2003 CHRYSLER CARAVAN Service Manual

emergency towing brake light maintenance reset MPG fuse diagram diagram

Page 1801 of 2177

CHRYSLER CARAVAN 2003 Service Manual (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) I

(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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Page 1802 of 2177

CHRYSLER CARAVAN 2003 Service Manual (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

(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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Page 1803 of 2177

CHRYSLER CARAVAN 2003 Service Manual 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 - ELE

Page 1804 of 2177

CHRYSLER CARAVAN 2003 Service Manual (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 ba

Page 1805 of 2177

CHRYSLER CARAVAN 2003 Service Manual INTERIOR
TABLE OF CONTENTS
page page
A-PILLAR LOWER EXTENSION TRIM
REMOVAL.............................73
INSTALLATION.........................73
A-PILLAR TRIM
REMOVAL.............................73
I

INTERIOR
TABLE OF CONTENTS
page page
A-PILLAR LOWER EXTENSION TRIM
REMOVAL.............................73
INSTALLATION.........................73
A-PILLAR TRIM
REMOVAL.............................73
INSTALLATION.........................73
ASSIST HANDLE
REMOVAL.............................73
INSTALLATION.........................73
B-PILLAR LOWER TRIM
REMOVAL.............................73
INSTALLATION.........................74
B-PILLAR UPPER TRIM
REMOVAL.............................74
INSTALLATION.........................74
CARPETS AND FLOOR MATS
REMOVAL.............................74
INSTALLATION.........................75
COWL TRIM
REMOVAL.............................75
INSTALLATION.........................75
C-PILLAR TRIM
REMOVAL.............................75
INSTALLATION.........................76
DOOR SILL TRIM PLATE
REMOVAL.............................76
INSTALLATION.........................76
HEADLINER
REMOVAL.............................76
INSTALLATION.........................76
LEFT D-PILLAR TRIM PANEL
REMOVAL.............................77
INSTALLATION.........................77
LIFTGATE SILL PLATE
REMOVAL.............................77
INSTALLATION.........................77
QUARTER TRIM BOLSTER
REMOVAL.............................77INSTALLATION.........................77
RIGHT QUARTER TRIM PANEL
REMOVAL.............................78
INSTALLATION.........................78
LEFT QUARTER TRIM PANEL
REMOVAL.............................78
INSTALLATION.........................78
REAR HEADER TRIM
REMOVAL.............................79
INSTALLATION.........................79
REAR HVAC LOUVER
REMOVAL.............................79
INSTALLATION.........................79
REAR VIEW MIRROR
REMOVAL.............................79
INSTALLATION.........................80
RIGHT D-PILLAR TRIM PANEL
REMOVAL.............................80
INSTALLATION.........................80
SLIDING DOOR SILL PLATE
REMOVAL.............................80
INSTALLATION.........................80
SUN VISOR
REMOVAL.............................81
INSTALLATION.........................81
SUN VISOR SUPPORT
REMOVAL.............................81
INSTALLATION.........................81
FLOOR CONSOLE TRAY
REMOVAL.............................81
INSTALLATION.........................81
FLOOR CONSOLE TRAY - BRACKET
ASSEMBLY
REMOVAL.............................82
INSTALLATION.........................82
23 - 72 INTERIORRS
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Page 1806 of 2177

CHRYSLER CARAVAN 2003 Service Manual 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 exte

Page 1807 of 2177

CHRYSLER CARAVAN 2003 Service Manual (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) Engag

(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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Page 1808 of 2177

CHRYSLER CARAVAN 2003 Service Manual (15) Roll and fold carpet forward away from rear
door opening.
(16) Extract carpet through sliding door opening
(Fig. 5).
INSTALLATION
(1) Insert carpet through sliding door opening.
(2) Roll carpet r

(15) Roll and fold carpet forward away from rear
door opening.
(16) Extract carpet through sliding door opening
(Fig. 5).
INSTALLATION
(1) Insert carpet through sliding door opening.
(2) Roll carpet rearward toward rear door opening.
(3) Roll carpet under instrument panel.(4) Install push pins fasteners through carpet and
grommet into floor to attach carpet to floor in front
seat area (Fig. 5).
(5) Install push pins fasteners in the rear area.
CAUTION: Ensure that the correct fasteners are
installed in the proper locations. Damage to the fuel
tank may result.
(6) Install floor escutcheons (Fig. 4).
(7) Install the floor console trays. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE TRAY -
INSTALLATION)
(8) Install Quarter trim panels.
(9) Install D-pillar trim covers.
(10) Install lower B-pillar trim covers.
(11) Install rear door sill plate.
(12) Install sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(13) Install front cowl panels and sill plates.
(14) Install the passenger seats. Refer to the Own-
er's Manual for proper procedures.
(15) Install front center console.
(16) Install front seats. (Refer to 23 - BODY/
SEATS/SEAT - INSTALLATION)
COWL TRIM
REMOVAL
(1) Remove door sill plate.
(2) Disengage hidden clips holding cowl trim to
cowl panel (Fig. 1).
(3) Remove cowl trim from vehicle.
INSTALLATION
(1) Place cowl trim panel in position on vehicle
(Fig. 1).
(2) Engage hidden clips attaching cowl trim to
cowl panel.
(3) Install door sill plate.
C-PILLAR TRIM
REMOVAL
(1) Remove quarter trim panel.
(2) Remove seat belt turning loop from height
adjuster.
(3) Remove screw attaching C-pillar trim panel to
C-pillar (Fig. 6).
(4) Disengage hidden clips attaching trim to upper
C-pillar.
(5) Remove upper C-pillar trim from vehicle.
Fig. 4 SEAT ESCUTCHEONS
1 - SEAT ESCUTCHEON
2 - FLOOR CARPET
Fig. 5 FLOOR CARPET
1 - CARPET LOCATOR GROMMET
2 - PUSH PIN
3 - CARPET
4 - CARPET GROMMET
5 - HEEL PROTECTOR PAD
6 - BODY ASSEMBLY
RSINTERIOR23-75
CARPETS AND FLOOR MATS (Continued)
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