Chrysler Dodge Caravan 2002 Manual page 1999

23 - 16 DOOR - FRONT
DOOR (Continued)
Fig. 4 FRONT DOOR - HINGE PIN REMOVAL
1 - FRONT DOOR
2 - CLIP
3 - A-PILLAR
4 - HINGE PIN
5 - CLIP
6 - DOOR CHECK STRAP
Fig. 5 FRONT DOOR - HINGE BOLT REMOVAL
1 - FRONT DOOR
2 - UPPER HINGE
3 - CHECK STRAP
4 - LOWER HINGE
INSTALLATION
NOTE: If new hinge pins are to be used, verify that
the knurling on the hinge pin is aligned with the
knurling on in the door hinge prior to driving in the
pin. Also, verify that the hinge pin is fully seated to
the door hinge and a new retaining clip is installed.
(1) Support door on suitable lifting device.
(2) Position door to vehicle. Verify net pierce nub-
bin is engaged if reusing original hinges.
(3) Steady door on lifting device and install bolts
attaching upper hinge to door end frame. Tighten
bolts to 34 N·m (25 ft. lbs.) torque.
(4) Install bolts attaching door check strap to
A-pillar. Tighten bolts to 12 N·m (105 in. lbs.) torque.
(5) Install bolts attaching lower hinge to door end
frame. Tighten bolts to 34 N·m (25 ft. lbs.) torque.
Align door to achieve equal spacing to surrounding
body panels. Panels should be flush across all gaps.
(6) Connect door harness into body wiring harness.
(7) Connect positive lock slide on the side of the
wire connectors.
(8) Connect clips attaching door harness wire con-
nector to inner fender brace.
(9) Install front wheelhouse splash shield.
(10) Verify door operation and alignment. Adjust
as necessary.
DOOR GLASS
REMOVAL
(1) Remove watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(2) Remove inner belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - REMOVAL)
(3) Remove outer belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR OUTER BELT
MOLDING - REMOVAL)
(4) Position glass to gain access to front and rear
regulator lift plates through front and rear access
holes in door panel.
(5) Remove clips attaching door glass to regulator
lift plates (Fig. 6).
(6) Remove glass from regulator lift plates.
(7) Disengage glass from glass run weatherstrip.
(8) Insert front of glass between glass run channel
and outer door panel.
(9) Lift glass upward and out of exterior side of
the opening at top of door (Fig. 7).
(10) Remove glass from vehicle.
RS