body CHRYSLER CARAVAN 2005 Service Manual

(1) Match the replacement cable up against the old
cable to verify the correct part.
(2) Position the hold open latch cable on the side
door.
NOTE: The hold open latch cable is marked with
white tape. It must be attached to the upper most
cable attachment at the latch. This position is
marked with a ªWº on the latch.
(3) Connect the hold open latch cable on the hold
open latch assembly. Hook the swedged cable end on
the latch link and gently push the cable sleeve
retainer in the latch bracket.
(4) Install the hold open latch on the side door.(Re-
fer to 23 - BODY/DOORS - SLIDING/HOLD OPEN
LATCH - INSTALLATION)
(5) Connect the hold open latch cable on the latch
assembly. Hook the swedged cable end on the latch
link and gently push the cable sleeve retainer in the
latch bracket.(6) Trace the outside handle cable along its routing
path and install on its retaining clips and position
foam insulators. Use previously made schematic as a
guide or remove the opposite side door trim panel
and use that door as a guide.
CAUTION: Be certain replacement cable is routed
and retained correctly and foam insulators are
properly positioned.
(7) Install the latch assembly. (Refer to 8 - ELEC-
TRICAL/POWER DOORS/LATCH - INSTALLATION)
(8) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(9) Install the appropriate side door trim panel on
the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - INSTALLATION)
(10) Connect the negative battery cable.
RSDOORS - SLIDING23-39
HOLD OPEN LATCH CABLE (Continued)

DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL.............................40
INSTALLATION.........................40
HINGE
REMOVAL.............................40
INSTALLATION.........................40
LATCH
REMOVAL.............................41
INSTALLATION.........................41
LATCH STRIKER
REMOVAL.............................41
INSTALLATION.........................42
LIFTGATE
REMOVAL.............................42
INSTALLATION.........................42
LOCK CYLINDER
REMOVAL.............................42INSTALLATION.........................42
SUPPORT CYLINDER
REMOVAL.............................42
INSTALLATION.........................43
TRIM PANEL
REMOVAL.............................43
INSTALLATION.........................43
SLAM BUMPER
REMOVAL
REMOVAL - BODY SIDE................44
REMOVAL - LIFTGATE SIDE.............44
INSTALLATION
INSTALLATION - BODY SIDE............44
INSTALLATION - LIFTGATE SIDE.........44
EXTERIOR HANDLE
REMOVAL
(1) Remove liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the exterior handle electrical con-
nectors.
(3) Remove the two outer screws and the two inner
screws.
(4) Remove the exterior handle/license plate light
assembly.
INSTALLATION
(1) Route the exterior handle electrical connector
through the door and position handle.
(2) Install the two out screws and tighten to 3 N´m
(22 in. lbs.).
(3) Install the two inner bolts and tighten to 5
N´m (40 in. lbs.).
(4) Connect the electrical connector.
(5) Install the trim panel. (Refer to 23 - BODY/
DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM
PANEL - INSTALLATION)
HINGE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device in
the full open position.
(3) Apply several layers of duct tape on the outside
of to roof across the gap to the lift gate to hold the
liftgate in position.
(4) Remove bolts attaching liftgate hinge to roof
header.
(5) Disconnect VTSS switch from the body har-
ness.
(6) Remove bolts attaching hinge to liftgate (Fig.
1).
(7) Remove hinge from vehicle.
INSTALLATION
(1) If necessary, paint replacement hinge before
installation.
(2) Place hinge in position on vehicle.
(3) Align hinge to marks on liftgate.
(4) Install bolts attaching hinge to liftgate (Fig. 1).
Tighten bolts to 33 N´m (24 ft. lbs.) torque.
(5) Align hinge to marks on roof header.
23 - 40 DECKLID/HATCH/LIFTGATE/TAILGATERS

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)

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

EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL.............................45
INSTALLATION.........................46
COWL GRILLE
REMOVAL.............................50
INSTALLATION.........................50
EXTERIOR NAME PLATES - TAPE ATTACHED
REMOVAL.............................51
INSTALLATION.........................51
EXTERIOR NAME PLATES - ADHESIVE
ATTACHED
REMOVAL.............................51
INSTALLATION.........................51
FRONT FENDER
REMOVAL.............................51
INSTALLATION.........................52
FUEL FILL DOOR
REMOVAL.............................52
INSTALLATION.........................52
FUEL FILL DOOR BLOCKER LATCH
REMOVAL.............................53
INSTALLATION.........................53
FUEL FILL DOOR BLOCKER LATCH STRIKER
REMOVAL.............................53
INSTALLATION.........................53
FUEL FILL DOOR BLOCKER LOCKOUT LINK
REMOVAL.............................54
INSTALLATION.........................54
GRILLE
DESCRIPTION.........................55REMOVAL.............................55
INSTALLATION.........................55
UPPER RADIATOR CROSSMEMBER
REMOVAL.............................56
INSTALLATION.........................56
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL.............................57
INSTALLATION.........................57
LUGGAGE RACK RISER
REMOVAL.............................57
INSTALLATION.........................58
LUGGAGE RACK CROSSBAR
REMOVAL.............................58
INSTALLATION.........................59
REAR QUARTER PANEL/FENDER AIR
EXHAUSTER
DESCRIPTION.........................59
REMOVAL.............................59
INSTALLATION.........................60
ROOF JOINT MOLDING
REMOVAL.............................60
INSTALLATION.........................60
SIDE VIEW MIRROR
REMOVAL.............................60
INSTALLATION.........................60
GLASS-OUTSIDE REARVIEW MIRROR
REMOVAL.............................61
INSTALLATION.........................61
BODY SIDE MOLDINGS
REMOVAL
Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig.
5)for proper location of fasteners holding the molding
to the wheelhouse lip and rocker panels.
(1) Warm the affected stick on molding and body
metal to approximately 38É C (100É F) using a suit-
able heat lamp or heat gun.(2) If equipped, remove pop rivets holding molding
edge to wheelhouse lip.
(3) Pull stick on molding from painted surface.
(4) Remove adhesive tape residue from painted
surface of vehicle. Use a 3M Scotch-BriteŸ Molding
Adhesive and Stripe Removal Disc, or equivalent, to
clean adhesive residue from painted surfaces. These
products are available from automotive paint suppli-
ers. Refer to instructions supplied with the specific
product for proper usage.
RSEXTERIOR23-45

INSTALLATION
Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig.
5)for proper location of fasteners to hold the molding
to the wheelhouse lip and rocker panels.
(1) If molding is to be reused;
(a) Remove tape residue from molding.
(b) Clean back of molding with MopartSuper
Kleen, or equivalent.
(c) Wipe molding dry with lint free cloth.
(d) Apply a single coat of MopartTPO Molding
Prep to tape side of molding and allow to dry thor-
oughly.
(e) Apply new body side molding (two sided
adhesive) tape to back of molding.(2) Clean body surface with MopartSuper Kleen,
or equivalent. Wipe surface dry with lint free cloth.
(3) Remove protective cover from tape on back of
molding.
(4) Apply molding to body from front to rear,
inserting locator pins into hole in body panel.
(5) Using a roller tool, roll molding onto body
panel with enough force to assure adhesion. Do not
apply excessive force, or damage to body panels may
result.
(6) Install pop rivets to hold molding edge to
wheelhouse lip, if necessary.
Fig. 1 BODY SIDE MOLDINGS - BASE TYPICAL
1 - GUIDE PINS
2 - FRONT DOOR MOLDING3 - SLIDING DOOR MOLDING
4 - QUARTER PANEL MOLDING
23 - 46 EXTERIORRS
BODY SIDE MOLDINGS (Continued)

Fig. 2 BODY SIDE MOLDINGS - HIGHLINE TYPICAL
1 - QUARTER PANEL
2 - FRONT FENDER
3 - POP-RIVET
4 - FENDER MOLDING
5 - FRONT DOOR MOLDING6 - SLIDING DOOR MOLDING
7 - GUIDE PINS
8 - QUARTER PANEL MOLDING
9 - LIFTGATE MOLDING
10 - POP-RIVET
RSEXTERIOR23-47
BODY SIDE MOLDINGS (Continued)

Fig. 3 BODY SIDE MOLDINGS - PREMIUM TYPICAL
1 - QUARTER PANEL
2 - FRONT FENDER
3 - POP-RIVET
4 - FENDER MOLDING
5 - POP-RIVET
6 - FASCIA7 - FRONT DOOR MOLDING
8 - SLIDING DOOR MOLDING
9 - QUARTER PANEL MOLDING
10 - FASCIA MOLDING
11 - POP-RIVET
23 - 48 EXTERIORRS
BODY SIDE MOLDINGS (Continued)

Fig. 4 BODY SIDE MOLDINGS - PREMIUM TYPICAL
1 - QUARTER PANEL
2 - FRONT FENDER
3 - POP-RIVET
4 - FENDER MOLDING
5 - POP-RIVET
6 - FASCIA7 - FRONT DOOR MOLDING
8 - SLIDING DOOR MOLDING
9 - QUARTER PANEL MOLDING
10 - FASCIA MOLDING
11 - POP-RIVET
RSEXTERIOR23-49
BODY SIDE MOLDINGS (Continued)

COWL GRILLE
REMOVAL
(1) Remove wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL)
(2) Remove four (4) screws securing cowl cover to
wiper module (Fig. 6).
(3) Disengage quarter turn fasteners at outboard
ends of cowl grill from body.
(4) Release hood latch and open hood.
CAUTION: To prevent hood scratching of cowl grille
before removal, cover outboard exterior ends of
cowl grille with masking tape or equivalent method.
NOTE: Do not over bend cowl grille during removal.
Bend cowl grille just enough to clear top of wiper
pivot shaft and bottom rear corner of hood.
(5) Remove cowl grill by raising above driver side
wiper pivot shaft and swinging away towards engine
compartment. The cowl grille will need to be bent onoutboard end to clear simultaneously top of wiper
pivot shaft and bottom corner of hood.
(6) Close hood. Do not latch. Remove outboard
screws. (Fig. 7).
(7) Disconnect washer hose in line connector.
(8) Disconnect washer hose and grommet from
hole in wiper module and pull out.
(9) Remove cowl grille by raising over opposite
wiper pivot shaft and removing away from vehicle.
(10) Remove cowl cover from vehicle.
INSTALLATION
(1) Reverse removal procedure.
(2) When installing cowl cover over wiper module,
make sure fore aft locator on the underside of cowl
grill seat into the locator grooves on top of wiper
module.
(3) Start all cowl grille mounting screws by hand
before torquing to specifications.
(4) Assure washer hose is properly routed and not
pinched.
(5) Center cowl grille to body and windshield.
(6) Assure ªarrowº indicator head of quarter turn
fasteners is pointing toward windshield.
Fig. 5 BODY SIDE MOLDINGS WITH APPLIQUE - TYPICAL
1 - FRONT ROCKER PANEL APPLIQUE
2 - FRONT DOOR MOLDING
3 - SLIDING DOOR MOLDING4 - REAR ROCKER PANEL APPLIQUE
5 - LIFTGATE MOLDING
6 - POP-RIVET
23 - 50 EXTERIORRS
BODY SIDE MOLDINGS (Continued)