2003 CHRYSLER CARAVAN roof rack

(10) Remove antenna mast from antenna base
(Fig. 3).
(11) Using cap nut tool, remove cap nut holding
antenna base to front fender (Fig. 4).(12) Remove antenna base from under front
fender.
INSTALLATION
(1) Install antenna base to underside of front
fender.
(2) Install cap nut holding antenna base to front
fender.
(3) Install antenna mast to antenna base.
(4) Install front wheelhouse splash shield.
(5) Install front wheel.
(6) Lower vehicle.
(7) Push antenna cable through opening in hinge
pillar.
(8) Insert rubber grommet into door hinge pillar.
(9) Install kick panel.
(10) Connect antenna cable connector to extension
cable.
(11) Install glove box to instrument panel.
(12) Connect the battery negative cable.
ANTENNA MODULE - EXPORT
DESCRIPTION
The antenna module is an electromagnetic circuit
component designed to capture and enhance RF
(Radio Frequency) signals in both the AM and FM
broadcast bands. The antenna module is mounted to
the right rear roof rail under the headliner. The mod-
ule is grounded through the mounting bracket and
fastener. The module has a two wire electrical con-
nector that connects to the integral radio antenna,
located on the right rear quarter glass. There is also
an electrical connector for battery voltage and a coax
cable connector.
OPERATION
The antenna module receives both AM and FM
radio signals supplied by the side window integral
radio antenna system and selectively amplifies them.
The amplified signal is then sent through the body
length coax cable to the radio input.
Fig. 3 Antenna Mast
1 - ANTENNA MAST
2 - ADAPTER
3 - CAP NUT
Fig. 4 Antenna Cap Nut
1 - CAP NUT
2 - ANTENNA ADAPTER
3 - TOOL
8A - 6 AUDIORS
ANTENNA BODY AND CABLE (Continued)
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MESSAGE SYSTEMS
TABLE OF CONTENTS
page page
OVERHEAD CONSOLE
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING - OVERHEAD
CONSOLE............................2
STANDARD PROCEDURE
STANDARD PROCEDURE - READING/
COURTESY LAMP REPLACEMENT.........3
STANDARD PROCEDURE - MODULE LAMP
REPLACEMENT.......................3
STANDARD PROCEDURE - COMPASS
CALIBRATION.........................3
STANDARD PROCEDURE - COMPASS
DEMAGNETIZING......................4
STANDARD PROCEDURE - COMPASS
VARIATION ADJUSTMENT................5
REMOVAL - OVERHEAD CONSOLE..........6
INSTALLATION..........................6
SPECIAL TOOLS
OVERHEAD CONSOLE..................6
ELECTRONIC VEHICLE INFO CENTER
DESCRIPTION..........................6
OPERATION............................7
DIAGNOSIS AND TESTING - ELECTRONIC
VEHICLE INFORMATION CENTER.........7
STANDARD PROCEDURE - ELECTRONIC
VEHICLE INFORMATION CENTER
PROGRAMMING.......................7
REMOVAL.............................9INSTALLATION..........................9
COMPASS/MINI-TRIP COMPUTER
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - COMPASS
MINI-TRIP COMPUTER.................10
REMOVAL.............................10
INSTALLATION.........................10
UNIVERSAL TRANSMITTER
DESCRIPTION.........................10
OPERATION...........................10
DIAGNOSIS AND TESTING - UNIVERSAL
TRANSMITTER.......................10
STANDARD PROCEDURE
STANDARD PROCEDURE - SETTING
TRANSMITTER CODES.................11
STANDARD PROCEDURE - ERASING
TRANSMITTER CODES.................11
REMOVAL.............................11
AMBIENT TEMP SENSOR
DESCRIPTION.........................11
OPERATION...........................11
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR...............12
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR CIRCUIT........12
REMOVAL.............................12
INSTALLATION.........................12
OVERHEAD CONSOLE
DESCRIPTION
Three overhead consoles are available on RS/RG
models. These are the Electronic Vehicle Information
Center (EVIC), Compass Mini-Trip Computer
(CMTC) or a Compass Temperature Computer (CT).
All consoles are equipped with two reading/courtesy
lamps and if the vehicle is equipped with a power
liftgate or power sliding door(s) the overhead console
will also include command switches for these fea-
tures. The overhead console is mounted with one
screw and two snap clips to a molded plastic retainer
bracket located above the headliner.
DESCRIPTION - COMPASS
All the available overhead consoles on this model
include Compass information. While in the compass/temperature mode, the compass will display the
direction in which the vehicle is pointed using the
eight major compass headings (Examples: north is N,
northeast is NE). The self-calibrating compass unit
requires no adjusting in normal use. The only cali-
bration that may prove necessary is to drive the vehi-
cle in three complete circles at 5 to 8 kilometers-per-
hour (3 to 5 miles-per-hour), on level ground, in not
less than forty-eight seconds. This will reorient the
compass unit to its vehicle.
The compass unit also will compensate for magne-
tism the body of the vehicle may acquire during nor-
mal use. However, avoid placing anything magnetic
directly on the roof of the vehicle. Magnetic mounts
for an antenna, a repair order hat, or a funeral pro-
cession flag can exceed the compensating ability of
the compass unit if placed on the roof panel. Mag-
netic bit drivers used on the fasteners that hold the
overhead console assembly to the roof header can
RSMESSAGE SYSTEMS8M-1
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SPECIFICATIONS
TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
All seat belt anchor bolts 39 29 Ð
Armrest shoulder bolt 29 21 Ð
Bench seat riser bolts 48 35 Ð
Bench seat track nuts 48 35 Ð
Quad bucket seat track to cushion frame bolts 40 30 Ð
Bucket seat back pivot bolts 33 24 Ð
Center seat to seat track bolts 24 17 Ð
Child seat module screws (bench seats) 7 Ð 62
Child seat module screws (quad seats) 13.5 10 Ð
Crossmember to radiator closure panel bolts 28 21 Ð
Door check strap to door end frame 12 Ð 105
Door latch to door end frame bolts 10 Ð 89
Floor latch to seat cushion frame bolts 27 19 Ð
Front cover to seat track screws 4 Ð 32
Front door hinge to hinge pillar bolts 34 25 Ð
Front door hinge to door nuts and bolts 34 25 Ð
Front door latch striker bolts 28 21 Ð
Front/quad seat cushion bolts 28.5 21 Ð
Front seat belt retractor bolts 38 28 Ð
Front seat riser to floor nuts 60 44 Ð
Front seat track cover screws 4 Ð 35
Front seat riser to seat track nuts 81 60 Ð
Front seatback pivot bolts 54 40 Ð
Front seatback recliner nut 12 Ð 105
Front seatback assist strap screws 2.5 Ð 22
Grocery bag holder screws 2 Ð 17
Hinge to liftgate bolts 33 24 Ð
Hood latch to bolts 13.5 10 Ð
Hood latch striker bolts 13.5 10 Ð
Hood hinge to hood bolts 13.5 10 Ð
Liftgate exterior handle outer screws 20 15 Ð
Liftgate exterior handle inner bolts 40 30 Ð
Lifgate hinge to roof header bolts 33 24 Ð
Liftgate latch bolts 16 12 Ð
Liftgate latch striker bolts 28 21 Ð
Liftgate lift motor link to liftgate 28 21 Ð
Liftgate spoiler bolts 9 Ð 80
Lifgate stabilizer wedge striker to D-pillar bolts 3 Ð 30
RSBODY23-11
BODY (Continued)
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DESCRIPTION N´m Ft. Lbs. In. Lbs.
Luggage rack crossbar fasteners 4 Ð 35
Lumbar support handle screw 1 Ð 9
Pivot bolt to the body half of hood hinge 28 21 Ð
Prop assembly to lifgate bolts 28 21 Ð
Rear door glass to regulator bolt 11 8 Ð
Rear door hinge to B-pillar bolt 28 20 Ð
Rear door hinge to door bolt 28 20 Ð
Rear door latch striker 28 20 Ð
Rear latch to sliding door end frame 28 20 Ð
Rear seat back to seat cushion bolt 27 19 Ð
Recliner to seat back frame 12 9 Ð
Seatback frame upper rail 8 Ð 71
Seatback hinge bolt 48 35 Ð
Seatback hinge cover screws 2.3 Ð 20
Shoulder belt turning loop onto height adjuster 39 29 Ð
Side view mirror bolts 10 Ð 85
Sliding door center hinge adjusting bolt 15 Ð 130
Sliding door glass nuts 3.4 Ð 30
Sliding door latch striker 28 21 Ð
Sliding door to roller arm bracket 12 9 Ð
Storage bin track guide to seat riser 3.5 Ð 31
Sunroof opening panel to lifter arm screws 5 44
Sunroof opening panel motor screws 4 35
Sunroof trough bracket to roof bolts 6 53
Sunroof trough to trough bracket bolts 6 53
Sunroof trough bracket bolts 6 53
Support cylinders to liftgate 28 21 Ð
BODY LUBRICATION
LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be
inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protection
against rust and wear. When performing other under
hood services, the hood latch release mechanism and
safety catch should be inspected, cleaned, and lubri-
cated. During the winter season, external door lock
cylinders should be lubricated to assure proper oper-
ation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating a com-
ponent, any excess oil or grease should be removed.
LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
(1) Apply a small amount of lubricant directly into
the lock cylinder.
(2) Apply a small amount of lubricant to the key.
(3) Insert key into lock cylinder and cycle the
mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the
cylinder.
(5) Wipe all lubricant from exterior of lock cylinder
and key.
ALL OTHER BODY MECHANISMS
(1) Clean component as described above.
23 - 12 BODYRS
BODY (Continued)
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OUTSIDE HANDLE
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel as necessary to access
outside release handle fasteners.
(4) Disengage clip attaching outside door handle
linkage to door cable.
(5) Remove linkage from outside door handle.
(6) Remove three nuts attaching outside door han-
dle to outer door panel (Fig. 22).
(7) Remove outside door handle from vehicle.
INSTALLATION
(1) Position outside door handle on vehicle.
(2) Install nuts attaching outside door handle to
outer door panel.
(3) Engage clip attaching linkage to outside door
handle.
(4) Engage rigging cam to latch/lock control mech-
anism.
(5) Move clip on latch/lock control to bottom of slot
and engage linkage to latch/lock control.
(6) Verify sliding door operation. Adjust as neces-
sary.(7) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(8) Install sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(9) Install sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
UPPER HINGE
REMOVAL
(1) Open sliding door, do not latch open.
(2) Remove screw attaching upper stop bracket to
upper roller bracket (Fig. 23).
(3) Remove stop bracket from vehicle.
(4) Place a padded block between the open sliding
door and the roof rail.
(5) Mark outline of upper hinge bracket on sliding
door.
(6) Remove bolts attaching upper roller to sliding
door (Fig. 24).
(7) Remove upper hinge from door.
(8) Slide roller out of rear end of roof upper chan-
nel.
(9) Remove upper hinge from vehicle.
INSTALLATION
(1) Place upper hinge in position on vehicle (Fig.
24).
(2) Slide roller into rear end of roof upper channel.
(3) Place upper hinge in position on door.
(4) Align outline marks on sliding door to upper
roller bracket
Fig. 22 SLIDING DOOR OUTSIDE LATCH RELEASE
HANDLE
1 - OUTSIDE DOOR PANEL
2 - LOCK LINK
3 - LATCH LINK
4 - LOCKING LINK AND SLEEVE LINK
5 - BELLCRANK
6 - KEY CYLINDER LOCK LINK (IF EQUIPPED)
7 - KEY CYLINDER (IF EQUIPPED)
Fig. 23 SLIDING DOOR UPPER STOP
1 - UPPER STOP PLATE
2 - SLIDING DOOR
3 - UPPER SLIDING DOOR HINGE
RSDOORS - SLIDING23-35
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(5) Install bolts attaching upper hinge to sliding
door.
(6) Remove padded block from between sliding
door and roof rail.
(7) Place stop bracket in position on vehicle.
(8) Install screw attaching upper stop bracket to
upper roller bracket (Fig. 23).
(9) Verify sliding door alignment and operation.
Adjust as necessary. (Refer to 23 - BODY/DOORS -
SLIDING/SLIDING DOOR - ADJUSTMENTS)
OUTSIDE HANDLE CABLE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - REMOVAL).
(3) Remove the appropriate side door trim panel.
(Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - REMOVAL)
(4) Peel watershield away from adhesive around
perimeter of inner door panel.
CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
(5) Trace the outside handle cable along its routing
path and disconnect from its retaining clips.(6) Disconnect the outside handle cable from the
latch assembly. Gently pry cable sleeve retainer out
of the latch mounting bracket and then unhook
swedged cable end from the latch link.
(7) Disconnect the outside handle cable from the
handle assembly. Gently pry cable sleeve retainer out
of the handle bracket and then unhook swedged
cable end from the handle link.
(8) Remove the outside handle cable from the side
door.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Match the replacement cable up against the old
cable to verify the correct part.
(2) Position the outside handle cable on the side
door.
(3) Connect the outside handle cable on the handle
assembly. Hook the swedged cable end on the handle
link and gently push the cable sleeve retainer in the
handle bracket.
NOTE: The outside handle cable is marked with red
tape. It must be attached to the latch at the lowest
point. This is marked with a ªRº on the latch.
(4) Connect the outside handle 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.
(5) 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.
(6) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(7) Install the appropriate side door trim panel on
the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - INSTALLATION)
(8) Install stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - INSTALLA-
TION).
(9) Connect the negative battery cable.
Fig. 24 SLIDING DOOR UPPER HINGE
1 - SLIDING DOOR UPPER HINGE
2 - SLIDING DOOR
23 - 36 DOORS - SLIDINGRS
UPPER HINGE (Continued)
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EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL.............................44
INSTALLATION.........................45
COWL GRILLE
REMOVAL.............................49
INSTALLATION.........................50
EXTERIOR NAME PLATES - TAPE ATTACHED
REMOVAL.............................50
INSTALLATION.........................50
EXTERIOR NAME PLATES - ADHESIVE
ATTACHED
REMOVAL.............................50
INSTALLATION.........................50
FRONT FENDER
REMOVAL.............................51
INSTALLATION.........................51
FUEL FILL DOOR
REMOVAL.............................51
INSTALLATION.........................51
FUEL FILL DOOR BLOCKER LATCH
REMOVAL.............................52
INSTALLATION.........................52
FUEL FILL DOOR BLOCKER LATCH STRIKER
REMOVAL.............................52
INSTALLATION.........................52
FUEL FILL DOOR BLOCKER LOCKOUT LINK
REMOVAL.............................52INSTALLATION.........................53
GRILLE OPENING REINFORCEMENT
REMOVAL.............................53
INSTALLATION.........................53
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL.............................54
INSTALLATION.........................54
LUGGAGE RACK RISER
REMOVAL.............................54
INSTALLATION.........................55
LUGGAGE RACK CROSSBAR
REMOVAL.............................55
INSTALLATION.........................56
REAR QUARTER PANEL/FENDER AIR
EXHAUSTER
DESCRIPTION.........................56
REMOVAL.............................56
INSTALLATION.........................57
ROOF JOINT MOLDING
REMOVAL.............................57
INSTALLATION.........................57
SIDE VIEW MIRROR
REMOVAL.............................57
INSTALLATION.........................57
SIDE VIEW MIRROR GLASS
REMOVAL.............................58
INSTALLATION.........................58
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.
23 - 44 EXTERIORRS
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(13) Install liftgate opening header trim.
(14) Install D-pillar trim covers.
(15) Install C-pillar upper trim covers.
(16) Install B-pillar upper trim covers.
(17) Install A-pillar trim covers.
LEFT D-PILLAR TRIM PANEL
REMOVAL
(1) Remove rear header trim cover.
(2) Remove liftgate sill plate.
(3) Remove second row seat belt turning loop on
long wheel base vehicle.
(4) Remove bolt attaching second row seat belt
lower anchor to quarter on short wheel base vehicle.
(5) Disengage hidden clips attaching trim to D-pil-
lar.
(6) Disconnect speaker wire connector, if equipped.
(7) Pass seat belt through slot in D-pillar trim
panel on short wheel base vehicle.
(8) Remove D-pillar trim from vehicle.
INSTALLATION
(1) Pass seat belt through slot in D-pillar trim
panel on short wheel base vehicle.
(2) Position D-pillar trim panel on vehicle.
(3) Connect speaker wire connector to speaker, if
equipped.
(4) Align locating pins on backside of trim panel to
mating holes in inner quarter panel.
(5) Engage hidden clips attaching trim to D-pillar.(6) Install bolt attaching second row seat belt
lower anchor to quarter on short wheel base vehicle.
Tighten all seat belt bolts to 39 N´m (29 ft. lbs.).
(7) Install second row seat belt turning loop on
long wheel base vehicle.
(8) Install liftgate sill plate.
(9) Install rear header trim cover.
LIFTGATE SILL PLATE
REMOVAL
(1) Disengage hidden clips holding sill plate to lift-
gate door opening sill (Fig. 9).
(2) Remove sill plate from vehicle.
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.
Fig. 8 HEADLINING
1 - ROOF
2 - OVERHEAD CONSOLE BRACKET
3 - HEADLINING ASSEMBLY
Fig. 9 LIFTGATE SILL PLATE
1 - LIFTGATE SILL PLATE
2 - LIFTGATE SILL
RSINTERIOR23-77
HEADLINER (Continued)
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