2003 CHRYSLER CARAVAN instrument panel

(11) If equipped with a mechanical transmission
range indicator:
(a) Connect the clip for the indicator cable and
guide tube to the shift cable bracket.
(b) Install the cable end to the gear selector.
(c) Install the clip holding the gear shift cable
end to the gear selector adapter.
(d) Install the indicator cable loop.
(12) Tighten the left side roll down bolt.
(13) Install the four nuts attaching the instrument
panel to the brake pedal support bracket.
(14) Install the four nuts retaining the steering
column and lower to the floor (Fig. 5).
(15) Connect the Occupant Restraint Controller
(ORC) harness connector.
(16) Connect the steering column wiring. There
are seven connectors and then clip the harness to the
column.
(17) Install the screws attaching the instrument
panel reinforcement (Fig. 4).
(18) Connect the shrouds and install the two steer-
ing column shroud retaining screws.
(19) Install five screws to the left under column
instrument panel reinforcement brace.
(20) Install the two screws to the hood release
handle.
(21) Connect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.(c) Five harness connectors.
(d) Driver airbag connector.
(22) Clip the Data Link Connector (DLC) to the
steering column backing plate.
(23) Install the eight screws to the steering column
backing plate.
(24) Install the four screws to the lower steering
column cover.
(25) Install the glove box:
(a) Install glove box into the vehicle. Line up the
hinges and firmly snap together.
(b) Push in on sides of glove box bin and raise
door.
(26) Install the both left and right side A-pillar
trim covers. Position trim cover over slots and firmly
snap into place.
(27) Install the two screws to each right and left
cowl trim covers.
(28) Connect the wire connectors to the Passenger
Airbag.
(29) Install the bolts attaching the lower supports
to the floor pan.
(30) Install the bolts attaching the lower supports
to the instrument panel frame (Fig. 3).
(31) Install the lower console:
(a) Install lower console to vehicle.
(b) Connect the auxiliary power outlet.
(c) Install the six retaining screws.
(32) Connect the battery negative cable.
Fig. 6 INSTRUMENT PANEL REMOVAL
1 - INSTRUMENT PANEL
2 - FIVE ATTACHING SCREWS
3 - 13 mm BOLT - TWO ON EACH SIDE4 - ROLL DOWN BRACKET
5 - 10 mm BOLT - STARTING BOLT ONE EACH SIDE
23 - 66 INSTRUMENT PANELRS
INSTRUMENT PANEL ASSEMBLY (Continued)
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INSTRUMENT PANEL CENTER
BEZEL
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Insert the trim stick (special tool #C-4755) or
equivalent between access cover and center bezel
gently pry outward.
(3) Carefully pry the access cover from the instru-
ment panel (Fig. 7).
(4) Remove the two center bezel attaching screws.
(5) Using a trim stick or equivalent, gently pry out
on the edge of the instrument panel center bezel and
pull outward.
(6) Disconnect the wire connectors to the accessory
switches and HVAC control.
(7) Remove the instrument panel center bezel from
the vehicle.
INSTALLATION
(1) Place center bezel near opening and connect
the wire connectors to the accessory switches and
HVAC control.
(2) Position the center bezel over the retaining
slots and firmly snap the instrument panel center
bezel into place (Fig. 7).
(3) Install the two center bezel attaching screws.
(4) Install the screw access cover to the bottom of
the center bezel.
INSTRUMENT PANEL END CAP
REMOVAL
(1) Open passenger side front door.
(2) Using a trim stick, disengage clips holding end
cover to instrument panel (Fig. 8).
INSTALLATION
(1) Position end cover over retaining slots and
firmly snap into place (Fig. 8).
(2) Close passenger side front door.
INSTRUMENT PANEL TOP
COVER
REMOVAL
(1) Remove A-pillar trim. Using a trim stick (spe-
cial tool #C-4755) or equivalent, gently pry out and
remove.
(2) Using a trim stick, disengage clips attaching
rear edge of top cover to instrument panel (Fig. 9).
NOTE: The Instrument Panel Top Cover may be
hard to unsnap from the instrument panel. Be sure
not to mar, scuff, or damage the instrument panel
pad.
(3) Pull top cover rearward to disengage hooks
attaching front of top cover to instrument panel.
(4) Remove top cover from vehicle.
INSTALLATION
(1) Place instrument panel top cover in position on
vehicle (Fig. 9).
Fig. 7 INSTRUMENT PANEL CENTER BEZEL
1 - LOWER INSTRUMENT PANEL
2 - INSTRUMENT PANEL CENTER BEZEL
3 - CUPHOLDER
Fig. 8 INSTRUMENT PANEL END CAP
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL END CAP
RSINSTRUMENT PANEL23-67
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(2) Push top cover forward to engage hooks attach-
ing front of top cover to instrument panel.
(3) Engage clips attaching rear edge of top cover to
instrument panel.
(4) Pull top cover rearward.
(5) Install A-pillar trim.
LOWER CONSOLE
REMOVAL
(1) Remove screws attaching the lower console to
floor bracket and instrument panel (Fig. 10).
(2) Slide lower console rearward from around
instrument panel supports.
(3) Disconnect the auxiliary power outlet wire con-
nector (if equipped).
(4) Remove lower console from vehicle.
INSTALLATION
(1) Connect the auxiliary power outlet wire con-
nector (if equipped).
(2) Install the lower console into the vehicle (Fig.
10).
(3) Slide console forward around instrument panel
supports.
(4) Install the screws attaching lower console to
floor bracket and instrument panel.
LOWER INSTRUMENT PANEL
REMOVAL
When servicing the lower instrument panel, refer
to Body, Instrument Panel, and then the appropriate
removal procedure.
(1) Remove the right end cover.
(2) Remove the lower steering column cover.
(3) Remove the center bezel.
(4) Remove the lower console.
(5) Remove the cup holder and track.
(6) Remove the glove box.
(7) Remove the glove box latch striker.
(8) Remove the glove box lamp.
(9) Remove the eighteen screws holding the lower
instrument panel to the reinforcement frame (Fig.
11).
(10) Remove the lower instrument panel from
vehicle.
INSTALLATION
When servicing the lower instrument panel, refer
to Body, Instrument Panel, and then the appropriate
removal procedure.
(1) Install the lower instrument panel into the
vehicle (Fig. 11).
(2) Install the eighteen screws holding the lower
instrument panel to the reinforcement frame.
(3) Install the glove box lamp.
(4) Install the glove box latch striker.
(5) Install the glove box.
(6) Install the cup holder and track.
(7) Install the lower console.
Fig. 9 INSTRUMENT PANEL TOP COVER
1 - INSTRUMENT PANEL TOP COVER
2 - INSTRUMENT PANEL
Fig. 10 INSTRUMENT PANEL FLOOR CONSOLE
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL FLOOR CONSOLE
23 - 68 INSTRUMENT PANELRS
INSTRUMENT PANEL TOP COVER (Continued)
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(8) Install the center bezel.
(9) Install the lower steering column cover.
(10) Install the right end cover.
LOWER STEERING COLUMN
COVER
REMOVAL
(1) Remove the four screws attaching the lower
steering column cover to instrument panel (Fig. 12).
(2) Remove the lower steering column cover from
the vehicle.
INSTALLATION
(1) Install the lower steering column cover into the
vehicle (Fig. 12).
(2) Install the four screws attaching the lower
steering column cover to instrument panel.
STEERING COLUMN COVER
BACKING PLATE
REMOVAL
(1) Remove lower steering column cover (Refer to
23 - BODY/INSTRUMENT PANEL/STEERING COL-
UMN OPENING COVER - REMOVAL).
(2) Remove the park brake release handle link
from the park brake release handle.
(3) Remove screws attaching lower steering col-
umn backing plate to instrument panel (Fig. 12).
(4) Unclip the Data Link Connector (DLC) from
the lower steering column backing plate.
(5) Remove lower steering column backing plate
from vehicle.
INSTALLATION
(1) Install the steering column cover backing plate
into vehicle (Fig. 12).
(2) Clip the Data Link Connector (DLC) to the
steering column cover backing plate
(3) Install the screws attaching steering column
cover backing plate to instrument panel.
(4) Connect the park brake release handle link to
the park release handle.
(5) Install the lower steering column cover (Refer
to 23 - BODY/INSTRUMENT PANEL/STEERING
COLUMN OPENING COVER - INSTALLATION).
OVER STEERING COLUMN
COVER
REMOVAL
(1) Taking a firm grasp of the over steering col-
umn cover front edge, give a quick upward pulling
motion to disengage the cover from the instrument
panel (Fig. 13).
(2) Remove the over steering column cover from
the vehicle.
INSTALLATION
(1) Place the over steering column cover into posi-
tion over the retaining slots and firmly snap into
place (Fig. 13).
Fig. 11 LOWER INSTRUMENT PANEL
1 - INSTRUMENT PANEL
2 - LOWER INSTRUMENT PANEL
Fig. 12 LOWER STEERING COLUMN COVER
1 - STEERING COLUMN COVER BACKING PLATE
2 - STEERING COLUMN COVER
RSINSTRUMENT PANEL23-69
LOWER INSTRUMENT PANEL (Continued)
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INSTRUMENT PANEL TOP PAD
ASSEMBLY
REMOVAL
(1) Remove the instrument cluster (Fig. 14). (Refer
to 8 - ELECTRICAL/INSTRUMENT CLUSTER -
REMOVAL)
(2) Remove the message center (Fig. 14). (Refer to
8 - ELECTRICAL/MESSAGE CENTER - REMOVAL)
(3) Remove the radio (Fig. 14). (Refer to 8 - ELEC-
TRICAL/AUDIO/RADIO - REMOVAL)
(4) Remove the headlamp switch (Fig. 14). (Refer
to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/HEADLAMP SWITCH - REMOVAL)
(5) Remove the lower console (Fig. 14). (Refer to 23
- BODY/INSTRUMENT PANEL/LOWER CONSOLE
- REMOVAL)
(6) Remove the lower panel. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER INSTRUMENT
PANEL TRIM - REMOVAL)
(7) Remove the instrument panel assembly. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL)
(8) Remove the instrument panel speakers.
(9) Remove the glove box light.
(10) Remove the two passenger air bag mounting
bolts (Fig. 15).
(11) Loosen the three passenger air bag support
bracket bolts to the hydro-form rail (Fig. 15).
(12) Remove the 16 screws along the upper edge of
the pad & panel assembly.
(13) Remove the 19 screws along the lower edge of
the pad & panel assembly.
(14) Remove the pad and panel assembly (Fig. 14).
INSTALLATION
(1) Position the pad & panel assembly onto the
instrument panel support structure.
Fig. 13 OVER STEERING COLUMN COVER
1 - INSTRUMENT PANEL OVER STEERING COLUMN COVER
2 - INSTRUMENT PANEL
Fig. 14 INSTRUMENT PANEL ASSEMBLY
1 - INSTRUMENT CLUSTER
2 - MESSAGE CENTER
3 - TOP COVER
4 - PAD AND PANEL ASSEMBLY
5 - LOWER CONSOLE
6 - LOWER PANEL
7 - RADIO
8 - HEADLAMP SWITCH
Fig. 15 AIRBAG MOUNTING HARDWARE
1 - AIR BAG SCREWS (2)
2 - ELECTRICAL CONNECTOR
3 - AIR BAG SUPPORT BRACKET BOLTS (3)
4 - HYDRO-FORM INSTRUMENT PANEL SUPPORT RAIL
23 - 70 INSTRUMENT PANELRS
OVER STEERING COLUMN COVER (Continued)
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(2) Install the 19 screws along the lower edge of
the pad & panel assembly.
(3) Install the 16 screws along the upper edge of
the pad & panel assembly.
(4) Install and tighten the two passenger air bag
mounting screws.
(5) Tighten the three passenger air bag support
bracket bolts to the hydro-form tube.
(6) Install the glove box light.
(7) Install the instrument panel speakers.
(8) Install the instrument panel assembly. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION)
(9) Install the lower panel. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER INSTRUMENT
PANEL TRIM - INSTALLATION)(10) Install the lower console. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER CONSOLE -
INSTALLATION)
(11) Install the headlamp switch. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP SWITCH - INSTALLATION)
(12) Install the radio. (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - INSTALLATION)
(13) Install the message center. (Refer to 8 -
ELECTRICAL/MESSAGE CENTER - INSTALLA-
TION)
(14) Install the instrument cluster. (Refer to 8 -
ELECTRICAL/INSTRUMENT CLUSTER - INSTAL-
LATION)
RSINSTRUMENT PANEL23-71
INSTRUMENT PANEL TOP PAD ASSEMBLY (Continued)
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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
(1) Slide lower seat belt cover rearward to expose
anchor bolt.
(2) Remove bolt attaching lower seat belt anchor to
floor.
(3) Remove upper B-pillar trim cover.
(4) Remove access panel from B-pillar trim (Fig.
3).
(5) Disengage hidden clips attaching lower trim
cover to B-pillar.
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
RSINTERIOR23-73
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(6) Remove lower B-pillar trim cover from vehicle.
INSTALLATION
(1) Place lower B-pillar trim cover in position on
vehicle (Fig. 3).
(2) Insert seat belt through hole in lower B-pillar
trim.
(3) Engage hidden clips attaching lower trim cover
to B-pillar.
(4) Install access cover.
(5) Install upper B-pillar trim cover.
(6) Place seat belt anchor in position on floor so
webbing is pointed rearward and slightly outboard.
(7) Install bolt attaching lower seat belt anchor to
floor. Tighten all seat belt bolts to 39 N´m (29 ft. lbs.)
torque.
(8) Verify that seat belt anchor does not interfere
with seat track travel.
B-PILLAR UPPER TRIM
REMOVAL
(1) Remove bolt attaching lower seat belt anchor to
floor.
(2) Lower shoulder belt height adjuster to the bot-
tom of travel.
(3) Remove shoulder belt turning loop from height
adjuster.(4) Use a Snap-ontTrim Pad Remover tool
(A179A), or equivalent, and remove shoulder belt
height adjuster knob.
(5) Remove shoulder belt bezel from trim cover
(Fig. 3).
(6) Remove screw attaching trim cover to B-pillar
from inside bezel cavity.
(7) Disengage hidden clips attaching trim cover to
B-pillar.
(8) Remove B-pillar trim cover from vehicle.
INSTALLATION
(1) Insert seat belt through B-pillar trim and web
guide (Fig. 3).
(2) Place B-pillar trim cover in position on vehicle.
(3) Engage hidden clips attaching trim cover to
B-pillar.
(4) Install shoulder belt bezel into trim cover.
(5) Install height adjuster knob.
(6) Install shoulder belt turning loop onto height
adjuster. Tighten bolt to 39 N´m (29 ft. lbs.) torque.
(7) Place seat anchor in position on floor so web-
bing is pointed rearward and slightly outboard.
(8) Install bolt attaching lower seat belt anchor to
floor. Tighten seat belt bolt to 39 N´m (29 ft. lbs.)
torque.
CARPETS AND FLOOR MATS
REMOVAL
(1) Remove front seats. (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL)
(2) Remove front center console.
(3) Remove the remaining seats. Refer to the Own-
er's Manual for the proper procedures.
(4) Remove front cowl panels and sill plates.
(5) Remove sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(6) Remove the cargo organizer, if equipped.
(7) Remove liftgate scuff plate. (Refer to 23 -
BODY/INTERIOR/LIFTGATE SCUFF PLATE -
REMOVAL)
(8) Remove lower B-pillar trim covers.
(9) Remove D-pillar trim covers.
(10) Remove Quarter trim panels.
(11) Remove floor escutcheons (Fig. 4).
(12) Remove the floor console trays. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE TRAY -
REMOVAL)
(13) Remove push pin fasteners attaching carpet to
floor in front seat and rear area.
(14) Roll carpet from under instrument panel to
center of sliding door.
Fig. 3 LOWER B-PILLAR TRIM COVER
1 - B-PILLAR UPPER TRIM
2 - B-PILLAR UPPER PLUG
3 - POWER SLIDING DOOR SWITCH AND BEZEL
4 - BELT ASSEMBLY
5 - B-PILLAR LOWER TRIM
23 - 74 INTERIORRS
B-PILLAR LOWER TRIM (Continued)
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