2003 CHRYSLER CARAVAN torque

INSTALLATION
(1) Reverse removal procedure.
(2) When installing cowl cover over wiper module,
make sure fore aft locator on the underside of cowl
grill seat into the locator grooves on top of wiper
module.
(3) Star all cowl grille mounting screws by hand
before torquing to specifications.
(4) Assure washer hose is properly routed and not
pinched.
(5) Center cowl grille to body and windshield.(6) Assure ªarrowº indicator head of quarter turn
fasteners is pointing toward windshield.
(7) Tighten screw to 1.2 N´m (11 in. lbs.) torque.
(8) Install the wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS - INSTAL-
LATION)
(9) Check for proper spray pattern from washer
nozzles.
EXTERIOR NAME PLATES -
TAPE ATTACHED
REMOVAL
(1) Mark reference points before removing.
(2) Using a heat gun gently apply heat in a circu-
lar motion to loosen the adhesive bond.
(3) Using a nonmetallic prying device, such as a
plastic or wood trim stick gently pry up at corners
and remove.
(4) Clean off all traces of adhesive or double sided
tape from the panel with a general purpose adhesive
remover.
INSTALLATION
(1) Clean panel surface with isopropy alcohol.
(2) Align badgeing to reference points.
(3) Install and press securely to full adhesive con-
tact
(4) Clean away any reference points.
EXTERIOR NAME PLATES -
ADHESIVE ATTACHED
REMOVAL
(1) Mark reference points before removing.
(2) Using a heat gun gently apply heat in a circu-
lar motion to loosen the adhesive bond.
(3) With your fingernail lift up and peel away
badgeing/tape from panel, using a heat gun as you
go.
(4) Clean off all traces of adhesive from the pan-
el(s) with a general purpose adhesive remover.
INSTALLATION
(1) Clean panel surface with isopropy alcohol.
(2) Remove paper carrier and align badgeing/tape
to reference points or adjacent panel.
(3) Install and press securely, using a plastic
spreader to eliminate all air bubbles.
(4) Remove top protective carrier.
(5) Clean away any reference points.
Fig. 6 COWL COVER
1 - COWL COVER
2 - WIPER PIVOT
3 - WASHER HOSES
4 - HOOD
Fig. 7 COWL COVER RETAINERS
1 - SCREW
2 - WINDSHIELD
3 - COWL COVER
4 - FRONT FENDER
23 - 50 EXTERIORRS
COWL GRILLE (Continued)
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(3) Align with paint breaks around bolt heads.
(4) Install bolts attaching ends of crossmember to
radiator closure panel (Fig. 14). Tighten bolts to 19
N´m (14 ft. lbs.) torque.
(5) Install bolts attaching radiator isolators to
crossmember.
(6) Install screw attaching coolant recovery bottle
to crossmember.
(7) Install bolt attaching air cleaner housing to
crossmember.
(8) Install engine air inlet resonator.
(9) Install radiator sight shield.
(10) Install hood prop rod.
(11) Align hood latch by placing latch over net
pierce tabs. If alignment is required, flatten tabs.
(12) Install bolts attaching hood latch to cross-
member. Tighten bolts to 13.5 N´m (10 ft. lbs.)
torque.
(13) Verify hood latch operation and hood align-
ment.
FRONT WHEELHOUSE
SPLASH SHIELD
REMOVAL
(1) Hoist and support vehicle on safety stands.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE).
(2) Remove front wheel.
(3) Remove push pin fasteners attaching splash
shield to frame rail forward of suspension.
(4) Remove push pin fasteners attaching splash
shield to frame rail rearward of suspension.
(5) Remove screws attaching wheelhouse splash
shield to front fender and front bumper fascia.
(6) Remove splash shield from vehicle (Fig. 15).
INSTALLATION
(1) Place splash shield in position on vehicle (Fig.
15).
(2) Install push pin fasteners attaching splash
shield to frame rail forward of suspension.
(3) Install push pin fasteners attaching splash
shield to frame rail rearward of suspension.
(4) Install screws attaching wheelhouse splash
shield to front fender.
(5) Install front wheel.
(6) Lower vehicle.
LUGGAGE RACK RISER
REMOVAL
(1) Remove two fasteners from the front riser.
Gently pull up on the luggage rack side rail and
detach the riser snap to remove riser from the rail
(Fig. 16).
(2) Repeat for the opposite side, if necessary.
(3) Remove front riser(s) from vehicle (Fig. 17).
Fig. 15 FRONT WHEELHOUSE SPLASH SHIELD
1 - FRONT FENDER WHEELHOUSE SPLASH SHIELD
2 - PUSH PIN FASTENERS
3 - ACCESSORY DRIVE SPLASH SHIELD
4 - SCREWS
Fig. 16 LUGGAGE RACK RISER COVER
1 - FRONT RISER COVER
2 - LOCK TABS
3 - LUGGAGE RACK SIDE RAIL
4 - FRONT RISER
23 - 54 EXTERIORRS
GRILLE OPENING REINFORCEMENT (Continued)
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INSTALLATION
NOTE: The crossbar assemblies are designed to be
installed in only one way. Check top and bottom
surfaces of the crossbar for the word FRONT and
directional arrows. The directional arrows must
point toward the front of the vehicle.
(1) Place crossbar in position on vehicle.
(2) Work from side to side sliding the crossbar
assembly back a little at a time to ensure it remains
perpendicular to the side rails.
(3) Position first crossbar assembly crossbar at the
second most rearward locator holes. Press the top of
the stanchion lever to lock it into position.
(4) Position the second crossbar assembly in the
second hole from the front. Lock into place.
(5) Place luggage rack riser into position.
(6) Install two fasteners into riser. Tighten fasten-
ers to 4 mm (35 in. lbs.) torque.
REAR QUARTER PANEL/
FENDER AIR EXHAUSTER
DESCRIPTION
Air exhausters, designed to conform to the body
structure, allow air entering at the front of the vehi-
cle to flow out the back. By reducing air pressure
within the vehicle, the exhausters also reduce blower
noise at any given air flow level compared to operat-
ing without them and help reduce door closing effort.
They are located in the lower rear comers of the
body.
REMOVAL
SHORT WHEELBASE
(1) Remove the rear fascia from the body. (Refer to
13 - FRAMES & BUMPERS/BUMPERS/REAR FAS-
CIA - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 19).
(3) Remove the air exhauster from the hole in the
lower aperture panel.
LONG WHEELBASE
NOTE: Models with the optional rear heater and air
conditioner do not have an air exhauster on the
right side of the vehicle, but have a plastic plug
installed in the right lower aperture panel. This plug
is removed using the same procedure used toremove the air exhauster from the short wheelbase
model. Refer to SHORT WHEELBASE.
(1) Remove the quarter trim panel from the inside
of the left or right quarter inner panel (Refer to 23 -
BODY/INTERIOR/RIGHT QUARTER TRIM PANEL
- REMOVAL) or (Refer to 23 - BODY/INTERIOR/
LEFT QUARTER TRIM PANEL - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 20).
(1) Remove the air exhauster from the hole in the
lower aperture panel.
Fig. 19 AIR EXHAUSTER - SWB
1 - LOWER APERTURE PANEL
2 - AIR EXHAUSTER
Fig. 20 AIR EXHAUSTER - LWB
1 - AIR EXHAUSTER
2 - PLUG
3 - LOWER APERTURE PANEL
23 - 56 EXTERIORRS
LUGGAGE RACK CROSSBAR (Continued)
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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
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INSTALLATION
(1) Place hood in position on vehicle. With assis-
tance from a helper at the opposite side of the vehicle
to support the hood, install bottom bolts attaching
hood to hinge finger tight.
(2) Install top bolts attaching hood to hinge finger
tight.
(3) Position bolts at marks and tighten. Tighten
bolts to 13.5 N´m (120 in. lbs.) torque. 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.
(4) Verify hood operation and alignment.
LATCH
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching hood latch to radiator
closure panel crossmember (Fig. 3).
(3) Remove hood latch from crossmember.
(4) Disconnect hood release cable from hood latch
(Fig. 4).
(5) Remove hood latch from vehicle.
INSTALLATION
(1) Position hood latch on vehicle.
(2) Connect hood release cable from hood latch.
(3) Position hood latch on crossmember.
(4) Align hood latch by placing latch over net
pierced tabs. If alignment is required, flatten or
grind tabs.
(5) Verify hood operation and alignment. Adjust as
necessary.(6) Tighten attaching bolts to 13.5 N´m (10 ft. lbs.)
torque.
LATCH RELEASE CABLE
REMOVAL
(1) Remove hood latch.
(2) Disengage cable end from hood latch locking
mechanism.
(3) Slide cable case end sideways in keyhole slot of
hood latch while pinching barb on cable case closed.
(4) Remove cable from latch (Fig. 4).
(5) Remove hood release handle from instrument
panel.
(6) Disengage rubber grommet cable insulator
from hole in dash panel.
(7) Attach a suitable length of mechanic's wire to
latch end of cable to assist cable installation.
Fig. 2 HOOD
1 - HOOD
2 - HOOD LATCH STRIKER
3 - HOOD HALF OF HOOD HINGE
Fig. 3 HOOD LATCH
1 - HOOD RELEASE CABLE
2 - HOOD LATCH
3 - RADIATOR CLOSURE PANEL CROSSMEMBER
Fig. 4 HOOD
1 - RELEASE CABLE CASE
2 - HOOD LATCH
3 - RELEASE CABLE END
23 - 60 HOODRS
HOOD (Continued)
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(8) Route cable back from latch through engine
compartment toward dash panel near power brake
booster (Fig. 5).
(9) Remove attaching clips from cable case.
(10) From inside vehicle, pull cable through dash
panel until mechanic's wire is exposed.
(11) Disconnect cable from mechanic's wire.
(12) Remove hood release cable from vehicle.
INSTALLATION
(1) Place hood release cable in position under
instrument panel.
(2) Attach latch end of hood release cable to
mechanic's wire protruding through dash panel.
(3) Route cable forward through engine compart-
ment toward latch by pulling on mechanic's wire
(Fig. 5).(4) Disconnect mechanic's wire from cable.
(5) Engage rubber grommet cable insulator into
hole in dash panel.
(6) Install hood release handle into instrument
panel.
(7) Place cable in position on latch.
(8) Slide cable case end sideways into keyhole slot
of hood latch.
(9) Engage cable end into hood latch locking mech-
anism.
(10) Install hood latch.
(11) Install attaching clips to cable case and install
clips into original holes in strut tower, fender, head-
lamp area, and radiator closure panel crossmember.
LATCH STRIKER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching striker to inside of
hood.
(3) Remove hood latch striker from vehicle.
INSTALLATION
(1) Position hood latch striker on vehicle.
(2) Install bolts attaching hood latch striker to
hood.
(3) Align hood latch striker to engage smoothly
into hood latch.
(4) Verify hood operation and alignment. Adjust as
necessary.
(5) Tighten attaching bolts to 13.5 N´m (10 ft. lbs.)
torque.Fig. 5 HOOD RELEASE CABLE ROUTING
1 - GROMMET
2 - HOOD RELEASE CABLE
3 - RADIATOR CLOSURE PANEL CROSSMEMBER
RSHOOD23-61
LATCH RELEASE CABLE (Continued)
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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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INSTALLATION
(1) Place upper C-pillar trim in position on vehicle
(Fig. 6).
(2) Engage hidden clips attaching trim to upper
C-pillar.
(3) Install screw attaching C-pillar trim panel to
C-pillar.
(4) Install seat belt turning loop onto height
adjuster. Tighten all seat belt bolts to 39 N´m (29 ft.
lbs.) torque.
(5) Install quarter trim panel.
DOOR SILL TRIM PLATE
REMOVAL
(1) Using trim stick (C-4755), disengage hidden
clips holding door sill plate from door sill.
(2) Remove sill plate from vehicle (Fig. 7).
INSTALLATION
(1) Place sill plate in position on vehicle (Fig. 7).
(2) Align interlock tabs at front and rear to mating
trim.
(3) Engage hidden clips to hold door sill plate to
door sill.
HEADLINER
REMOVAL
(1) Remove sun visors and vanity mirrors.
(2) Remove sun visor center supports.
(3) If equipped, remove coat hooks.
(4) If equipped, remove roof rail modules.
(5) Remove A-pillar trim covers.
(6) Remove B-pillar upper trim covers.
(7) Remove C-pillar upper trim covers.
(8) Remove D-pillar trim covers.
(9) Remove liftgate opening header trim.
(10) If equipped, remove overhead console screw.
(11) If equipped, remove reading lamp.
(12) Remove dome lamp.
(13) Remove push in locking fasteners attaching
headlining to rear roof header and roof bows (Fig. 8).
(14) Remove wiring connections.
(15) Remove headlining from roof.
(16) Extract headlining through liftgate opening.
INSTALLATION
(1) Insert headlining through liftgate opening.
(2) Place headlining in position on roof.
(3) Connect wire connectors.
(4) Install left sun visor support.
(5) Install push in locking fasteners attaching
headlining to rear roof header and bows (Fig. 8).
(6) Install right sun visor support.
(7) Install sun visors and vanity mirrors.
(8) If equipped, install roof rail modules.
(9) If equipped, install coat hooks.
(10) Install dome lamp.
(11) If equipped, install reading lamp.
(12) If equipped, install overhead console.
Fig. 6 C-PILLAR
1 - C-PILLAR TRIM PANEL
2 - C-PILLAR
Fig. 7 DOOR SILL PLATE
1 - CLIPS
2 - SLIDING DOOR SILL TRIM PLATE
3 - FRONT DOOR SILL TRIM PLATE
23 - 76 INTERIORRS
C-PILLAR TRIM (Continued)
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