2003 CHRYSLER CARAVAN instrument panel

(10) Remove the 3 bolts mounting the wiring junc-
tion block to the instrument panel.
NOTE: When removing the lower mounting bolt,
push the park brake pedal down 5 clicks to access
the lower mounting bolt.
(11) Remove the lower bolt mounting the park
brake pedal to the body (Fig. 103).
(12) Remove the forward nut mounting the park
brake pedal to the body (Fig. 103).
(13) Remove the upper bolt mounting the park
brake pedal to the body (Fig. 103).
(14) Pull downward on front park brake cable
while rotating park brake pedal mechanism out from
behind junction block.
(15) Remove park brake pedal release link from
park brake mechanism.
(16) Remove the warning lamp ground switch con-
nector from the park brake pedal mechanism (Fig.
103).
(17) Remove front park brake cable button from
park brake pedal mechanism. Tap end housing for
front park brake cable out of park brake pedal mech-
anism.
INSTALLATION
(1) Install park brake cable end housing into park
brake pedal mechanism.
(2) Install cable retainer onto the park brake cable
strand and then install retainer into pedal bracket.
(3) Install cable strand button into the clevis on
the park brake pedal mechanism.
(4) Install wiring harness connector on warning
indicator lamp ground switch.(5) Install the park brake release rod on the
release mechanism of the park brake pedal.
(6) Position the park brake pedal mechanism into
its installed position on the body of the vehicle.
(7) Loosely install the top bolt mounting the park
brake pedal mechanism to the body (Fig. 103).
(8) Loosely install the forward nut mounting the
park brake pedal mechanism to the body (Fig. 103).
(9) Loosely install the lower bolt mounting the
park brake pedal mechanism to the body (Fig. 103).
(10) Tighten pedal mechanism attaching bolts and
nut to 28 N´m (250 in. lbs.).
(11) Verify that the park brake pedal is in the fully
released (full up) position.
(12) Raise vehicle.
(13) Install the front park brake cable on the park
brake cable equalizer (Fig. 102).
NOTE: If the original lever assembly is being used,
the lever mechanism auto adjuster spring tension
will need to be reset. (Refer to 5 - BRAKES/PARK-
ING BRAKE - STANDARD PROCEDURE)
(14) Lower vehicle.
(15) Remove the lock-out pin (if a new lever has
been installed) from the automatic cable adjuster on
the park brake pedal mechanism.
(16) Install the electrical junction block on the
instrument panel.
(17) Install the reinforcement on the lower instru-
ment panel.
(18) Install the steering column lower cover on the
lower instrument panel.
(19) Install the silencer panel under the instru-
ment panel.
(20) Install the left side kick panel.
(21) Install the sill scuff plate on the lower sill of
the left door.
(22) Install the negative (ground) cable on the bat-
tery.
(23) Cycle the park brake pedal one time. This will
seat the park brake cables and will allow the auto-
matic self adjuster to properly tension the park brake
cables.
LEVER - PARKING BRAKE
(EXPORT)
REMOVAL - PARKING BRAKE LEVER AND
FRONT CABLE
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding
Fig. 103 PARKING BRAKE LEVER MOUNTING
1 - WIRE HARNESS CONNECTOR
2 - LEVER MECHANISM
3 - FRONT CABLE
RSBRAKES - BASE5-65
LEVER - PARKING BRAKE (Continued)
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INSTALLATION
(1) Carefully route master cylinder plumbing into
engine compartment as removed and position master
cylinder to dash panel hole.
(2) Rotate master cylinder 45É clockwise, insert
into dash panel hole, engaging clutch pedal bracket.
Rotate master cylinder 45É counter-clockwise, secur-
ing it to pedal bracket (Fig. 13).
(3) Install and secure grommet to dash panel.
(4) Connect pushrod to clutch pedal pin. Install
retainer clip (Fig. 13).
(5) Secure master cylinder plumbing to retainers
in engine compartment.
(6) Connect clutch master cylinder plumbing to
slave cylinder ªquick connectº fitting. An audible
ªclickº should be heard. Verify connection by pulling
outward.
(7) Connect A/C suction/discharge line to evapora-
tor junction block.
(8)Diesel models:Install wiper module assembly.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION)
(9) Install battery and tray.
(10) Connect battery negative cable
(11) Charge Air Conditioning system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE)
MASTER CYLINDER - LHD
REMOVAL
(1) Disconnect battery cables.
(2) Remove instrument panel lower silencer (Fig.
14).
(3) Remove knee bolster (Fig. 15).
(4) Remove clutch master cylinder pushrod
retainer clip (Fig. 16).
(5) Disconnect pushrod from clutch pedal (Fig. 16).
(6) Remove battery shield.
(7) Remove battery.
(8) Remove battery tray.
(9) Remove windshield wiper module assembly
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - REMOVAL).
Fig. 13 Clutch Master Cylinder at Pedal Bracket
1 - CLUTCH MASTER CYLINDER
2 - RETAINER CLIP
3 - CLUTCH PEDAL PIN
4 - PUSH RODFig. 14 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 15 Knee Bolster
1 - KNEE BOLSTER
RSCLUTCH6-9
MASTER CYLINDER - RHD (Continued)
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(10) Using Tool 6638A, disconnect clutch master
cylinder ªquick connectº fitting (Fig. 17). Disengage
plumbing retainer from body stud.
(11) Remove master cylinder reservoir-to-strut
tower nuts (Fig. 18). Reposition reservoir off to side.
(12) Remove clutch master cylinder from dash
panel by rotating clockwise 45É and removing from
dash panel (Fig. 18).(13) Remove master cylinder and plumbing from
engine compartment. Use care not to bend or kink
plumbing. Note plumbing routing to aid in installa-
tion.
INSTALLATION
(1) Install master cylinder into position, while
routing plumbing as originally installed.
(2) Insert master cylinder pushrod through dash
panel (Fig. 18) and rotate 45É counter-clockwise to
secure.
(3) Connect master cylinder plumbing quick-con-
nect fitting. An audible ªclickº should be heard. Ver-
ify connection by pulling outward.
(4) Install master cylinder reservoir onto strut
tower. Install and tighten two (2) master cylinder
reservoir-to-strut tower nuts to 11 N´m (100 in. lbs.)
(Fig. 18).
(5) Install windshield wiper module assembly
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION).
(6) Install battery tray.
(7) Install battery.
(8) Install battery shield.
(9) Connect master cylinder pushrod to clutch
pedal lever (Fig. 16). Install retainer clip.
(10) Install knee bolster and instrument panel
lower silencer (Fig. 15) (Fig. 14).
(11) Connect battery cables.
Fig. 16 Master Cylinder Pushrod at Pedal
1 - MASTER CYLINDER PUSHROD
2 - CLUTCH/BRAKE PEDAL ASSEMBLY
3 - PUSHROD RETAINER
Fig. 17 Disconnect Quick-Connect Using Tool 6638A
1 - QUICK CONNECT FITTING
2 - TOOL 6638A
Fig. 18 Clutch Master Cylinder Removal/Installation
1 - CLUTCH MASTER CYLINDER
2 - RESERVOIR
3 - NUT (2)
6 - 10 CLUTCHRS
MASTER CYLINDER - LHD (Continued)
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CLUTCH PEDAL INTERLOCK
SWITCH
REMOVAL
LHD
(1) Disconnect battery negative cable.
(2) Remove instrument panel lower silencer (Fig.
23).
(3) Remove knee bolster (Fig. 24).
(4) Disconnect interlock switch connector (Fig. 25).
(5) Remove interlock switch by depressing four (4)
plastic wing tabs, and sliding switch through mount-
ing bracket (Fig. 25). If difficulty is encountered gain-
ing access to and removing interlock switch,
removing the upstop switch/bracket assembly (Fig.25) allows for over-travel of the pedal, giving more
room for interlock switch access.
(6) Remove interlock switch harness from pedal
bracket at retainer. Remove switch.
RHD
(1) Disconnect battery negative cable.
(2) Remove instrument panel lower silencer (Fig.
23).
(3) Remove knee bolster (Fig. 24).
(4) Remove master cylinder to clutch pedal pin
retainer clip (Fig. 26). Disengage pushrod from clutch
pedal pin.
(5) Disconnect interlock and upstop switch connec-
tors.
(6) Disengage master cylinder grommet from dash
panel.
(7) Remove clutch master cylinder tubing from
retainers in engine compartment.
(8) Remove clutch master cylinder from dash pan-
el/clutch pedal bracket by rotating 45É clockwise and
pulling outward towards engine (Fig. 26).
(9) Remove clutch pedal bracket assembly (Fig.
27).
(10) Remove interlock switch harness from pedal
bracket at retainer. Remove switch (Fig. 28).
Fig. 23 Instrument Panel Lower SilencerÐLHD
Shown
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 24 Knee BolsterÐLHD Shown
1 - KNEE BOLSTER
Fig. 25 Interlock/Upstop Switch Location
1 - INTERLOCK SWITCH
2 - UPSTOP SWITCH
3 - RETAINER - UPSTOP BRACKET
4 - CONNECTORS
RSCLUTCH6-13
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INSTALLATION
LHD
(1) Install interlock switch into pedal bracket hole,
and secure harness with retainer as shown in (Fig.
28). Make sure switch wing tabs are fully expanded.
(2) Connect interlock switch connector.
(3) Install knee bolster (Fig. 24).
(4) Install instrument panel lower silencer (Fig.
23).
(5) Connect battery negative cable.
(6) Verify function of starter interlock switch.
Switch must actuate when pedal is depressed.
RHD
(1) Install interlock switch to pedal bracket assem-
bly as shown in (Fig. 28). Secure connector with
retainer to hole in bracket.
(2) Install clutch pedal bracket assembly into posi-
tion. Install pedal bracket mounting nuts and torque
to 28 N´m (250 in. lbs.).
(3) Connect interlock and upstop switch connec-
tors.
(4) Install clutch master cylinder into position and
rotate 45É counter-clockwise to secure to pedal
bracket (Fig. 26). Secure dash panel grommet and
secure hydraulic pluming into dash panel retainers.
(5) Connect master cylinder pushrod to clutch
pedal pin and secure with retainer clip (Fig. 26).
(6) Install knee bolster (Fig. 24).
Fig. 26 Clutch Master Cylinder at Pedal Bracket
1 - CLUTCH MASTER CYLINDER
2 - RETAINER CLIP
3 - CLUTCH PEDAL PIN
4 - PUSH ROD
Fig. 27 Clutch Pedal/Bracket Assembly
1 - CLUTCH PEDAL/BRACKET ASSY.
2 - NUT (4)
Fig. 28 Clutch Pedal Interlock Switch
1 - CLUTCH INTERLOCK SWITCH
2 - CLUTCH PEDAL/BRACKET ASSY.
6 - 14 CLUTCHRS
CLUTCH PEDAL INTERLOCK SWITCH (Continued)
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(7) Install instrument panel lower silencer (Fig.
23).
(8) Connect battery negative cable.
(9) Verify function of starter interlock switch.
Switch must actuate when pedal is depressed.
CLUTCH PEDAL UPSTOP
SWITCH
REMOVAL
LHD
(1) Disconnect battery negative cable.
(2) Remove instrument panel lower silencer (Fig.
29).(3) Remove knee bolster (Fig. 30).
(4) Remove upstop switch by depressing four (4)
plastic wing tabs, and sliding switch through mount-
ing bracket. If necessary, remove mounting bracket
and remove switch (Fig. 31).
Fig. 29 Instrument Panel Lower SilencerÐLHD
Shown
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 30 Knee BolsterÐLHD Shown
1 - KNEE BOLSTER
Fig. 31 Interlock/Upstop Switch Location
1 - INTERLOCK SWITCH
2 - UPSTOP SWITCH
3 - RETAINER - UPSTOP BRACKET
4 - CONNECTORS
RSCLUTCH6-15
CLUTCH PEDAL INTERLOCK SWITCH (Continued)
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RHD
(1) Disconnect battery negative cable.
(2) Remove instrument panel lower silencer (Fig.
29).
(3) Remove knee bolster (Fig. 30).
(4) Disconnect upstop switch connector (Fig. 32).
(5) Remove upstop switch/bracket-to-clutch pedal
bracket nut. Remove switch (Fig. 32).
INSTALLATION
LHD
(1) Install upstop switch into bracket (Fig. 31).
Ensure switch wing tabs are fully expanded. If
removed, re-install bracket and torque to 13 N´m
(115 in. lbs.).
(2) Connect upstop switch connector.
(3) Install knee bolster (Fig. 30).
(4) Install instrument panel lower silencer (Fig.
29).
(5) Connect battery negative cable.
RHD
(1) Install switch and bracket assembly. Torque
nut to 12 N´m (110 in. lbs.) (Fig. 32).
(2) Connect upstop switch assembly (Fig. 32).
(3) Install knee bolster (Fig. 30).
(4) Install instrument panel lower silencer (Fig.
29).(5) Connect battery negative cable.
Fig. 32 Clutch Pedal Upstop SwitchÐRHD
1 - CONNECTOR
2 - NUT
3 - UPSTOP SWITCH/BRACKET
6 - 16 CLUTCHRS
CLUTCH PEDAL UPSTOP SWITCH (Continued)
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AUDIO
TABLE OF CONTENTS
page page
AUDIO/VIDEO
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING - AUDIO..........2
ANTENNA BODY AND CABLE
DESCRIPTION..........................4
OPERATION............................4
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE..........................4
REMOVAL.............................5
INSTALLATION..........................6
ANTENNA MODULE - EXPORT
DESCRIPTION..........................6
OPERATION............................6
DIAGNOSIS AND TESTING - ANTENNA
MODULE - EXPORT....................7
REMOVAL.............................7
INSTALLATION..........................7
CD CHANGER
DESCRIPTION..........................7
OPERATION............................7
REMOVAL.............................8
INSTALLATION..........................8
DVD PLAYER
DESCRIPTION..........................8
OPERATION............................8
REMOVAL.............................8
INSTALLATION..........................8
INSTRUMENT PANEL ANTENNA CABLE
REMOVAL.............................8
INSTALLATION..........................9QUARTER GLASS INTEGRAL ANTENNA -
EXPORT
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - QUARTER
GLASS INTEGRAL ANTENNA - EXPORT.....9
RADIO
DESCRIPTION.........................10
OPERATION...........................10
DIAGNOSIS AND TESTING - RADIO.........10
REMOVAL.............................11
INSTALLATION.........................11
RADIO NOISE SUPPRESSION COMPONENTS
DESCRIPTION.........................11
OPERATION...........................12
REMOTE SWITCHES
DESCRIPTION.........................12
OPERATION...........................12
DIAGNOSIS AND TESTING - REMOTE
SWITCHES..........................12
REMOVAL.............................13
INSTALLATION.........................14
SPEAKER
DIAGNOSIS AND TESTING - SPEAKER......14
REMOVAL.............................14
INSTALLATION.........................15
VIDEO SCREEN
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................16
INSTALLATION.........................16
AUDIO/VIDEO
DESCRIPTION
An audio system is standard factory-installed
equipment on this model. A rear seat video system is
an available option. Several combinations of radio
receivers are offered on this model. The audio/video
system uses an ignition switched source of battery
current so that the system will only operate when
the ignition switch is in the RUN or ACCESSORY/
ACCESSORY DELAY positions.
The audio system includes the following compo-
nents:
²Antenna
²CD changer (if equipped)
²DVD player (if equipped)²Radio noise suppression components
²Radio receiver
²Speakers
²Video screen (if equipped)
Certain functions and features of the audio/video
system rely upon resources shared with other elec-
tronic modules in the vehicle over the Programmable
Communication Interface (PCI) bus network. The
data bus network allows the sharing of sensor infor-
mation. For diagnosis of these electronic modules or
of the data bus network, the use of a DRB IIItscan
tool and the proper Diagnostic Procedures manual
are recommended.
Refer to the appropriate wiring information in this
service manual for complete standard and premium
audio system circuit diagrams. The wiring informa-
tion includes proper wire and connector repair proce-
RSAUDIO8A-1
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