tailgate CHRYSLER CARAVAN 2005 User Guide

INSTALLATION
(1) Place striker in position on vehicle.
(2) Align striker to outline mark on sill.
(3) Install screws attaching striker to sill. Tighten
screws to 28 N´m (21 ft. lbs.) torque.
(4) Verify liftgate alignment and operation.
LIFTGATE
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Release liftgate latch and open liftgate.
(3) Remove liftgate upper frame molding.
(4) Remove screws attaching liftgate wire connec-
tor to rear header.
(5) Disconnect liftgate wire harness from body
wire harness.
(6) Disconnect rear window washer hose from
spray nozzle.
(7) Support liftgate on a suitable lifting device.
(8) Disconnect power liftgate link, if equipped.
(9) Remove screws attaching support cylinders to
liftgate.
(10) Remove bolts attaching liftgate hinge to roof
header (Fig. 4).
(11) With assistance, remove liftgate from vehicle.
INSTALLATION
(1) With assistance, place liftgate in position on
vehicle.
(2) Install bolts attaching liftgate hinge to roof
header. Tighten bolts to 33 N´m (24 ft. lbs.) torque.
(3) Install screws attaching support cylinders to
liftgate. Tighten bolts to 28 N´m (21 ft. lbs.) torque.(4) Reconnect power liftgate link, if equipped.
(5) Remove lifting device from under liftgate.
(6) Connect liftgate wire harness into body wire
harness.
(7) Install screws attaching wire connector to rear
header.
(8) Connect rear window washer hose onto spray
nozzle.
(9) Install liftgate upper frame molding.
(10) Install battery negative cable.
(11) Verify liftgate alignment. The liftgate should
have a gap to adjacent panels and fit flush across the
gaps. The gap is; (Refer to 23 - BODY/BODY STRUC-
TURE/GAP AND FLUSH - SPECIFICATIONS).
²8.0 mm   2.5 to the rear fascia,
²8.0 mm   2.0 to the roof,
²2.0 mm   0.5 mm to the aperture.
LOCK CYLINDER
REMOVAL
(1) Remove the liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the electrical connector.
(3) Disconnect the latch rod.
(4) Rotate plastic lock cylinder nut one quarter
turn and remove nut and spring washer.
(5) Remove the lock cylinder from the liftgate.
INSTALLATION
(1) Install lock cylinder into liftgate.
(2) Install the plastic lock cylinder lock nut, spring
washer and rotate one quarter turn.
(3) Connect the electrical connector.
(4) Connect the latch rod.
(5) Install the trim panel. (Refer to 23 - BODY/
DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM
PANEL - INSTALLATION)
(6) Verify lock cylinder operation.
SUPPORT CYLINDER
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device in
the full open position.
(3) Pull liftgate opening weatherstrip from D-pillar
flange next to prop assembly end pivot.
(4) Remove bolt attaching end pivot to D-pillar
(Fig. 5).
(5) Remove bolt attaching prop assembly to lift-
gate.
(6) Remove prop assembly from vehicle.
Fig. 4 LIFTGATE
1 - HINGE
2 - ROOF
3 - NET HOLE OR SLOT
23 - 42 DECKLID/HATCH/LIFTGATE/TAILGATERS
LATCH STRIKER (Continued)

INSTALLATION
Ensure that the cylinder end is attached to the
D-pillar and the shaft end is attached to the liftgate.
(1) Place prop assembly in position.
(2) Install bolt attaching prop assembly to liftgate.
(3) Install bolt attaching end pivot to D-pillar.
Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(4) Install liftgate opening weatherstrip to D-pillar
flange next to prop assembly end pivot.
(5) Close liftgate. Check liftgate operation.
TRIM PANEL
REMOVAL
(1) Remove the bolt attaching the lift motor link, if
equipped (Fig. 6).
(2) Remove liftgate upper frame molding (Fig. 7).
(3) Remove assist handle screws.
(4) Disengage hidden clips holding trim panel to
liftgate from around perimeter or liftgate (Fig. 7).
(5) Disconnect wire connector from lamps.
(6) Remove liftgate trim panel from vehicle.
INSTALLATION
(1) Place liftgate trim panel in position on vehicle.
(2) Engage hidden clips to hold trim panel to lift-
gate and fasteners around perimeter of liftgate (Fig.
7).(3) Connect wire connector into lamp.
(4) Install courtesy lamps into liftgate trim.
(5) Install screws to hold assist handle to liftgate.
(6) Install upper frame side moldings.
(7) Install liftgate upper frame molding.
(8) Install the bolt attaching the lifgate motor link
and tighten to 28 N´m (21 ft. lbs.)
Fig. 5 LIFTGATE PROP ASSEMBLY
1 - LIFTGATE
2 - PROP ASSEMBLY
Fig. 6 LIFTGATE MOTOR
1 - LIFTGATE MOTOR LINK BOLT
2 - LIFTGATE MOTOR
3 - LIFTGATE
Fig. 7 LIFTGATE TRIM
1 - LIFTGATE
2 - LOWER TRIM PANEL
3 - ASSIST HANDLE SCREWS
4 - UPPER TRIM
5 - UPPER TRIM CLIPS
RSDECKLID/HATCH/LIFTGATE/TAILGATE23-43
SUPPORT CYLINDER (Continued)

SLAM BUMPER
REMOVAL
REMOVAL - BODY SIDE
(1) Open liftgate.
(2) Remove liftgate stop bumper body side attach-
ing bolts (Fig. 8).
(3) Remove liftgate stop bumper.
REMOVAL - LIFTGATE SIDE
(1) Open liftgate.
(2) Remove liftgate stop bumper liftgate side
attaching rivets by drilling out old rivets.
(3) Remove liftgate stop bumper.
INSTALLATION
INSTALLATION - BODY SIDE
(1) Place liftgate stop bumper into position.
(2) Install bolts attaching liftgate stop bumper to
body side (Fig. 8).
(3) Close liftgate.
INSTALLATION - LIFTGATE SIDE
(1) Place liftgate stop bumper into position.
(2) Install rivets attaching liftgate stop bumper to
liftgate.
NOTE: Verify that ships or parts of drilled out rivet
does not rattle in the liftgate. If there is rattling
sound, detrim liftgate and retrieve debris.
(3) Close liftgate.
Fig. 8 LIFTGATE STOP BUMPER - BODY SIDE
1 - LIFTGATE STOP BUMPER
2 - LIFTGATE OPENING
23 - 44 DECKLID/HATCH/LIFTGATE/TAILGATERS