing
edge of the side door assembly (Fig. 5). This power
latch assembly is comprised of many different compo-
nents which have the ability to perform the power
cinch, release, lock, unlock and safety related opera-
tions. These components are the door latch, lock/un-
lock actuator, cinch/release actuator and child
lockout, pawl, ratchet and handle switches. The pawl
and ratchet switches are used to indicate the primaryand secondary latched positions. The cinch latch also
provides a connection point for the interior handle,
exterior handle and hold open latch cables.
The power latch is a replaceable component. Con-
sult your Mopar parts catalog for specific part num-
bers.
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 actuator 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 side door has reached its secondary latch
position (determined by pawl and ratchet switches).
During a power open cycle, the power release actua-
tor will stop once the side door has moved from pri-
mary latch position.
The power latch uses inputs from the lock/unlock
actuator, power side door control module and child
lockout, pawl, ratchet and handle switches to provide
safe power cinch and release operations. Refer to
Power Side Door Operation for additional informa-
tion.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate side door trim panel.
Refer to the Body section for the procedure.
(3) Remove the weather shield if necessary. Refer
to the Body section for the procedure.
(4) Open the side door all the way and remove the
door latch retaining bolts (Fig. 6).
(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.
Fig. 5 Removing/Installing Power Latch in Sliding
Door
1 - Power Latch Assembly
RSPOWER SLIDING DOOR SYSTEM8N-29
POWER SLIDING DOOR SYSTEM (Continued)
ProCarManuals.com