body CHRYSLER CARAVAN 2005 Service Manual

WARNING: TO AVOID PERSONAL INJURY OR
DEATH ON VEHICLES EQUIPPED WITH THE OCCU-
PANT CLASSIFICATION SYSTEM (OCS), ONLY THE
OCCUPANT CLASSIFICATION MODULE (OCM) AND
THE SEAT CUSHION TRIM MAY BE SERVICED SEP-
ARATELY. ALL OTHER COMPONENTS OF THE PAS-
SENGER SIDE FRONT SEAT CUSHION ASSEMBLY
MUST BE SERVICED ONLY AS A COMPLETE FAC-
TORY-CALIBRATED, ASSEMBLED AND TAMPER-EV-
IDENT SERVICE REPLACEMENT PACKAGE. THIS
PACKAGE INCLUDES THE FRAME, SPRINGS, PAD,
BLADDER, SENSOR, FOAM, WIRING AND A CALI-
BRATED OCM. WHEN INSTALLING THIS PACKAGE
ALWAYS REPLACE ALL OF THE EXISTING COMPO-
NENTS WITH THE NEW COMPONENTS AS A UNIT.
DO NOT ATTEMPT TO SEPARATE OR DISCONNECT
ANY OF THE NEW OCS COMPONENTS IN THE SER-
VICE REPLACEMENT PACKAGE FROM EACH
OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF
THE REPLACED COMPONENTS IN THIS OR ANY
OTHER VEHICLE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN FAILURE OF
THE PASSENGER AIRBAG TO DEPLOY WHEN
REQUIRED, OR IN PASSENGER AIRBAG DEPLOY-
MENT WHEN NOT REQUIRED.
(1) Place rear cover in position on seat.
(2) Engage fasteners attaching rear cover to slots
on power seat track.
(3) Engage arrowhead retainer into loop strip
attaching rear cover to power seat track crossbar
(Fig. 42).
ARMREST - SECOND ROW -
FOLD-IN-FLOOR
REMOVAL
(1) Remove armrest plug with a small flat bladed
tool (Fig. 43).
(2) Remove attaching screw.
(3) Remove armrest from seat back.
INSTALLATION
(1) Place armrest into position (Fig. 43).
(2) Install attaching screw.
(3) Install armrest plug.
ARMREST ROTATING
ASSEMBLY - SECOND ROW -
FOLD-IN-FLOOR
REMOVAL
(1) Remove headrest and headrest sleeves. (Refer
to 23 - BODY/SEATS/HEADREST SLEEVE -
REMOVAL).
(2) Remove both armrest. (Refer to 23 - BODY/
SEATS/ARMREST - REMOVAL).
(3) Remove seat back panel. (Refer to 23 - BODY/
SEATS/SEAT BACK - REMOVAL).
(4) Disengage J-strap from seat back (Fig. 44).
(5) Move seat back cover and foam to access the
armrest rotating assembly.
(6) Remove armrest rotating assembly attaching
screws (Fig. 45).
(7) Remove armrest rotating assembly from the
seat back frame.
INSTALLATION
(1) Place armrest rotating assembly into position
(Fig. 45).
(2) Install two armrest rotating assembly attach-
ing screws.
(3) Move seat back cover and foam to into proper
position and engage J-straps (Fig. 44).
(4) Install seat back panel. (Refer to 23 - BODY/
SEATS/SEAT BACK - INSTALLATION).
(5) Install both armrest. (Refer to 23 - BODY/
SEATS/ARMREST - INSTALLATION).
Fig. 43 SECOND ROW SEAT ARMREST
1 - ARMREST PLUG
23 - 130 SEATSRS
FRONT SEAT TRACK REAR COVER - OCS (Continued)

(6) Install headrest sleeves and headrest. (Refer to
23 - BODY/SEATS/HEADREST SLEEVE - INSTAL-
LATION).
HEADREST SLEEVE - SECOND
ROW - FOLD-IN-FLOOR
REMOVAL
(1) Remove headrest (Fig. 46).(2) Using a trim tool remove sleeve by prying
sleeve away from the seat back frame to unlock it
(Fig. 47).
(3) Pull headrest sleeve upward and out the top of
the seat back frame and remove from seat.
INSTALLATION
(1) Place headrest sleeve into position and push
downward until sleeve locks into position.
(2) Install headrest (Fig. 46).
Fig. 44 SECOND ROW SEAT BACK
1 - J-STRAPS
Fig. 45 SECOND ROW ARMREST ROTATING
ASSEMBLY
1 - ATTACHING SCREWS
Fig. 46 HEADREST
1 - HEADREST
2 - DEPRESS TAB
Fig. 47 HEADREST SLEEVE
1 - REMOVE SLEEVE
RSSEATS23 - 131
ARMREST ROTATING ASSEMBLY - SECOND ROW - FOLD-IN-FLOOR (Continued)

SEAT BACK COVER/FOAM -
SECOND ROW - FOLD-IN-
FLOOR
REMOVAL
(1) Remove both armrest. (Refer to 23 - BODY/
SEATS/ARMREST - REMOVAL).
(2) Remove headrest and headrest sleeves. (Refer
to 23 - BODY/SEATS/HEADREST SLEEVE -
REMOVAL).
(3) Remove seat back panel. (Refer to 23 - BODY/
SEATS/SEAT BACK PANEL - REMOVAL).
(4) Disengage seat back cover J-straps (Fig. 52).
(5) Remove two push pin fasteners attaching seat
back cover at the bottom of seat back.
(6) Remove seat back cover and foam from seat
back frame (Fig. 53).
(7) Separate seat back cover from the foam (Fig.
54).
INSTALLATION
(1) Place the seat back cover and foam together
(Fig. 54) and (Fig. 53).
(2) Place seat back cover/foam on the seat back
frame.
(3) Install two push pin fasteners attaching seat
back cover at the bottom of seat back.
(4) Engage seat back cover J-straps (Fig. 52).
(5) Remove seat back panel. (Refer to 23 - BODY/
SEATS/SEAT BACK PANEL - INSTALLATION)
(6)(7) Install headrest sleeves and headrest. (Refer to
23 - BODY/SEATS/HEADREST SLEEVE - INSTAL-
LATION).
(8) Install both armrest. (Refer to 23 - BODY/
SEATS/ARMREST - INSTALLATION).
Fig. 52 SECOND ROW SEAT BACK
1 - J-STRAPS
Fig. 53 SEAT BACK COVER 1
1 - LOCKING STRIPS
Fig. 54 SEAT BACK FOAM
1 - LOCKING CLIPS
RSSEATS23 - 133

SEAT BACK FRAME - SECOND
ROW - FOLD-IN-FLOOR
REMOVAL
(1) Remove seat back cover and foam. (Refer to 23
- BODY/SEATS/SEAT BACK COVER/FOAM -
REMOVAL).
(2) Remove two seat back frame bolts on each side
and remove frame (Fig. 55).
INSTALLATION
(1) Place seat back frame into position on seat
cushion pan (Fig. 56).
(2) Install the two inner and outer bolts attaching
seat back frame (Fig. 57).
(3) Install seat cushion upper side shield. (Refer to
23 - BODY/SEATS/SEAT CUSHION UPPER SIDE
SHIELDS - INSTALLATION).
(4) Install seat back cover and foam. (Refer to 23 -
BODY/SEATS/SEAT BACK COVER/FOAM -
INSTALLATION).
SEAT BACK PANEL - SECOND
ROW -FOLD-IN-FLOOR
REMOVAL
(1) Using a trim stick or thin flat bladed tool, pry
seat back panel to release push pin fasteners from
the seat back (Fig. 58).
(2) Remove seat back panel from seat.
INSTALLATION
(1) Place seat back panel into position (Fig. 58).
(2) Press on seat back panel to seat the push pin
fastens.
SEAT BASE RISER - SECOND
ROW - FOLD-IN-FLOOR
REMOVAL
(1) Remove seat from vehicle. (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL).
Fig. 55 SEAT BACK FRAME
1 - ATTACHING BOLTS
Fig. 56 SECOND ROW SEAT BACK FRAME
Fig. 57 SEAT BACK FRAME
1 - ATTACHING BOLTS
23 - 134 SEATSRS

(2) Remove seat back frame. (Refer to 23 - BODY/
SEATS/SEAT BACK FRAME - REMOVAL).
(3) Remove seat cushion cover and foam. (Refer to
23 - BODY/SEATS/SEAT CUSHION/FOAM -
REMOVAL).
(4) Remove the cushion support (snap on elastic
pad) (Fig. 59).
(5) Remove six cushion frame nuts and separate
from raiser (Fig. 60), (Fig. 61) and (Fig. 62).
(6) Remove seat track from raiser (Fig. 63).
INSTALLATION
(1) Install seat tracks to seat raiser (Fig. 63).
(2) Place cushion frame into position on seat
tracks (Fig. 62).
(3) Install six cushion frame nuts (Fig. 60).
(4) Install the cushion support (snap on elastic
pad) (Fig. 59).
(5) Install seat back frame. (Refer to 23 - BODY/
SEATS/SEAT BACK FRAME - INSTALLATION).
Fig. 58 SECOND ROW SEAT BACK COVER
1 - PRY UP TO RELEASE PUSH PIN FASTENERS
Fig. 59 SEAT CUSHION FRAME ASSEMBLY
1 - CUSHION SUPPORT
Fig. 60 SEAT CUSHION FRAME AND TRACK
ASSEMBLY
1 - SEAT CUSHION FRAME
2 ATTACHING NUTS
3 - SEAT RAISER
Fig. 61 REMOVE SEAT RISER FROM TRACK
SEAT TRACK STUDS
RSSEATS23 - 135
SEAT BASE RISER - SECOND ROW - FOLD-IN-FLOOR (Continued)

(6) Install seat cushion cover and foam. (Refer to
23 - BODY/SEATS/SEAT CUSHION/FOAM -
INSTALLATION).
SEAT CUSHION COVER/FOAM
-SECOND ROW - FOLD-IN-
FLOOR
REMOVAL
(1) Remove seat cushion upper cushion side
shields. (Refer to 23 - BODY/SEATS/SEAT UPPER
CUSHION SIDE SHIELDS - REMOVAL)(2) Disengage J-straps attaching seat cushion
cover to cushion pan (Fig. 64).
(3) Remove seat cushion cover and foam from
cushion pan (Fig. 65).
(4) Separate the seat cushion cover from the foam.
INSTALLATION
(1) Place the seat cushion cover and foam together
and place on seat cushion pan (Fig. 65).
(2) Engage J-straps attaching seat cushion cover to
cushion pan (Fig. 64).
(3) Install seat cushion upper cushion side shields.
(Refer to 23 - BODY/SEATS/SEAT UPPER CUSH-
ION SIDE SHIELDS - INSTALLATION).
Fig. 62 SECOND ROW SEAT RISER
1 - SEAT RISER ASSEMBLY
Fig. 63 SEAT TRACK
1 - SEAT TRACK
2 - ATTACHING STUDS
Fig. 64 SECOND ROW CUSHION ATTACHING
POINTS
1 - J-STRAPS
Fig. 65 SECOND ROW SEAT CUSHION ASSEMBLY
23 - 136 SEATSRS
SEAT BASE RISER - SECOND ROW - FOLD-IN-FLOOR (Continued)

SEAT RECLINER/FORWARD
FOLDING MECHANISM
-SECOND ROW -FOLD-IN-
FLOOR
REMOVAL
(1) Remove seat back cover and foam (Fig. 66).
(Refer to 23 - BODY/SEATS/SEAT BACK COVER/
FOAM - REMOVAL)
(2) Remove two seat back frame bolts on each side
and remove frame (Fig. 67).(3) Remove the two reclining mechanism bolts
from each side of the frame (Fig. 68) and (Fig. 69).
(4) Remove both armrest rotating assembly. (Refer
to 23 - BODY/SEATS/ARMREST ROTATING
ASSEMBLY - REMOVAL).
INSTALLATION
(1) Install both armrest rotating assembly. (Refer
to 23 - BODY/SEATS/ARMREST ROTATING
ASSEMBLY - INSTALLATION).
(2) Install the two reclining mechanism bolts on
each side of frame (Fig. 68) and (Fig. 69).
(3) Install seat back frame (Fig. 67).
(4) Install seat back cover and foam (Fig. 66).
Fig. 66 SECOND ROW SEAT BACK
Fig. 67 SEAT BACK FRAME
1 - ATTACHING BOLTS
Fig. 68 SECOND ROW INBOARD SIDE
1 - ATTACHING BOLT
Fig. 69 SEAT BACK OUTBOARD SIDE
ATTACHING BOLTS
RSSEATS23 - 137

INSTALLATION
(1) Place prop rod into position.
(2) Install lower attaching screw (Fig. 78).
(3) Install prop rod top screw (Fig. 77).
(4) Install lower front shield (Fig. 76).
BUCKET SEAT BACK - QUAD
BUCKET
REMOVAL
NOTE: Quad seats equipped with child restraint
seats have an interlock feature that will not allow
the seat back to fold forward with the child seat
open.
(1) Remove the headrests. (Refer to 23 - BODY/
SEATS/HEADREST - REMOVAL)
(2) Remove the armrests, if equipped. (Refer to 23
- BODY/SEATS/ARMREST - REMOVAL)
(3) Remove the seat back hinge covers. (Refer to
23 - BODY/SEATS/SEAT BACK HINGE COVERS -
QUAD BUCKET, 50/50 SPLIT, BENCH - REMOVAL)
(4) Disconnect the child seat synchronizer cable, if
equipped. (Fig. 79)
(5) Remove the seat back frame bolts and remove
the seat back. (Fig. 80)
Fig. 77 PROP ROD TOP SCREW
1 - ATTACHING SCREW
Fig. 78 PROP RODS
1 - ATTACHING PIN
2 - ATTACHING SCREW
Fig. 79 QUAD SEAT SYNCHRONIZER CABLE
1 - CABLE END CONNECTOR
2 - SYNCHRONIZER CABLE
3 - SEATBACK HINGE
23 - 140 SEATSRS
SEAT PROP ROD - SECOND ROW - FOLD-IN-FLOOR (Continued)

INSTALLATION
(1) Install the seat back.
(2) Install the shoulder bolts attaching the seat
back hinge to the seat back frame and tighten to 48
N´m (35 ft. lbs.) torque.
(3) Connect the child seat synchronizer cable, if
equipped.
(4) Install the seat back hinge covers. (Refer to 23
- BODY/SEATS/SEAT BACK HINGE COVERS -
QUAD BUCKET, 50/50 SPLIT, BENCH - INSTALLA-
TION)
(5) Install the armrests. (Refer to 23 - BODY/
SEATS/ARMREST - INSTALLATION)
(6) Install the headrest. (Refer to 23 - BODY/
SEATS/HEADREST - INSTALLATION)
(7) Verify seat back operation.
QUAD SEAT CUSHION
REMOVAL
(1) Remove the quad bucket seat side shields and
cup holder. (Refer to 23 - BODY/SEATS/SEAT SIDE
SHIELD/QUAD BUCKET SEAT SIDE SHIELD/CUP
HOLDER - REMOVAL) and (Refer to 23 - BODY/
SEATS/QUAD BUCKET SEAT SIDE SHIELD - NO
CUP HOLDER - REMOVAL)
(2) Remove seat track front and rear covers if
equipped. (Refer to 23 - BODY/SEATS/SEAT TRACK
REAR COVER - REMOVAL) and (Refer to 23 -
BODY/SEATS/SEAT TRACK FRONT COVER -
REMOVAL)(3) If equipped, open storage bin to access front
pan bolts.
(4) Remove bolts attaching seat cushion pan to
seat riser.
(5) Disconnect wire connectors, if equipment.
(6) Remove seat cushion from seat.
(7) Disengage J-strap retainers holding seat cover
to cushion.
(8) Remove seat cushion pan from cover and pad.
INSTALLATION
(1) Place seat cushion cover in position on seat
cushion.
(2) Engage J-strap retainers to hold seat cover to
cushion.
(3) Place seat cushion in position on seat.
(4) Connect wire connectors, if equipment.
(5) Install bolts attaching seat cushion to seat
riser. Tighten bolts to 40 N´m (29.5 ft. lbs.) torque.
(6) If equipped, close storage bin.
(7) Install seat track front and rear covers, if
equipped. (Refer to 23 - BODY/SEATS/SEAT TRACK
REAR COVER - INSTALLATION) and (Refer to 23 -
BODY/SEATS/SEAT TRACK FRONT COVER -
INSTALLATION)
(8) Install the quad seat side shield and cup holder
if equipped. (Refer to 23 - BODY/SEATS/QUAD
BUCKET SEAT SIDE SHIELD/CUP HOLDER -
INSTALLATION) and (Refer to 23 - BODY/SEATS/
QUAD BUCKET SEAT SIDE SHIELD - NO CUP
HOLDER - INSTALLATION)
(9) Install seat cushion side covers. (Refer to 23 -
BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - INSTALLATION)
QUAD BUCKET SEAT SIDE
SHIELD/CUP HOLDER
REMOVAL
(1) Remove the seat from the vehicle. Refer to
Owner's Manual for proper procedures.
(2) Remove the two screws and remove the hinge
cover (Fig. 81)
(3) Remove the dump latch handle.
(4) Remove the three screws (Fig. 82).
(5) Depress the tab on the cup holder assembly
(Fig. 83).
(6) Using a deep well socket or equivalent, depress
the push pin tabs and remove the cup holder assem-
bly (Fig. 84).
Fig. 80 SEAT BACK HINGE - TYPICAL
1 - SEATBACK FRAME SHOULDER BOLTS
2 - SEAT CUSHION FRAME BOLTS
3 - SEATBACK HINGE
RSSEATS23 - 141
BUCKET SEAT BACK - QUAD BUCKET (Continued)

QUAD BUCKET SEAT SIDE
SHIELD - NO CUP HOLDER
REMOVAL
(1) Remove the three screws (Fig. 85).
(2) Remove the side shield.
INSTALLATION
(1) Install the side shield hook into the rectangu-
lar hole on the riser.
(2) Install the three screws.
QUAD BUCKET SEAT RISER
REMOVAL
(1) Remove the seat from vehicle. Refer to Owner's
Manual for proper procedures.
(2) Remove seat side shield/cup holder. (Refer to 23
- BODY/SEATS/QUAD BUCKET SEAT SIDE
SHIELD/CUP HOLDER - REMOVAL)
(3) Remove the seat side shield. (Refer to 23 -
BODY/SEATS/QUAD BUCKET SEAT SIDE SHIELD
- NO CUP HOLDER - REMOVAL)
(4) Remove the five bolts, two nuts, strut bushing
and remove the riser from the seat (Fig. 86).
INSTALLATION
(1) Install the riser, the strut bushing into the
hole, the five bolts, two nuts and tighten all fasteners
to 40 N´m (30 ft. lbs.).
(2) Install the seat side shield. (Refer to 23 -
BODY/SEATS/QUAD BUCKET SEAT SIDE SHIELD
- NO CUP HOLDER - INSTALLATION)
(3) Install the seat side shield/cup holder. (Refer to
23 - BODY/SEATS/QUAD BUCKET SEAT SIDE
SHIELD/CUP HOLDER - INSTALLATION)
(4) Install the seat. Refer to Owner's Manual for
proper procedures.
BENCH SEAT BACK PANEL
REMOVAL
(1) On third row seats remove plastic grocery bag
retainer. (Refer to 23 - BODY/SEATS/PLASTIC GRO-
CERY BAG RETAINER - REMOVAL)
(2) Using a fork type prying tool (C4829) on three
pass seats, disengage push-in fasteners holding seat
back cover to seat back frame and remove seat back
cover from seat. (Fig. 87).
(3) Using a fork type prying tool (C4829) on two
pass seats, disengage push-in fasteners holding the
upper corners and lower edge of the seat back panel
to seat back frame and remove seat back cover from
seat by pulling the lower edge out away from the
seat back to disengage the upper two hooks. (Fig. 88).
Fig. 85 SEAT SIDE COVER - QUAD BUCKETS
1 - SIDE SHIELD SCREWS
2 - SIDE SHIELD
Fig. 86 BUCKET SEAT RISER - QUAD BUCKET
1 - SEAT SIDE SHIELD/CUP HOLDER
2 - SEAT RISER
3 - SEAT SIDE SHIELD
4 - RISER BOLTS
RSSEATS23 - 143