body CHRYSLER CARAVAN 2005 Service Manual

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
NOTE: The driver's side a double ended stud is
used. A nut has to be removed for the seat belt
anchor removal and the stud for the retractor
removal.
NOTE: On the passenger side there is a belt tension
sensor.
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
RSINTERIOR23-79

CARPETS AND FLOOR MATS
REMOVAL
(1) Remove front seats. (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL)
(2) Remove front center console.
(3) Remove heel blocker (plastic block below accel-
erator pedal).
(4) Remove the remaining seats. Refer to the Own-
er's Manual for the proper procedures.
(5) Remove front cowl panels and sill plates.
(6) Remove sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(7) Remove the cargo organizer, if equipped.
(8) Remove liftgate scuff plate. (Refer to 23 -
BODY/INTERIOR/LIFTGATE SCUFF PLATE -
REMOVAL)
(9) Remove lower B-pillar trim covers.
(10) Remove D-pillar trim covers.
(11) Remove Quarter trim panels.
(12) Remove floor escutcheons (Fig. 4).
(13) Remove the floor console trays. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE TRAY -
REMOVAL)
(14) Remove push pin fasteners attaching carpet to
floor in front seat and rear area.
(15) Roll carpet from under instrument panel to
center of sliding door.
(16) Roll and fold carpet forward away from rear
door opening.
(17) 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 heel blocker (plastic block below accel-
erator pedal).
(17) Install front seats. (Refer to 23 - BODY/
SEATS/SEAT - INSTALLATION)
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
RSINTERIOR23-81

CARPETS - FOLD-IN-FLOOR
REMOVAL
(1) Remove floor mats.
(2) Remove front seats. (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL)
(3) Remove instrument panel lower console. (Refer
to 23 - BODY/INSTRUMENT PANEL/STORAGE
BIN - REMOVAL).
(4) Remove the floor console base tray and discon-
nect wire connector from the base tray.(Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE BASE TRAY -
REMOVAL)
(5) Remove heel blocker (plastic block below accel-
erator pedal).
(6) Remove winch plug (spare tire winch) (Fig. 6).
(7) Remove front cowl panels and sill plates.
(8) Remove kick plate and heel pad at gas pedal
(9) Remove seat belt anchors at the passenger side
B-pillar and driver side C-pillars
(10) Fold in floor second and third row seats. Refer
to the Owner's Manual for the proper procedures.
(11) Remove front carpet trim ring and cover (Fig.
7)(Refer to 23 - BODY/INTERIOR/CARPETS ANDFLOOR MATS - REMOVAL). (Refer to 23 - BODY/
INTERIOR/CARPETS TRIM RING AND COVER
REMOVAL).
Fig. 6 ACCESS TO WINCH
1 - WINCH PLUG
2 - ACCESS HOLE TO WINCH
Fig. 7 FRONT TRIM RING AND COVER ASSEMBLY
1 - FORWARD 4-WAY LOCATOR
2 - REARWARD 2-WAY LOCATOR
3 - LOAD FLOOR PLUG (8)4 - WELD STUD NUTS (10)
5 - TRIM RING COVER
23 - 82 INTERIORRS

(12) Remove sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(13) Remove lower B-pillar trim covers.
(14) Remove push pin fasteners attaching carpet to
floor in front seat area.
(15) Roll carpet from under instrument panel to
center of sliding door.
(16) Pull carpet out from under the quarter trim
panel (Fig. 8).
(17) Using a trim stick, release clips attaching
third row carpet cover, and remove (Fig. 9).
(18) Remove rear carpet screws attaching rear of
carpet.
(19) Roll and fold carpet forward away from rear
door opening.
(20) Remove carpet through sliding door opening.
INSTALLATION
(1) Place carpet through sliding door opening into
position.
(2) Roll carpet rearward towards the rear door
opening.
Fig. 8 FRONT FLOOR CARPET
FRONT CARPET
Fig. 9 ANCHOR MOLDING
1 - 2-WAY CLIPS INTO SEAT FRAME
2 - 4-WAY LOCATING PINS (2)
3 - FRONT SEAT ANCHOR MOLDING
RSINTERIOR23-83
CARPETS - FOLD-IN-FLOOR (Continued)

(3) Roll carpet forward under instrument panel
(Fig. 8).
(4) Install push pins fasteners through carpet and
grommet into floor to attach carpet to floor in front
seat area.
(5) Pull wire harnesses through the carpet as
needed.
(6) Smooth out the carpet and allowing weld studs
to go all the way through the carpet.
(7) Install rear push pins fasteners attaching rear
of carpet.
(8) Place third row carpet cover into position and
press clips into position (Fig. 9).
(9) Slide the carpet under the quarter trim panel
into position.
(10) Install lower B-pillar trim covers.
(11) Install sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION).
(12) Install front carpet trim ring and cover (Fig.
7). (Refer to 23 - BODY/INTERIOR/CARPETS TRIM
RING AND COVER - INSTALLATION)
(13) Install seat belt anchors at the passenger side
B-pillar and driver side C-pillars
(14) Install kick plate and heel pad at the gas
pedal
(15) Install winch plug (spare tire winch) (Fig. 6).
(16) Install front cowl panels and sill plates.
(17) Install heel blocker (plastic block below accel-
erator pedal).
(18) Install the floor console base tray and discon-
nect wire connector from the base tray. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE BASE TRAY -
INSTALLATION).
(19) Install instrument panel lower console. (Refer
to 23 - BODY/INSTRUMENT PANEL/STORAGE
BIN - INSTALLATION).
(20) Install front seats. (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL).
(21) Install floor mats.CARPET TRIM RING AND
COVER - FOLD-IN-FLOOR
REMOVAL
(1) Move front seats to the full forward position.
(2) Fold the second row seats into the floor.
(3) Remove the load floor plugs (Fig. 10).
(4) Remove the ten weld nuts.
(5) Open door covers (Fig. 11).
(6) Remove the four inter weld nuts (Fig. 12).
(7) Raise the front trim ring and cover up off of
the weld studs and remove from vehicle.
INSTALLATION
(1) Place front trim ring and cover assembly into
position.
(2) Open door covers (Fig. 11).
(3) Install the four inter weld nuts (Fig. 12).
(4) Close door covers.
(5) Install the ten weld nuts (Fig. 10).
(6) Install the eight load floor plugs.
(7) Open the second row seats into position.
(8) Move front seats to the position.
23 - 84 INTERIORRS
CARPETS - FOLD-IN-FLOOR (Continued)

DOOR SILL TRIM PLATE
REMOVAL
(1) Using trim stick (C-4755), disengage hidden
clips holding door sill plate from door sill.
(2) Remove sill plate from vehicle (Fig. 15).
INSTALLATION
(1) Place sill plate in position on vehicle (Fig. 15).
(2) Align interlock tabs at front and rear to mating
trim.
(3) Engage hidden clips to hold door sill plate to
door sill.
FLOOR CONSOLE BASE TRAY
REMOVAL
(1) Remove the floor carpet. (Refer to 23 - BODY/
INTERIOR/CARPETS AND FLOOR MATS -
REMOVAL)
(2) Disconnect the electrical connector.
(3) Remove the four screws and remove the base
tray.
INSTALLATION
(1) Place the base tray into position and connect
the wire connector.
(2) Install the four screws attaching base tray.
(3) Install the floor console.
FLOOR CONSOLE - FOLD-IN-
FLOOR
REMOVAL
(1) Open floor console door and storage bin can be
lifted out of the console (Fig. 16).
(2) The floor console inner mat is just laying in the
bottom of the console. It can be removed by pulling
the mat upwards and out.
(3) The power outlet cover is snap into the console.
It can be removed by pulling upward on the inner
edge of the power cover to release it.
(4) The cell phone holder can be removed by com-
pressing the two legs towards each other and remov-
ing phone holder from the console housing (Fig. 17).
INSTALLATION
(1) Compress the legs on the cell phone holder and
place into position (Fig. 17).
(2) Place power outlet cover into position and snap
into position.
(3) Set mat into console housing and lay into posi-
tion.
(4) Set storage bin into console housing and close
door. (Fig. 16).
Fig. 15 DOOR SILL PLATE
1 - CLIPS
2 - SLIDING DOOR SILL TRIM PLATE
3 - FRONT DOOR SILL TRIM PLATE
Fig. 16 FLOOR CONSOLE
1 - POWER OUTLET COVER
2 - FLOOR CONSOLE INNER MAT
3 - STORAGE BIN
4 - FLOOR CONSOLE
RSINTERIOR23-89

HEADLINER
REMOVAL
(1) Remove sun visors and vanity mirrors.
(2) Remove sun visor center supports.
(3) If equipped, remove coat hooks.
(4) If equipped, remove roof rail modules.
(5) Remove A-pillar trim covers. (Refer to 23 -
BODY/INTERIOR/A-PILLAR TRIM - REMOVAL).
(6) Remove B-pillar upper trim covers (Fig. 20).
(Refer to 23 - BODY/INTERIOR/B-PILLAR UPPER
TRIM - REMOVAL).
(7) Remove C-pillar upper trim covers (Fig. 21).
(Refer to 23 - BODY/INTERIOR/C-PILLAR TRIM -
REMOVAL).
(8) Remove D-pillar trim covers. (Refer to 23 -
BODY/INTERIOR/RIGHT D-PILLAR TRIM PANEL -
REMOVAL) and (Refer to 23 - BODY/INTERIOR/
LEFT D-PILLAR TRIM PANEL - REMOVAL).
(9) Remove liftgate opening header trim.
(10) If equipped, remove overhead console screws.
(11) If equipped, remove reading lamps.
(12) Remove dome lamp.
(13) Remove push in locking fasteners attaching
headlining to rear roof header and roof bows (Fig.
22).(14) Remove wiring connections.
(15) Remove headlining from roof (Fig. 23), (Fig.
24), (Fig. 25), and (Fig. 26).
(16) Extract headlining through liftgate opening.
Fig. 20 HEADLINER AT B-PILLAR
1 - FRONT AND SLIDING DOOR WEATHERSTRIP SEAL
2 - B-PILLAR UPPER TRIM PANEL
Fig. 21 HEADLINER AT C-PILLAR
1 - SLIDING DOOR WEATHERSTRIP
2 - C-PILLAR UPPER TRIM PANEL
3 - REAR QUARTER WINDOW OPENING WEATHERSTRIP
Fig. 22 HEADLINER PUSH PINS
RSINTERIOR23-91

INSTALLATION
(1) Insert headlining through liftgate opening (Fig.
23), (Fig. 24), (Fig. 25), and (Fig. 26).
(2) Place headlining in position on roof.
(3) Connect wire connectors.
(4) Install left sun visor support.
(5) Install push in locking fasteners attaching
headlining to rear roof header and bows (Fig. 22).
(6) Install right sun visor support.
(7) Install sun visors and vanity mirrors.
(8) If equipped, install roof rail modules.
(9) If equipped, install coat hooks.
(10) Install dome lamp.
(11) If equipped, install reading lamp.
(12) If equipped, install overhead console.
(13) Install liftgate opening header trim.
(14) Install D-pillar trim covers. (Refer to 23 -
BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL -
INSTALLATION), and (Refer to 23 - BODY/INTERI-
OR/RIGHT D-PILLAR TRIM PANEL - INSTALLA-
TION).(15) Install C-pillar upper trim covers. (Refer to 23
- BODY/INTERIOR/C-PILLAR TRIM - INSTALLA-
TION).
(16) Install B-pillar upper trim covers. (Refer to 23
- BODY/INTERIOR/B-PILLAR UPPER TRIM -
INSTALLATION).
(17) Install A-pillar trim covers. (Refer to 23 -
BODY/INTERIOR/A-PILLAR TRIM - INSTALLA-
TION).
Fig. 23 HEADLINER WITH SIDE CURTAINS
1 - 4-WAY LOCATOR AT FRONT OF HEADLINER
2 - PUSH IN CLIPS ON SUN VISOR RETAINER RACKET AND
TWO SCREWS IN SUN VISOR SWIVEL BRACKET
3 - ONE SCREW IN OVER HEAD CONSOLE
4 - PUSH PINS ATTACHING HEADLINER TO OVERHEAD5-2WAYLOCATOR AT REAR OF HEADLINER
6 - COAT HANGER HOOKS
7 - 2-WAY LOCATORS
8 - WIRE HARNESS
23 - 92 INTERIORRS
HEADLINER (Continued)

INSTALLATION
(1) Place sill plate in position on vehicle.
(2) Align engage hook tabs at end of liftgate sill
plate to D-pillar trim.
(3) Engage hidden clips to hold sill plate to liftgate
door opening sill.
QUARTER TRIM BOLSTER
REMOVAL
The speaker grille in the quarter trim panel is not
removable. The trim panel must be removed to ser-
vice the speaker.
(1) Disengage hidden clips attaching trim bolster
to quarter trim panel.
(2) Remove quarter trim panel from vehicle.
INSTALLATION
The speaker grille in the quarter trim bolster is
not removable. The trim bolster must removed to ser-
vice the speaker.
(1) Place quarter trim bolster in position on vehi-
cle.
(2) Engage hook retainer attaching front of trim
bolster to quarter trim panel, if applicable.
(3) Engage hidden clips attaching trim bolster to
quarter trim panel.
REAR FLOOR TUB CARPETS
INSERT - FOLD-IN-FLOOR
REMOVAL
(1) Open liftgate.
(2) Remove liftgate sill plate. (Refer to 23 - BODY/
INTERIOR/LIFTGATE SILL PLATE - REMOVAL).
(3) Fold third row seats in to floor well.
(4) Using a trim stick, unclip anchor molding (Fig.
28).(5) Remove two screws attaching front edge of
floor tub carpet.
(6) Fold seat back into the upright position.
(7) Remove nuts attaching third row seat lower
trim cover (Fig. 29)
(8) Lift rear tub carpet insert out of floor well (Fig.
30).
(9) Remove tub insert from vehicle
Fig. 27 LIFTGATE SILL PLATE
1 - LIFTGATE SILL PLATE
2 - LIFTGATE SILL
Fig. 28 ANCHOR MOLDING
1 - 2-WAY CLIPS INTO SEAT FRAME
2 - 4-WAY LOCATING PINS (2)
3 - FRONT SEAT ANCHOR MOLDING
Fig. 29 REAR SEAT TRIM COVER
1 - PLASTIC NUTS ON WELD STUDS
2 - LOWER TRIM COVER
RSINTERIOR23-95
LIFTGATE SILL PLATE (Continued)

INSTALLATION
(1) Place rear tub carpet insert into position on
weld studs (Fig. 30).
(2) Slip carpet edges under quarter trim panel.
(3) Install nuts attaching third row seat lower trim
cover (Fig. 29). Follow the tightening sequence.
(4) Fold third row seats in to floor well.
(5) Install two screws attaching front edge of floor
tub carpet.
(6) Place anchor molding into position push on
clips to lock (Fig. 28).
(7) Remove liftgate sill plate. (Refer to 23 - BODY/
INTERIOR/LIFTGATE SILL PLATE - INSTALLA-
TION).
(8) Close liftgate.
REAR HEADER TRIM
REMOVAL
(1) Disengage hidden clips holding trim to rear
header (Fig. 31).
(2) Separate rear header trim from vehicle.
INSTALLATION
(1) Place rear header trim in position on vehicle.
(2) Align guide pins on trim to holes in header.
(3) Engage hidden clips to hold trim to rear
header.
(4) Engage interlock tabs at D-pillar trim.
REAR HVAC LOUVER
REMOVAL
(1) Using a trim stick (C-4755), pry edge of louver
from bezel.
(2) Remove HVAC louver from bezel.
(3) Using a trim stick, pry lower edge of HVAC
bezel away from headlining (Fig. 32).
(4) Remove louver from vehicle.
Fig. 30 REAR FLOOR TUB CARPET INSERT
1 - REAR TUB
2- TAB ON SIDE OF CARPET IN WHEELHOUSE AREA
3 - REAR TUB CARPET
4 - LOAD THROUGH LIFTGATE OPENING
Fig. 31 REAR HEADER TRIM
1 - REAR HEADER
2 - GUIDE PINS
3 - CLIPS
Fig. 32 REAR HVAC LOUVER
1 - HEVAC DUCT
2 - REAR HEVAC LOUVER
3 - HEADLINING
4 - CLIP
23 - 96 INTERIORRS
REAR FLOOR TUB CARPETS INSERT - FOLD-IN-FLOOR (Continued)