instrument panel CHRYSLER CARAVAN 2003 Service Manual

INSTRUMENT PANEL TOP PAD
ASSEMBLY
REMOVAL
(1) Remove the instrument cluster (Fig. 14). (Refer
to 8 - ELECTRICAL/INSTRUMENT CLUSTER -
REMOVAL)
(2) Remove the message center (Fig. 14). (Refer to
8 - ELECTRICAL/MESSAGE CENTER - REMOVAL)
(3) Remove the radio (Fig. 14). (Refer to 8 - ELEC-
TRICAL/AUDIO/RADIO - REMOVAL)
(4) Remove the headlamp switch (Fig. 14). (Refer
to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/HEADLAMP SWITCH - REMOVAL)
(5) Remove the lower console (Fig. 14). (Refer to 23
- BODY/INSTRUMENT PANEL/LOWER CONSOLE
- REMOVAL)
(6) Remove the lower panel. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER INSTRUMENT
PANEL TRIM - REMOVAL)
(7) Remove the instrument panel assembly. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL)
(8) Remove the instrument panel speakers.
(9) Remove the glove box light.
(10) Remove the two passenger air bag mounting
bolts (Fig. 15).
(11) Loosen the three passenger air bag support
bracket bolts to the hydro-form rail (Fig. 15).
(12) Remove the 16 screws along the upper edge of
the pad & panel assembly.
(13) Remove the 19 screws along the lower edge of
the pad & panel assembly.
(14) Remove the pad and panel assembly (Fig. 14).
INSTALLATION
(1) Position the pad & panel assembly onto the
instrument panel support structure.
Fig. 13 OVER STEERING COLUMN COVER
1 - INSTRUMENT PANEL OVER STEERING COLUMN COVER
2 - INSTRUMENT PANEL
Fig. 14 INSTRUMENT PANEL ASSEMBLY
1 - INSTRUMENT CLUSTER
2 - MESSAGE CENTER
3 - TOP COVER
4 - PAD AND PANEL ASSEMBLY
5 - LOWER CONSOLE
6 - LOWER PANEL
7 - RADIO
8 - HEADLAMP SWITCH
Fig. 15 AIRBAG MOUNTING HARDWARE
1 - AIR BAG SCREWS (2)
2 - ELECTRICAL CONNECTOR
3 - AIR BAG SUPPORT BRACKET BOLTS (3)
4 - HYDRO-FORM INSTRUMENT PANEL SUPPORT RAIL
23 - 70 INSTRUMENT PANELRS
OVER STEERING COLUMN COVER (Continued)
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(2) Install the 19 screws along the lower edge of
the pad & panel assembly.
(3) Install the 16 screws along the upper edge of
the pad & panel assembly.
(4) Install and tighten the two passenger air bag
mounting screws.
(5) Tighten the three passenger air bag support
bracket bolts to the hydro-form tube.
(6) Install the glove box light.
(7) Install the instrument panel speakers.
(8) Install the instrument panel assembly. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION)
(9) Install the lower panel. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER INSTRUMENT
PANEL TRIM - INSTALLATION)(10) Install the lower console. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER CONSOLE -
INSTALLATION)
(11) Install the headlamp switch. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP SWITCH - INSTALLATION)
(12) Install the radio. (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - INSTALLATION)
(13) Install the message center. (Refer to 8 -
ELECTRICAL/MESSAGE CENTER - INSTALLA-
TION)
(14) Install the instrument cluster. (Refer to 8 -
ELECTRICAL/INSTRUMENT CLUSTER - INSTAL-
LATION)
RSINSTRUMENT PANEL23-71
INSTRUMENT PANEL TOP PAD ASSEMBLY (Continued)
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A-PILLAR LOWER EXTENSION
TRIM
REMOVAL
(1) Remove instrument panel side cover.
(2) Remove A-pillar extension trim from vehicle by
disengaging hidden clips (Fig. 1).
INSTALLATION
(1) Place A-pillar extension trim in position on
vehicle (Fig. 1).
(2) Install instrument panel side cover.
A-PILLAR TRIM
REMOVAL
(1) Remove the assist handle if equipped. (Refer to
23 - BODY/INTERIOR/ASSIST HANDLE -
REMOVAL)
(2) Disengage hidden clips holding A-pillar trim
panel to A-pillar (Fig. 2).
(3) Remove A-pillar trim from vehicle.
INSTALLATION
(1) Position foot on A-pillar trim panel into instru-
ment panel top cover channel.
(2) Position A-pillar trim in vehicle.
(3) Align locator pins.
(4) Engage hidden clips.(5) Install the assist handle, if equipped. (Refer to
23 - BODY/INTERIOR/ASSIST HANDLE - INSTAL-
LATION)
ASSIST HANDLE
REMOVAL
(1) Using a trim stick (C-4755), remove screw
access covers from grab-handle.
(2) Remove screws holding grab-handle to roof rail.
(3) Remove grab-handle from vehicle.
INSTALLATION
(1) Place grab-handle in position on vehicle.
(2) Install screws to hold grab-handle to roof rail.
(3) Install screw access covers into grab-handle.
B-PILLAR LOWER TRIM
REMOVAL
(1) Slide lower seat belt cover rearward to expose
anchor bolt.
(2) Remove bolt attaching lower seat belt anchor to
floor.
(3) Remove upper B-pillar trim cover.
(4) Remove access panel from B-pillar trim (Fig.
3).
(5) Disengage hidden clips attaching lower trim
cover to B-pillar.
Fig. 1 A-PILLAR LOWER EXTENSION TRIM
1 - FRONT LOWER EXTENSION TRIM
2 - FRONT EXTENSION TRIM TO INSTRUMENT PANEL
RETAINER
3 - CLIP
4 - COWL TRIM PANEL
Fig. 2 A-PILLAR TRIM
1 - A-PILLAR
2 - CLIPS
RSINTERIOR23-73
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(6) Remove lower B-pillar trim cover from vehicle.
INSTALLATION
(1) Place lower B-pillar trim cover in position on
vehicle (Fig. 3).
(2) Insert seat belt through hole in lower B-pillar
trim.
(3) Engage hidden clips attaching lower trim cover
to B-pillar.
(4) Install access cover.
(5) Install upper B-pillar trim cover.
(6) Place seat belt anchor in position on floor so
webbing is pointed rearward and slightly outboard.
(7) Install bolt attaching lower seat belt anchor to
floor. Tighten all seat belt bolts to 39 N´m (29 ft. lbs.)
torque.
(8) Verify that seat belt anchor does not interfere
with seat track travel.
B-PILLAR UPPER TRIM
REMOVAL
(1) Remove bolt attaching lower seat belt anchor to
floor.
(2) Lower shoulder belt height adjuster to the bot-
tom of travel.
(3) Remove shoulder belt turning loop from height
adjuster.(4) Use a Snap-ontTrim Pad Remover tool
(A179A), or equivalent, and remove shoulder belt
height adjuster knob.
(5) Remove shoulder belt bezel from trim cover
(Fig. 3).
(6) Remove screw attaching trim cover to B-pillar
from inside bezel cavity.
(7) Disengage hidden clips attaching trim cover to
B-pillar.
(8) Remove B-pillar trim cover from vehicle.
INSTALLATION
(1) Insert seat belt through B-pillar trim and web
guide (Fig. 3).
(2) Place B-pillar trim cover in position on vehicle.
(3) Engage hidden clips attaching trim cover to
B-pillar.
(4) Install shoulder belt bezel into trim cover.
(5) Install height adjuster knob.
(6) Install shoulder belt turning loop onto height
adjuster. Tighten bolt to 39 N´m (29 ft. lbs.) torque.
(7) Place seat anchor in position on floor so web-
bing is pointed rearward and slightly outboard.
(8) Install bolt attaching lower seat belt anchor to
floor. Tighten seat belt bolt to 39 N´m (29 ft. lbs.)
torque.
CARPETS AND FLOOR MATS
REMOVAL
(1) Remove front seats. (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL)
(2) Remove front center console.
(3) Remove the remaining seats. Refer to the Own-
er's Manual for the proper procedures.
(4) Remove front cowl panels and sill plates.
(5) Remove sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(6) Remove the cargo organizer, if equipped.
(7) Remove liftgate scuff plate. (Refer to 23 -
BODY/INTERIOR/LIFTGATE SCUFF PLATE -
REMOVAL)
(8) Remove lower B-pillar trim covers.
(9) Remove D-pillar trim covers.
(10) Remove Quarter trim panels.
(11) Remove floor escutcheons (Fig. 4).
(12) Remove the floor console trays. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE TRAY -
REMOVAL)
(13) Remove push pin fasteners attaching carpet to
floor in front seat and rear area.
(14) Roll carpet from under instrument panel to
center of sliding door.
Fig. 3 LOWER B-PILLAR TRIM COVER
1 - B-PILLAR UPPER TRIM
2 - B-PILLAR UPPER PLUG
3 - POWER SLIDING DOOR SWITCH AND BEZEL
4 - BELT ASSEMBLY
5 - B-PILLAR LOWER TRIM
23 - 74 INTERIORRS
B-PILLAR LOWER TRIM (Continued)
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(15) Roll and fold carpet forward away from rear
door opening.
(16) Extract carpet through sliding door opening
(Fig. 5).
INSTALLATION
(1) Insert carpet through sliding door opening.
(2) Roll carpet rearward toward rear door opening.
(3) Roll carpet under instrument panel.(4) Install push pins fasteners through carpet and
grommet into floor to attach carpet to floor in front
seat area (Fig. 5).
(5) Install push pins fasteners in the rear area.
CAUTION: Ensure that the correct fasteners are
installed in the proper locations. Damage to the fuel
tank may result.
(6) Install floor escutcheons (Fig. 4).
(7) Install the floor console trays. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE TRAY -
INSTALLATION)
(8) Install Quarter trim panels.
(9) Install D-pillar trim covers.
(10) Install lower B-pillar trim covers.
(11) Install rear door sill plate.
(12) Install sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(13) Install front cowl panels and sill plates.
(14) Install the passenger seats. Refer to the Own-
er's Manual for proper procedures.
(15) Install front center console.
(16) Install front seats. (Refer to 23 - BODY/
SEATS/SEAT - INSTALLATION)
COWL TRIM
REMOVAL
(1) Remove door sill plate.
(2) Disengage hidden clips holding cowl trim to
cowl panel (Fig. 1).
(3) Remove cowl trim from vehicle.
INSTALLATION
(1) Place cowl trim panel in position on vehicle
(Fig. 1).
(2) Engage hidden clips attaching cowl trim to
cowl panel.
(3) Install door sill plate.
C-PILLAR TRIM
REMOVAL
(1) Remove quarter trim panel.
(2) Remove seat belt turning loop from height
adjuster.
(3) Remove screw attaching C-pillar trim panel to
C-pillar (Fig. 6).
(4) Disengage hidden clips attaching trim to upper
C-pillar.
(5) Remove upper C-pillar trim from vehicle.
Fig. 4 SEAT ESCUTCHEONS
1 - SEAT ESCUTCHEON
2 - FLOOR CARPET
Fig. 5 FLOOR CARPET
1 - CARPET LOCATOR GROMMET
2 - PUSH PIN
3 - CARPET
4 - CARPET GROMMET
5 - HEEL PROTECTOR PAD
6 - BODY ASSEMBLY
RSINTERIOR23-75
CARPETS AND FLOOR MATS (Continued)
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(4) Remove A-pillar trim panels.
(5) Place protective covers over instrument panel
and hood.
(6) Remove windshield molding. Using pliers, pull
outward on molding at the bottom of A-pillars.
(7) Using a sharp cold knife, cut urethane adhe-
sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 1). A power
cutting device can be used if available.
(8) Remove windshield from vehicle.
WINDSHIELD REMOVAL ± INTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Remove instrument panel top cover. Refer to
Group 8E, Instrument Panel and Systems.
(3) Remove A-pillar trim covers.
(4) Place protective covers over instrument panel
and hood.
(5) Using a reciprocating or oscillating power
knife, cut urethane adhesive holding the windshield
to the A-pillars, roof header and cowl pinch weld
fences. Refer to instructions provided with the equip-
ment being used.
(6) Remove windshield from vehicle.
INSTALLATION
The urethane adhesive holding the windshield to
the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment. If a door is slammed before
urethane bonding is cured, water leaks can result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.To avoid stressing the replacement windshield, the
urethane bonding material on the windshield fence
should be smooth and consistent to the shape of
the replacement windshield. The support spacers
should be cleaned and properly installed on weld
studs or repair screws at bottom of windshield
opening.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the compression spacers.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement windshield. If not, the pinch weld fence
must be formed to the shape of the new glass.
(3) Remove replacement windshield from wind-
shield opening.
(4) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 2).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(5) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.
(6) Install molding to perimeter of windshield.
(7) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of windshield and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.
(8) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying time.
(9) Using a razor knife, remove as much original
urethane as possible. Do not damage paint on wind-
shield fence.
(10) Apply pinch weld primer 19 mm (0.75 in.)
wide around the windshield fence. Allow at least
three minutes drying time.
(11) If a low viscosity urethane adhesive is used,
install compression spacers on the fence around the
windshield opening (Fig. 3).
(12) Apply a 10 mm (0.4 in.) bead of urethane on
center line of windshield fence.
(13) With the aid of a helper, position the wind-
shield over the windshield opening.
(14) Slowly lower windshield glass to windshield
opening fence. Guide the molding into proper position
as necessary. Push windshield inward until molding
is flush to roof line and A-pillars (Fig. 3).
(15) Clean access urethane from exterior with
MopartSuper Kleen or equivalent.
Fig. 1 CUT URETHANE AROUND WINDSHIELD
1 - COLD KNIFE
2 - WINDSHIELD
23 - 106 STATIONARY GLASSRS
WINDSHIELD (Continued)
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DESCRIPTION FIGURE
REAR SEAT REINFORCEMENTS - SHORT WHEEL BASE ONLY 98
CENTER CONSOLE REINFORCEMENT - SHORT WHEEL BASE ONLY 99
WHEELHOUSES - SHORT WHEEL BASE ONLY 100
FRONT SEAT CROSS MEMBER - SHORT WHEELBASE, ALL WHEEL DRIVE ONLY 101
FLOOR PAN SIDE RAIL - LONG WHEEL BASE ONLY 102
INNER BODY SIDE SILL REINFORCEMENTS 103
TOE BOARD CROSS MEMBER 104
FRONT SIDE RAIL - SHORT WHEEL BASE ONLY 105
DASH PANEL REINFORCEMENT 106
LOWER COWL PLENUM 107
UPPER COWL PLENUM SUPPORT 108
UPPER DASH PANEL 109
COWL SIDE PANELS 110
INSTRUMENT PANEL ATTACHMENT TAPPING PLATES 111
INSTRUMENT PANEL, DASH PANEL, ACM MODULE AND ACCELERATOR PEDAL 112
STRUT TOWER BRACKET AND COWL PLENUM 113
FRONT SIDE RAILS TO LOWER DASH PANEL 114
INNER BODY SIDE SILL TO LOWER DASH PANEL 115
FRONT HINGE TAPPING PLATE 116
FRONT HINGE PILLAR 117
INNER WINDSHIELD FRAME 118
WINDSHIELD FRAME 119
FENDER BRACKET 120
INNER B-PILLAR 121
STRIKER LATCH AND TAPPING PLATES 122
RIGHT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY 123
RIGHT REAR INNER QUARTER PANEL/OUTER WHEELHOUSE - LONG WHEEL BASE
ONLY124
RIGHT REAR BODY SIDE APERTURE - LONG WHEEL BASE ONLY 125
STRIKER LATCH REINFORCEMENT - LONG WHEEL BASE ONLY 126
BELT TAPPING PLATE - LONG WHEEL BASE ONLY 127
C-PILLAR REINFORCEMENT - LONG WHEEL BASE ONLY 128
OUTER WHEELHOUSE - LONG WHEEL BASE ONLY 129
C AND D-PILLAR INNER REINFORCEMENTS - LONG WHEEL BASE ONLY 130
LEFT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY 131
OUTER WHEELHOUSE EXTENSION - LONG WHEEL BASE ONLY 132
TAIL LAMP - LONG WHEEL BASE ONLY 133
SLIDING DOOR LATCH - LONG WHEEL BASE ONLY 134
ROOF BOW EXTENSION - LONG WHEEL BASE ONLY 135
RIGHT REAR INNER QUARTER PANEL - SHORT WHEEL BASE ONLY 136
LATCH REINFORCEMENT AND OUTER WHEELHOUSE - SHORT WHEEL BASE ONLY 137
D-PILLAR REINFORCEMENT - SHORT WHEEL BASE ONLY 138
23 - 162 BODY STRUCTURERS
WELD LOCATIONS (Continued)
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Fig. 110 COWL SIDE PANELS
Fig. 111 INSTRUMENT PANEL ATTACHMENT TAPPING PLATES
RSBODY STRUCTURE23 - 207
WELD LOCATIONS (Continued)
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Fig. 112 INSTRUMENT PANEL, DASH PANEL, ACM MODULE AND ACCELERATOR PEDAL
23 - 208 BODY STRUCTURERS
WELD LOCATIONS (Continued)
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HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - SINGLE ZONE...........1
DESCRIPTION - DUAL ZONE.............1
DESCRIPTION - MANUAL THREE ZONE.....1
DESCRIPTION - AUTOMATIC
TEMPERATURE CONTROL...............2
OPERATION
OPERATION - DUAL ZONE...............3
OPERATION - MANUAL THREE ZONE......3
OPERATION - THREE ZONE ATC..........3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C COOL
DOWN TEST..........................4DIAGNOSIS AND TESTING - A/C
PERFORMANCE TEST..................5
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST..................6
SPECIFICATIONS - HEATER-A/C SYSTEM.....7
CONTROLS - FRONT......................8
CONTROLS - REAR......................29
DISTRIBUTION - FRONT...................39
DISTRIBUTION - REAR....................52
PLUMBING - FRONT.....................60
PLUMBING - REAR......................94
DIESEL SUPPLEMENTAL HEATER - DCHA -
EXPORT..............................106
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - SINGLE ZONE
A single zone heating and air conditioning system
allows one temperature setting for the entire vehicle.
The full range of temperatures that the system can
produce are available by rotating the temperature
control located in control panel.
The control panel and integral computer is
mounted in the instrument panel.
DESCRIPTION - DUAL ZONE
A manual Dual Zone Heating and Air Conditioning
system allows completely independent side-to-side
tempeture control of the discharge air.
The control panel and integral computer is located
in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²a power button which allows the system to be
completely turned off. Contains an LED that illumi-
nates to show when the function is operational.
²rear window defogger on/off switch. Contains an
LED that illuminates to show when the function is
operational.
²slide controls for completely independent side-to-
side temperature control of the discharged air. The
full range of temperature that the system can pro-
duce in any mode is available on either side of thevehicle by independently positioning the slide con-
trols on the instrument panel.
²air recirculation on/off switch. The Recirculate
button contains an LED that illuminates to show
when the function is in operation.
²air conditioning on/off switch. The Snowflake
button contains an LED that illuminates to shown
when the function is in operation.
²rotary knob for fan speed selection.
²a rotary knob for mode control.
DESCRIPTION - MANUAL THREE ZONE
The fully adjustable Three-Zone front and rear
heating and air conditioning system allows interme-
diate seat passengers the ability to regulate air tem-
perature as well as fan speed. All controls are
identified by ISO graphic symbols.
FRONT CONTROL PANEL
The front control panel and integral computer is
mounted in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²a power button which allows the system to be
completely turned off.
²rear window defogger on/off switch.
²slide controls for completely independent side-to-
side temperature control of the discharge air. The full
range of temperature that the system can produce in
any mode is available on either side of the vehicle by
independently positioning the slide controls on the
instrument panel.
RSHEATING & AIR CONDITIONING24-1
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