body CHRYSLER CARAVAN 2005 Service Manual

INSTALLATION
(1) On three pass seats place seat back panel in
position on seat and install the push-in fasteners
(Fig. 87).
(2) On two pass seats engage the two upper hooks
of the panel, place the panel into position and install
the push-in fasteners (Fig. 88).
(3) On third row bench seats install grocery bag
holder. (Refer to 23 - BODY/SEATS/PLASTIC GRO-
CERY BAG RETAINER - INSTALLATION)
SEAT CUSHION COVER - QUAD
BUCKET, 50/50 SPLIT, BENCH
REMOVAL
BENCH SEAT & 50/50 SPLIT
(1) Remove seat from vehicle. Refer to Owner's
Manual for proper procedures.
(2) Remove seat back. (Refer to 23 - BODY/SEATS/
BENCH SEAT BACK - REMOVAL)
(3) Remove seat risers. (Refer to 23 - BODY/
SEATS/BENCH SEAT RISER - 50/50 SPLIT -
REMOVAL) and (Refer to 23 - BODY/SEATS/BENCH
SEAT RISER - FIRST ROW - REMOVAL) and (Refer
to 23 - BODY/SEATS/BENCH SEAT RISER - SEC-
OND ROW - REMOVAL)
(4) Disconnect the cushion cover J-straps.
(5) Remove seat cushion cover from seat cushion.
QUAD BUCKET
(1) Remove seat from vehicle. Refer to Owner's
Manual for proper procedures.
(2) Remove seat back.(Refer to 23 - BODY/SEATS/
BUCKET SEAT BACK - QUAD BUCKET -
REMOVAL)
(3) Remove seat risers. (Refer to 23 - BODY/
SEATS/QUAD BUCKET SEAT RISER - REMOVAL)
(4) Disconnect the cushion cover J-straps.
(5) Remove seat cushion cover from seat cushion.
INSTALLATION
BENCH SEAT & 50/50 SPLIT
(1) Position the seat cushion cover on the cushion.
(2) Engage the J-strap retainers.
(3) Steam wrinkles from seat cushion, if necessary.
(4) Install seat risers. (Refer to 23 - BODY/SEATS/
BENCH SEAT RISER - 50/50 SPLIT - INSTALLA-
TION) and (Refer to 23 - BODY/SEATS/BENCH
SEAT RISER - SECOND ROW - INSTALLATION)
and (Refer to 23 - BODY/SEATS/BENCH SEAT
RISER - THIRD ROW - INSTALLATION)
(5) Install seat back. (Refer to 23 - BODY/SEATS/
BENCH SEAT BACK - INSTALLATION)
(6) Install seat into vehicle.
QUAD BUCKET
(1) Position the seat cushion cover on the cushion.
(2) Engage the J-strap retainers.
(3) Steam wrinkles from seat cushion, if necessary.
(4) Install seat risers. (Refer to 23 - BODY/SEATS/
QUAD BUCKET SEAT RISER - INSTALLATION)
(5) Install seat back. (Refer to 23 - BODY/SEATS/
BUCKET SEAT BACK - QUAD BUCKET - INSTAL-
LATION)
(6) Install seat into vehicle.
Fig. 87 THREE - PASS BENCH SEAT BACK PANEL
1 - SEAT BACK REAR PANEL
2 - FIRST REAR CHILD RESTRAINT SEAT
Fig. 88 TWO - PASSENGER BENCH SEAT BACK
PANEL
1 - SEAT BACK REAR PANEL
2 - SEAT BACK
23 - 144 SEATSRS
BENCH SEAT BACK PANEL (Continued)

BENCH SEAT RISER - 50/50
SPLIT
REMOVAL
(1) Remove the seat from the vehicle. Refer to the
Owners Manual for proper procedures.
(2) Unclip the seat cushion cover J-strap. (Fig. 89).
(3) Remove the six bolts and remove the riser.
INSTALLATION
(1) Place the riser onto the seat install the bolts
and tighten to 48 N´m (35 ft. lbs.) torque.
(2) Clip seat cushion cover J-strap onto the riser.
(3) Install the seat into the vehicle. Refer to the
Owner's Manual for proper procedure.
BENCH SEAT RISER - SECOND
ROW
REMOVAL
(1) Remove seat from vehicle. Refer to Owner's
Manual for proper procedures.
(2) Place seat bottom side up on a clean covered
work surface.
(3) Remove bolts attaching seat riser to seat cush-
ion frame (Fig. 90).
(4) Remove riser from seat.
INSTALLATION
(1) Place riser in position on seat.
(2) Install bolts attaching seat riser to seat cush-
ion frame (Fig. 90). Tighten bolts to 48 N´m (35 ft.
lbs.) torque.
(3) Install seat into vehicle.
BENCH SEAT RISER - THIRD
ROW
REMOVAL
(1) Remove seat track. (Refer to 23 - BODY/
SEATS/BENCH SEAT TRACK - REMOVAL)
(2) Remove bolts attaching riser to seat cushion
frame and remove the riser. (Fig. 95).
INSTALLATION
(1) Place riser in position on seat.
(2) Install bolts attaching riser to seat cushion
frame (Fig. 95). Tighten bolts to 48 N´m (35 ft. lbs.)
torque.
(3) Install seat track. (Refer to 23 - BODY/SEATS/
BENCH SEAT TRACK - INSTALLATION)
Fig. 89 BENCH SEAT RISER - 50/50 SPLIT
1 - SEAT CUSHION COVER CLIP
2 - SEAT RISER BOLTS
3 - SEAT RISER
Fig. 90 BENCH SEAT RISER - SECOND ROW
1 - RISER
2 - FIRST ROW BENCH SEAT
3 - RISER BOLTS
RSSEATS23 - 145

SEAT BACK HINGE COVERS -
QUAD BUCKET, 50/50 SPLIT,
BENCH
REMOVAL
(1) Remove seat from vehicle. Refer to Owner's
Manual for proper procedures.
(2) Remove screws attaching upper hinge cover to
seat back hinge (Fig. 91).
(3) Remove upper cover from seat back hinge.
(4) Remove screws attaching lower cover to seat
back hinge.
(5) Remove lower cover from hinge.
INSTALLATION
(1) Place lower cover in position on hinge.
(2) Install screws attaching lower cover to seat
back hinge (Fig. 91). Tighten screws to 2.3 N´m (20
in. lbs.) torque.
(3) Place upper cover in position on seat back
hinge.
(4) Install screws attaching upper hinge cover to
seat back hinge. Tighten screws to 2.3 N´m (20 in.
lbs.) torque.
(5) Install seat in vehicle.
BENCH SEAT BACK HINGE
REMOVAL
NOTE: Bench seats equipped with child restraint
seats have an interlock feature that will not allowthe seat back to fold forward with the child seat
open.
(1) Remove the bench seat back upper and lower
hinge covers. (Refer to 23 - BODY/SEATS/SEAT
BACK HINGE COVERS - 50/50 SPLIT, BENCH -
REMOVAL)
(2) Remove the seat back. (Refer to 23 - BODY/
SEATS/BENCH SEAT BACK - REMOVAL)
(3) Remove bolts attaching seat back hinge to seat
cushion frame (Fig. 92).
(4) Remove seat back hinge from seat.
INSTALLATION
INSTALLATION
NOTE: Bench 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) Place hinge in position on seat.
(2) Engage synchronizing cable end into (clip on
left side) hinge latch release arm.
(3) Engage synchronizing cable housing into seat
back hinge.
(4) Place seat back hinge in position on seat.
(5) Install bolts attaching seat back hinge to seat
cushion frame. Tighten bolts to 48 N´m (35 ft. lbs.)
torque.
(6) Install shoulder bolts attaching seat back hinge
to seat back frame (Fig. 92). Tighten bolts to 34 N´m
(25 ft. lbs.) torque.(Refer to 23 - BODY/SEATS/
BENCH SEAT BACK - INSTALLATION)
Fig. 91 BENCH SEAT BACK HINGE COVERS -
TYPICAL
1 - UPPER COVER SCREWS
2 - LOWER COVER
3 - LOWER COVER SCREWS
4 - UPPER COVER
Fig. 92 BENCH SEAT BACK HINGE
1 - SEATBACK FRAME SHOULDER BOLTS
2 - SEAT CUSHION FRAME BOLTS
3 - SEATBACK HINGE
23 - 146 SEATSRS

(7) Install bench seat back hinge covers. (Refer to
23 - BODY/SEATS/SEAT BACK HINGE COVERS -
50/50 SPLIT, BENCH - INSTALLATION)
(8) Verify seat back hinge operation and adjust
synchronizing cable, if equipped. (Refer to 23 -
BODY/SEATS/SYNCHRONIZING CABLE ADJUST-
MENT)
SYNCHRONIZING CABLE ADJUSTMENT
NOTE:
Bench 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.
If the seat back hinges do not release at the same
time the synchronizing cable must be adjusted.
(1) Remove seat from vehicle. Refer to Owner's
Manual for proper procedures.
(2) Disengage cable from the recline mechanism by
pulling the cable end toward the front of the seat
(Fig. 93).
(3) Pull U-shaped locking tab on self-adjusting
mehcanism to disengage auto-adjust feature.
(4) Reattach self-adjusting mechanism, pulling
against spring load to tighten cable.
(5) Press locking tab onto the adjusting mecha-
nism to lock into place.
BENCH SEAT BACK
REMOVAL
NOTE: Bench 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 upper hinge cover. (Refer to 23 -
BODY/SEATS/SEAT BACK HINGE COVERS -
REMOVAL)
(4) Disengage synchronizing cable housing from
seat back hinge, if equipped.
(5) Disengage synchronizing cable end from (clip
on left side) hinge latch release arm, if equipped.
(6) Remove shoulder bolts attaching seat back
hinge to seat back frame (Fig. 94).
(7) Remove the seat back.
INSTALLATION
NOTE: Bench 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.
Fig. 93 SYNCHRONIZING CABLE
1 - CABLE END
2 - LOCKING TAB
3 - SETBACK HINGE
Fig. 94 SEAT BACK HINGE - TYPICAL
1 - SEATBACK FRAME SHOULDER BOLTS
2 - SEAT CUSHION FRAME BOLTS
3 - SEATBACK HINGE
RSSEATS23 - 147
BENCH SEAT BACK HINGE (Continued)

(1) Install the seat back.
(2) Install the shoulder bolts attaching the seat
back hinge to the seat back frame and tighten to 34
N´m (25 ft. lbs.) torque.
(3) Connect the synchronizing cable end from (clip
on left side) hinge latch release arm, if equipped.
(4) Connect the synchronizing cable housing to the
seat back hinge, if equipped.
(5) Install the upper hinge cover. (Refer to 23 -
BODY/SEATS/SEAT BACK HINGE - INSTALLA-
TION)
(6) Install the armrests, if equipped. (Refer to 23 -
BODY/SEATS/ARMREST - INSTALLATION)
(7) Install the headrest sleeves. (Refer to 23 -
BODY/SEATS/HEADREST SLEEVE - INSTALLA-
TION)
(8) Adjust synchronizing cable, if equipped. (Refer
to 23 - BODY/SEATS/SYNCHRONIZING CABLE
ADJUSTMENT)
BENCH SEAT BACK COVER
REMOVAL
(1) Remove the bench seat back. (Refer to 23 -
BODY/SEATS/BENCH SEAT BACK - REMOVAL)
(2) Remove the bench seat back panel. (Refer to 23
- BODY/SEATS/BENCH SEAT BACK PANEL -
REMOVAL)
(3) Disconnect the cover J-straps.
(4) Remove the seat back cover from the seat back
assembly.
INSTALLATION
(1) Install seat back cover onto the seat back
frame and cushion assembly.
(2) Connect the J-straps.
(3) Install the bench seat back panel. (Refer to 23 -
BODY/SEATS/BENCH SEAT BACK PANEL -
INSTALLATION)
(4) Install the seat back. (Refer to 23 - BODY/
SEATS/BENCH SEAT BACK - INSTALLATION)
BENCH SEAT TRACK
REMOVAL
(1) Remove second row seat from vehicle. Refer to
Owner's Manual for proper procedure.
(2) Place seat on clean covered work surface.
(3) Disengage seat track adjuster link wire from
track being removed.
(4) Remove nuts attaching track to seat riser (Fig.
95).
(5) Remove track from seat riser.
INSTALLATION
(1) Place track in position on seat riser.
(2) Install nuts attaching track to seat riser. (Fig.
95). Tighten nuts to 48 N´m (35 ft. lbs.) torque.
(3) Engage seat track adjuster link wire onto track
being installed.
(4) Install second row seat into vehicle.
Fig. 95 BENCH SEAT TRACK
1 - SEAT TRACK ADJUSTER LINK
2 - RISER
3 - SEAT TRACK NUTS
4 - SEAT TRACK
5 - RISER BOLTS
23 - 148 SEATSRS
BENCH SEAT BACK (Continued)

UNDER SEAT STORAGE BIN
GUIDE
REMOVAL
(1) Remove under seat storage bin. (Refer to 23 -
BODY/SEATS/UNDER SEAT STORAGE BIN -
REMOVAL)
(2) Remove screws attaching storage bin track
guide to seat riser (Fig. 99).
(3) Remove track guide from vehicle.
INSTALLATION
(1) Place track guide in position on seat riser.
(2) Install screws attaching storage bin track guide
to seat riser (Fig. 99). Tighten screws to 3.6 N´m
(31.8 in lbs.) torque.
(3) Install under seat storage bin. (Refer to 23 -
BODY/SEATS/UNDER SEAT STORAGE BIN -
INSTALLATION)
UNDER SEAT STORAGE BIN
LOCK/LATCH
REMOVAL
(1) Open under seat storage bin.
(2) Remove screws holding under seat storage bin
lock/latch to storage bin (Fig. 100).
(3) Remove lock/latch from bin.
INSTALLATION
(1) Place lock/latch in position on storage bin.
(2) Install screws to hold lock/latch to storage bin
(Fig. 100).
(3) Verify under seat storage bin latch operation.
LUMBAR SUPPORT
REMOVAL
(1) Remove screw attaching lumbar handle to seat
back (Fig. 101).
(2) Remove seat back assembly from cushion.
(3) Detrim the seat back assembly.
(4) Remove frame and replace.
INSTALLATION
(1) Trim the seat back frame.
(2) Install seat back assembly to cushion.
(3) Install attaching screw to lumbar handle. The
handle is to be installed, between two and three
O'clock position. Tighten screw to 1 N´m (11 ft. lbs.)
torque.
(4) Test lumbar operation.
Fig. 99 UNDER SEAT STORAGE BIN GUIDE
1 - STORAGE BIN TRACK GUIDE
2 - RISER
Fig. 100 UNDER SEAT STORAGE BIN LOCK/LATCH
1 - UNDER SEAT STORAGE BIN
2 - LOCK/LATCH
Fig. 101 LUMBAR HANDLE
1 - LUMBAR HANDLE
23 - 150 SEATSRS

SEAT RISER LATCH LOCKING
LINK
REMOVAL
(1) Remove seat as necessary to access latch lock-
ing link.
NOTE: If the seat is locked in the seated position
and cannot be tilted forward, it can be released by
reaching into the escutcheons with a hook tool or a
finger from the rear. Pulling the latch toward the
rear of the vehicle will unlock the seat latch allow-
ing the seat to tilt forward.
(2) Using a flat bladed tool pry plastic latch lock-
ing link free from both pins (Fig. 102).
(3) Remove link from seat.
INSTALLATION
(1) Place latch locking link into position (Fig. 102).
(2) Press latch locking link onto pins lock and seat
fully.
(3) Place seat into position and verify proper oper-
ation.
QUAD BUCKET SEAT SIDE
SHIELD/CUP HOLDER - FLAP
AND SPRING ASSEMBLY
REMOVAL
(1) Inspect the flap retaining tabs on cup holder
for damage (Fig. 103).(2) If cracked or broken, replace quad bucket seat
side shield with cup holder. (Refer to 23 - BODY/
SEATS/SEAT SIDE SHIELD - REMOVAL).
(3) If flap retaining tabs are not damaged replace
flap and spring assembly.
INSTALLATION
(1) Ensure the spring is position into mounting tab
(Fig. 104).
(2)
Hold flap and spring assembly in the horizontal
position and snap into cup holder flap retaining tabs.
(3) Verify cup holder flap operation several times
to ensure proper operation. Flap should fold down-
ward with little effort and spring back to a horizontal
position when released.
Fig. 102 SEAT RISER LATCH LOCKING LINK
1 - LATCH LOCKING LINK
2 - FLAT BLADED TOOL
3 - SEAT RISER
Fig. 103 CUP HOLDER FLAP RETAINING TABS
1 - FLAP RETAINING TABS
Fig. 104 FLAP AND SPRING ASSEMBLY
1 - CUP HOLDER FLAP
2 - SPRING IN MOUNTING TAB
RSSEATS23 - 151

INSTALLATION
(1) Place seat back foam into cover.
(2) Install seat cover and foam onto seat back
frame (Fig. 121).
(3) Engage J-straps (Fig. 122).
(4) Install seat back panel. (Refer to 23 - BODY/
SEATS/SEAT BACK - INSTALLATION).
SEAT BACK FRAME - THIRD
ROW - FOLD-IN-FLOOR
REMOVAL
(1) Remove seat back cover and foam. (Refer to 23
- BODY/SEATS/SEAT BACK COVER/FOAM -
REMOVAL).
(2) Remove strap at top of frame (Fig. 123).
(3) Remove two bolts on each side of frame.
(4) Remove seat back frame from seat.
Fig. 120 THIRD ROW SEAT BACK COVER & FOAM
1 - SEAT BACK COVER
2 - FOAM
3 - SEAT BACK FRAME
Fig. 121 THIRD ROW SEAT BACK COVER & FOAM
1 - SEAT BACK COVER
2 - FOAM
3 - SEAT BACK FRAME
Fig. 122 THIRD ROW SEAT BACK
1 - J-STRAPS
Fig. 123 THIRD ROW SEAT BACK COVER & FOAM
1 - SEAT BACK COVER
2 - FOAM
3 - SEAT BACK FRAME
23 - 156 SEATSRS
SEAT BACK COVER/FOAM - THIRD ROW - FOLD-IN-FLOOR (Continued)

INSTALLATION
(1) Place seat back frame into position.
(2) Install two bolts on each side of seat back
frame.
(3) Install strap at top of frame (Fig. 123).
(4) Install seat back cover and foam. (Refer to 23 -
BODY/SEATS/SEAT BACK COVER - INSTALLA-
TION).
SEAT BELT CENTER LAP BELT
- FOLD-IN-FLOOR
REMOVAL
(1) Set third row seat in the upright position.
(2) Remove the third row cushion back cover (Fig.
124).
(3) Fold the third row seat into floor well.
(4) Remove seat cushion pan carpet to floor panel
using a trim tool (Fig. 125).
(5) Using a trim tool, remove seat cushion pan bot-
tom side panel (Fig. 126).
(6) Remove handle from cushion.
(7) Remove seat cushion cover and foam from
cushion pan. (Refer to 23 - BODY/SEATS/SEAT
CUSHION COVER/FOAM - REMOVAL).(8) Remove nut attaching center tip half and
buckle together.
(9) Remove center tip half and buckle from seat
(Fig. 127).
INSTALLATION
(1) Place seat with seat cushion in the upright
position.
(2) Place center tip half and buckle into position.
(3) Install nut attaching center tip and buckle
(Fig. 127).
Fig. 124 THIRD ROW SEAT BACK COVER
1 - ATTACHING SCREW
Fig. 125 SEAT CUSHION CARPETING
1 - CARPET FROM SEAT TO FLOOR
2 - SEAT CUSHION PAN COVER
Fig. 126 THIRD ROW CUSHION PAN COVER
RSSEATS23 - 157
SEAT BACK FRAME - THIRD ROW - FOLD-IN-FLOOR (Continued)

(4) Install seat cushion cover and foam. (Refer to
23 - BODY/SEATS/SEAT CUSHION COVER/FOAM -
INSTALLATION).
(5) Install handle to cushion.
(6) Install seat cushion pan bottom side panel (Fig.
126).
(7) Fold the third row seat into floor well.
(8) Place seat cushion pan carpet to floor panel
into position and push on panel to seat push pin fas-
teners (Fig. 125).
(9) Third row seat in the upright position.
(10) Install the third row cushion back cover (Fig.
124).
SEAT BACK PANEL - THIRD
ROW -FOLD-IN-FLOOR
REMOVAL
(1) Third row seat in the upright position.
(2) Using a trim tool, remove seat back panel (Fig.
128).
INSTALLATION
(1) Place seat back panel into position (Fig. 128).
(2) Push on seat back panel to seat push pin fas-
teners.
SEAT BACKSTOW STRAP -
THIRD ROW - FOLD-IN-FLOOR
REMOVAL
(1) Third row seat in the upright position.
(2) Remove seat back cover and foam as necessary
to access stow strap
(3) Slide stow strap from frame loop (Fig. 129).
INSTALLATION
(1) Slide stow strap onto frame loop (Fig. 129).
(2) Install seat back cover and foam. (Refer to 23 -
BODY/SEATS/SEAT CUSHION COVER/FOAM -
INSTALLATION).
Fig. 127 CENTER TIP AND BUCKLE - THIRD ROW -
FOLD-IN-FLOOR
1 - CENTER TIP HALF AND BUCKLE
2 - SEAT BELT BUCKLE
Fig. 128 SEAT BACK PANEL
1 - TRIM STICK
Fig. 129 THIRD ROW SEAT BACK UP STOW STRAP
1- STOW STRAP
23 - 158 SEATSRS
SEAT BELT CENTER LAP BELT - FOLD-IN-FLOOR (Continued)