2003 CHRYSLER CARAVAN height

TIRES
DESCRIPTION
DESCRIPTION - TIRE
Tires are designed and engineered for each specific
vehicle. They provide the best overall performance
for normal operation. The ride and handling charac-
teristics match the vehicle's requirements. With
proper care they will give excellent reliability, trac-
tion, skid resistance, and tread life.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain, in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are:
²Rapid acceleration
²Severe application of brakes
²High-speed driving
²Taking turns at excessive speeds
²Striking curbs and other obstacles
²Operating vehicle with over or under inflated
tire pressures
Radial ply tires are more prone to irregular tread
wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation. This will
help to achieve a greater tread-life potential.
TIRE IDENTIFICATION
Tire type, size, load index and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the Tire Identification
chart to decipher the code. For example purposes, the
tire size P225/60 R 16 97 T is used in the chart. An
All Season type tire will also have eitherM+S,M&
SorM-S(indicating mud and snow traction)
imprinted on the side wall. An Extra or Light Load
marking ªXLº or ªLLº may also be listed on the side-
wall. The absence of an ªXLº or ªLLº marking infers
a standard load tire.
TIRE IDENTIFICATION
PTIRE TYPE (Not
present on all tires)P - Passenger
T - Temporary
C - Commercial
LT - Light Truck
225SECTIONAL WIDTHSHOWN IN
MILLIMETERS
60ASPECT RATIOSECTIONAL HEIGHT
÷ SECTIONAL WIDTH
(Refer to Aspect Ratio
Figure 22 )
Fig. 20 Mounting Tire Using Rotating Wheel
Machine
1 - HEAD OF CHANGER LOCATED HERE
2 - VALVE STEM
Fig. 21 Mounting Tire Using Rotating Tool Machine
1 - VALVE STEM
2 - MOUNTING END OF TOOL
3 - BEAD BREAKER (KEEP CLEAR OF SENSOR)
RSTIRES/WHEELS22-13
SENSOR - TPM (Continued)
ProCarManuals.com

RCONSTRUCTION
TYPER - RADIAL
B - BIAS BELTED
D - DIAGONAL (BIAS)
16WHEEL DIAMETER SHOWN IN INCHES
97LOAD INDEX *
TSPEED RATING *
* NOTE: Consult the tire manufacturer regarding
any questions on tire specifications or capabilities.
TIRE CHAINS
Refer to the owners manual supplied with the vehi-
cle to determine whether the use of tire chains is per-
mitted on this vehicle.
DESCRIPTION - RADIAL-PLY TIRES
Radial-ply tires improve handling, tread life, ride
quality and decrease rolling resistance.
Radial-ply tires must always be used in sets of four
and under no circumstances should they be used on
the front only. It is recommended that tires from dif-
ferent manufacturers NOT be mixed. They may be
mixed with a temporary spare tire when necessary. A
maximum speed of 80 km/h (50 mph) is recom-
mended while a temporary spare is in use.
Radial-ply tires have the same load-carrying capac-
ity as other types of tires of the same size. They also
use the same recommended inflation pressures.
DESCRIPTION - REPLACEMENT TIRES
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.It is recommended that tires equivalent to the orig-
inal equipment tires be used when replacement is
needed.
Failure to use equivalent replacement tires may
adversely affect the safety and handling of the vehi-
cle.
The original equipment tires provide a proper com-
bination of many characteristics such as:
²Ride
²Noise
²Handling
²Durability
²Tread life
²Traction
²Rolling resistance
²Speed capability
The use of tires smaller than the minimum tire
size approved for the vehicle can result in tire over-
loading and failure.
Use tires that have the approved load rating for
the vehicle and never overload them. Failure to equip
the vehicle with tires having adequate speed capabil-
ity can result in sudden tire failure and loss of vehi-
cle control.
The use of oversize tires may cause interference
with vehicle components. Under extremes of suspen-
sion and steering travel, interference with vehicle
components may cause tire damage.
DESCRIPTION - SPARE TIRE (TEMPORARY)
The temporary (convenience) spare tire is designed
for emergency use only. The original tire should be
repaired and reinstalled, or replaced with a new, at
the first opportunity.
The temporary (convenience) spare tire should be
inflated to the pressure listed on its sidewall. Do not
exceed speeds of 80 km/h (50 mph) when the tempo-
rary spare tire is in use on the vehicle. Refer to the
Owner's Manual for more details.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - TIRE NOISE
Unusual tire noise can be associated with tire and
wheel vibration or irregular tire wear. For vibration,
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING). For irregular tire wear, (Refer to 22 -
TIRES/WHEELS/TIRES - DIAGNOSIS AND TEST-
ING).
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD
Use the following Vehicle Lead Diagnosis And Cor-
rection Chart to diagnose and correct a vehicle lead
or drift problem.
Fig. 22 Tire Aspect Ratio
1 - SECTIONAL WIDTH
2 - SECTIONAL HEIGHT
22 - 14 TIRES/WHEELSRS
TIRES (Continued)
ProCarManuals.com

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)
ProCarManuals.com

(10) Install center stop on sliding door. (Refer to 23
- BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(11) Place upper roller stop bumper in position on
upper roller arm.
(12) Install screw attaching upper roller arm stop
bumper to upper roller arm (Fig. 9).
(13) Remove masking tape from body surfaces.
(14) Verify door operation and fit. Adjust as neces-
sary. (Refer to 23 - BODY/DOORS - SLIDING/SLID-
ING DOOR - ADJUSTMENTS)
ADJUSTMENTS
SLIDING DOOR ADJUSTMENTS
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
PRELIMINARY CHECKS
(1) Close the sliding door, visually checking C-post
striker alignment entry into latch. Striker at this
point must not affect alignment. Striker should go
straight into the latching mechanism.
(2) On vehicles with left sliding doors, check the
fuel door blocker striker entry into latch. Striker at
this point must not affect alignment.
(3) Check C-post and B-post for door to aperture
gaps and door to door gaps. All gaps should be 5 mm
  1 mm.
(4) Check door for height using character lines as
a reference. Also check roof contour as a controlling
factor.
Using the procedures noted below, adjust the side
door in the order the individual steps are called out.
DOOR FLUSHNESS ADJUSTMENT
(1) Check sliding door flushness at the C-pillar
striker.
(2) Adjust the C-pillar striker in or out until the
door is flush.
(3) Check upper B-pillar flushness to A-pillar
cover.
(4) Loosen one nut on upper hinge and adjust door
in or out until the door is flush.
(5) Check flushness at upper C-pillar.
(6) If upper C-pillar flushness is out of specifica-
tion use a heavy rubber mallet on the door assembly
until door is in specifications.
DOOR GAP ADJUSTMENT - UP/DOWN
(1) Visually inspect the sliding door for fitting low
at the top of the door by checking the alignment of
the top contour of the door to the quarter panel.
(2) Fully open the sliding door.
(3) Verify that all center hinge bolts are tight.
(4) Adjust the rear of the sliding door up by turn-
ing the center hinge bolt clockwise (Fig. 13).
(5) Close the door and check the sliding door align-
ment.
(6) Adjust the front of the sliding door up by
adjusting lower hinge bolts.
(7) Open door half way and remove lower hinge
bolt access plug.
(8) Loosen bolts as necessary to move the front of
door up or down.
Fig. 11 SLIDING DOOR UPPER ROLLER
1 - SLIDING DOOR
2 - UPPER HINGE
3 - UPPER CHANNEL
Fig. 12 SLIDING DOOR CENTER ROLLER
1 - SLIDING DOOR
2 - QUARTER GLASS
3 - CENTER HINGE ROLLERS
4 - CENTER HINGE
23 - 30 DOORS - SLIDINGRS
SLIDING DOOR (Continued)
ProCarManuals.com

(9) Check the upper hinge for possible bind, adjust
as necessary.
(10) Close the door and check the sliding door
alignment.
(11) Fully open door and apply thread lock nut
onto the center hinge bolt. Tighten nut until till it
butts up against the welded nut on the center hinge.
Tighten nut to 15 N´m (130 in. lbs.). It may be nec-
essary to hold the center hinge bolt to prevent it
from turning while tightening nut.
(12) Verify alignment, adjust as necessary.
DOOR GAP ADJUSTMENT - FORE/AFT
(1) Check height of sliding door at the B-post and
C-post to determine which area is contributing the
greatest to the incorrect gaps.
(2) If the sliding door is high at the C-post;
(a) Open the door to mid-point of travel.
(b) Mark outline of center hinge on sliding door
to assist in making adjustments.
(c) Loosen center hinge bolts (Fig. 13).
(d) Move hinge fore or aft to position the sliding
door into the correct location.
(e) Tighten center hinge bolts.
(f) Verify alignment, adjust as necessary.
(3) If the sliding door is low at the B-post;
(a) Remove access plug in the sliding door trim
panel.
(b) Open the door to mid-point of travel.
(c) Mark outline of lower roller arm bracket on
sliding door to assist in making adjustments.
(d) Loosen lower roller arm bracket bolts (Fig.
14).
(e) Move hinge downward to raise the door.(f) Tighten lower roller arm bracket bolts.
(g) Verify alignment, adjust as necessary.
(4) If the sliding door is low at the C-post;
(a) Open the door to mid-point of travel.
(b) Mark outline of center hinge on sliding door
to assist in making adjustments.
(c) Adjust the adjustment bolt up or down to
move the door position. (Fig. 13).
(d) Move hinge downward to raise the door.
(e) Tighten center hinge bolts.
(f) Verify alignment adjust as necessary.
(5) If the sliding door is high at the B-post;
(a) Remove access plug in the sliding door trim
panel.
(b) Open the door to mid-point of travel.
(c) Mark outline of lower roller arm bracket on
sliding door to assist in making adjustments.
(d) Loosen lower roller arm bracket bolts (Fig.
14).
(e) Move hinge upward to raise the door.
(f) Tighten lower roller arm bracket bolts.
(g) Verify alignment, adjust as necessary.
DOOR SEAL COMPRESSION
(1) First check Gap & Flush (Refer to 23 - BODY/
BODY STRUCTURE/GAP AND FLUSH - SPECIFI-
CATIONS). Check seal compression near the middle
of the door even with the latch assembly. Using a
piece of paper, place it across door seal and close
door. Pull paper out of door opening. If paper tears
setting is to tight, if paper slides thought to easily
the compression is insufficient and needs to be
adjusted.
(2) Adjust seal compression at the top of the
B-post seal;
Fig. 13 SLIDING DOOR CENTER HINGE
1 - ADJUSTING BOLT
2 - WELD NUT
Fig. 14 SLIDING DOOR LOWER ROLLER ARM
1 - LOWER ROLLER ARM BRACKET
2 - BOLTS
3 - SLIDING DOOR
RSDOORS - SLIDING23-31
SLIDING DOOR (Continued)
ProCarManuals.com

HOOD
TABLE OF CONTENTS
page page
HINGE
REMOVAL.............................59
INSTALLATION.........................59
HOOD
REMOVAL.............................59
INSTALLATION.........................60
LATCH
REMOVAL.............................60INSTALLATION.........................60
LATCH RELEASE CABLE
REMOVAL.............................60
INSTALLATION.........................61
LATCH STRIKER
REMOVAL.............................61
INSTALLATION.........................61
HINGE
REMOVAL
(1) Remove Front Wiper Unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL) for procedure.
(2) Raise hood.
(3) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation.
(4) Remove pivot bolt from the body half of hood
hinge and use suitable device to support the hood.
(5) Remove bolts attaching body half of hood hinge
to front fender flange and remove hinge from vehicle
(Fig. 1).
INSTALLATION
(1) If necessary, paint new hinge before installa-
tion.
(2) Place body half of hood hinge in position on
vehicle.
(3) Install bolts attaching hood hinge to front
fender flange. Tighten bolts to 8 N´m (70 in. lbs.)
torque.
(4) Install pivot bolt to the body half of hood hinge.
Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(5) Install Front Wiper Unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION) for proper procedures.
(6) Align all marks and secure bolts. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers. Shims can be added or removed under hood
hinge to achieve proper hood height. Tighten bolts to
13.5 N´m (10 ft. lbs.) torque.Close hood.
HOOD
REMOVAL
(1) Raise hood to full up position.
(2) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation.
(3) Remove the top bolts attaching hood to hinge
and loosen the bottom bolts until they can be
removed by hand (Fig. 2).
(4) With assistance from a helper at the opposite
side of the vehicle to support the hood, remove bot-
tom bolts attaching hood to hinge.
(5) Remove the hood from the vehicle.
Fig. 1 HOOD HINGE
1 - HOOD
2 - HOOD HALF OF HOOD HINGE
3 - HOOD HINGE PIVOT BUSHING
4 - BODY HALF OF HOOD HINGE
5 - FENDER
RSHOOD23-59
ProCarManuals.com

(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)
ProCarManuals.com

(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)
ProCarManuals.com