2003 CHRYSLER CARAVAN remove seats

(4) Place seat back hinge in position on seat.
(5) Install bolts attaching seat back hinge to seat
cushion frame. Tighten bolts to 48 N´m (35 ft. lbs.)
torque.
(6) Install shoulder bolts attaching seat back hinge
to seat back frame (Fig. 37). Tighten nuts to 34 N´m
(25 ft. lbs.) torque.(Refer to 23 - BODY/SEATS/
BENCH SEAT BACK - INSTALLATION)
(7) Install bench seat back hinge covers. (Refer to
23 - BODY/SEATS/SEAT BACK HINGE COVERS -
50/50 SPLIT, BENCH - INSTALLATION)
(8) Verify seat back hinge operation and adjust
synchronizing cable, if equipped. (Refer to 23 -
BODY/SEATS/SYNCHRONIZING CABLE ADJUST-
MENT)
SYNCHRONIZING CABLE ADJUSTMENT
NOTE:
Bench seats equipped with child restraint seats
have an interlock feature that will not allow the seat
back to fold forward with the child seat open.
If the seat back hinges do not release at the same
time the synchronizing cable must be adjusted.
(1) Remove seat from vehicle. Refer to Owner's
Manual for proper procedures.
(2) Disengage cable from the recline mechanism by
pulling the cable end toward the front of the seat
(Fig. 38).
(3) Pull U-shaped locking tab on self-adjusting
mehcanism to disengage auto-adjust feature.
(4) Reattach self-adjusting mechanism, pulling
against spring load to tighten cable.
(5) Press locking tab onto the adjusting mecha-
nism to lock into place.
BENCH SEAT BACK
REMOVAL
NOTE: Bench seats equipped with child restraint
seats have an interlock feature that will not allow
the seat back to fold forward with the child seat
open.
(1) Remove the headrests. (Refer to 23 - BODY/
SEATS/HEADREST - REMOVAL)
(2) Remove the armrests, if equipped. (Refer to 23
- BODY/SEATS/ARMREST - REMOVAL)
(3) Remove the upper hinge cover. (Refer to 23 -
BODY/SEATS/SEAT BACK HINGE COVERS -
REMOVAL)
(4) Disengage synchronizing cable housing from
seat back hinge, if equipped.
(5) Disengage synchronizing cable end from (clip
on left side) hinge latch release arm, if equipped.
(6) Remove shoulder bolts attaching seat back
hinge to seat back frame (Fig. 39).
(7) Remove the seat back.
INSTALLATION
NOTE: Bench seats equipped with child restraint
seats have an interlock feature that will not allow
the seat back to fold forward with the child seat
open.
Fig. 37 BENCH SEAT BACK HINGE
1 - SEATBACK FRAME SHOULDER BOLTS
2 - SEAT CUSHION FRAME BOLTS
3 - SEATBACK HINGE
Fig. 38 SYNCHRONIZING CABLE
1 - CABLE END
2 - LOCKING TAB
3 - SETBACK HINGE
RSSEATS23 - 101
BENCH SEAT BACK HINGE (Continued)
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(1) Install the seat back.
(2) Install the shoulder bolts attaching the seat
back hinge to the seat back frame and tighten to 34
N´m (25 ft. lbs.) torque.
(3) Connect the synchronizing cable end from (clip
on left side) hinge latch release arm, if equipped.
(4) Connect the synchronizing cable housing to the
seat back hinge, if equipped.
(5) Install the upper hinge cover. (Refer to 23 -
BODY/SEATS/SEAT BACK HINGE - INSTALLA-
TION)
(6) Install the armrests, if equipped. (Refer to 23 -
BODY/SEATS/ARMREST - INSTALLATION)
(7) Install the headrest sleeves. (Refer to 23 -
BODY/SEATS/HEADREST SLEEVE - INSTALLA-
TION)
(8) Adjust synchronizing cable, if equipped. (Refer
to 23 - BODY/SEATS/SYNCHRONIZING CABLE
ADJUSTMENT)
BENCH SEAT BACK COVER
REMOVAL
(1) Remove the bench seat back. (Refer to 23 -
BODY/SEATS/BENCH SEAT BACK - REMOVAL)
(2) Remove the bench seatback panel. (Refer to 23
- BODY/SEATS/BENCH SEATBACK PANEL -
REMOVAL)
(3) Disconnect the cover J-straps.
(4) Remove the seat back cover from the seat back
assembly.
INSTALLATION
(1) Install seat back cover onto the seat back
frame and cushion assembly.(2) Connect the J-straps.
(3) Install the bench seatback panel. (Refer to 23 -
BODY/SEATS/BENCH SEATBACK PANEL -
INSTALLATION)
(4) Install the seat back. (Refer to 23 - BODY/
SEATS/BENCH SEAT BACK - INSTALLATION)
BENCH SEAT TRACK
REMOVAL
(1) Remove second row seat from vehicle. Refer to
Owner's Manual for proper procedure.
(2) Place seat on clean covered work surface.
(3) Disengage seat track adjuster link wire from
track being removed.
(4) Remove nuts attaching track to seat riser (Fig.
40).
(5) Remove track from seat riser.
INSTALLATION
(1) Place track in position on seat riser.
(2) Install nuts attaching track to seat riser. (Fig.
40). Tighten nuts to 48 N´m (35 ft. lbs.) torque.
(3) Engage seat track adjuster link wire onto track
being installed.
(4) Install second row seat into vehicle.
Fig. 39 SEAT BACK HINGE - TYPICAL
1 - SEATBACK FRAME SHOULDER BOLTS
2 - SEAT CUSHION FRAME BOLTS
3 - SEATBACK HINGE
Fig. 40 BENCH SEAT TRACK
1 - SEAT TRACK ADJUSTER LINK
2 - RISER
3 - SEAT TRACK NUTS
4 - SEAT TRACK
5 - RISER BOLTS
23 - 102 SEATSRS
BENCH SEAT BACK (Continued)
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PLASTIC GROCERY BAG
RETAINER
REMOVAL
3-PASS BENCH SEAT
(1) Remove five screws attaching the plastic gro-
cery bag retainer to the steel slats on the back frame
(Fig. 41).
(2) Remove retainer.
50/50 SPLIT BENCH SEAT
(1) Remove the screws. (Fig. 42)
(2) Pull top of retainer away from the seatback
and lift off of the two bottom attachment hooks.
INSTALLATION
3-PASS BENCH SEAT
(1) Place retainer in position.
(2) Install the five attaching screws and tighten 2
N´m (17 in. lbs.) torque.
50/50 SPLIT BENCH SEAT
(1) Engage bottom hooks of the retainer and place
into position.
(2) Install the attaching screws and tighten 2 N´m
(17 in. lbs.) torque.
UNDER SEAT STORAGE BIN
REMOVAL
(1) Release under seat storage bin latch and open
bin.
(2) Depress lock tabs at the rear/top edge of the
storage bin (Fig. 43).
(3) Pull storage bin from bucket seat riser.
INSTALLATION
(1) Engage storage bin tracks into guides on each
side of seat riser.
(2) Push storage bin inward until lock tabs snap
past retaining ridge on tracks
(3) Verify storage bin latch operation.
Fig. 41 PLASTIC GROCERY BAG RETAINER
1 - SCREWS
2 - SCREWS
Fig. 42 PLASTIC GROCERY BAG RETAINER - 50/50
SPLIT
1 - SEATBACK
2 - SCREWS
3 - SEATBACK PANEL
4 - GROCERY BAG RETAINER
5 - ATTACHMENT HOOKS
Fig. 43 STORAGE BIN
1 - PASS. SIDE BUCKET SEAT
2 - UNDER SEAT STORAGE BIN
3 - RISER
4 - LOCK TAB
RSSEATS23 - 103
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UNDER SEAT STORAGE BIN
GUIDE
REMOVAL
(1) Remove under seat storage bin. (Refer to 23 -
BODY/SEATS/UNDER SEAT STORAGE BIN -
REMOVAL)
(2) Remove screws attaching storage bin track
guide to seat riser (Fig. 44).
(3) Remove track guide from vehicle.
INSTALLATION
(1) Place track guide in position on seat riser.
(2) Install screws attaching storage bin track guide
to seat riser (Fig. 44). Tighten screws to 3.6 N´m
(31.8 in lbs.) torque.
(3) Install under seat storage bin. (Refer to 23 -
BODY/SEATS/UNDER SEAT STORAGE BIN -
INSTALLATION)
UNDER SEAT STORAGE BIN
LOCK/LATCH
REMOVAL
(1) Open under seat storage bin.
(2) Remove screws holding under seat storage bin
lock/latch to storage bin (Fig. 45).
(3) Remove lock/latch from bin.
INSTALLATION
(1) Place lock/latch in position on storage bin.
(2) Install screws to hold lock/latch to storage bin
(Fig. 45).
(3) Verify under seat storage bin latch operation.
LUMBAR SUPPORT
REMOVAL
(1) Remove screw attaching lumbar handle to seat
back (Fig. 46).
(2) Remove seat back assembly from cushion.
(3) Detrim the seat back assembly.
(4) Remove frame and replace.
INSTALLATION
(1) Trim the seat back frame.
(2) Install seat back assembly to cushion.
(3) Install attaching screw to lumbar handle. The
handle is to be installed, between two and three
O'clock position. Tighten screw to 1 N´m (11 ft. lbs.)
torque.
(4) Test lumbar operation.
Fig. 44 UNDER SEAT STORAGE BIN GUIDE
1 - STORAGE BIN TRACK GUIDE
2 - RISER
Fig. 45 UNDER SEAT STORAGE BIN LOCK/LATCH
1 - UNDER SEAT STORAGE BIN
2 - LOCK/LATCH
Fig. 46 LUMBAR HANDLE
1 - LUMBAR HANDLE
23 - 104 SEATSRS
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SYMPTOM POSSIBLE CAUSE
Buzz, Squeak,Rattles from sunroof Loose or broken attaching hardware.
No lubracation in track.
Worn or broken mechanism.
Cables bunched or kinked
Sunshade will not function or does not
operate smoothlySunshade feet are missing, broken or loose.
No lubracation in track.
Track obstructions or interference.
Glass movement not consistant or glass does
not operate smoothlyGlass and Track timing.
Glass and Track alignment
Cables and Guide alignment
WATER DRAINAGE AND WIND NOISE DIAGNOSIS
The sliding glass panel is designed to seal water
entry with a snug fit between the roof and the seal.
The fit can be checked by inserting a piece of paper
between the roof and the seal. The piece of paper
should have some resistance when pulled out when
the glass panel is in the closed position. The sunroof
housing will drain off a minimum amount of water.
Excessive wind noise could result if the gap clear-
ances are exceeded. The sunroof glass panel may
need to be adjusted. Refer to Sunroof Glass Panel
Adjustment for proper procedures.
Adequate drainage is provided by a drain trough in
the sunroof housing which encircles the sliding glass
panel and leads to drain hoses. If a wet headliner or
other water leak complaints are encountered, before
performing any adjustments, first ensure that the
drainage system is not plugged or disconnected. Use
a pint container to pour water into the sunroof hous-
ing drain trough. If water flow is restricted, use com-
pressed air to blow out any material plugging the
drain system. Retest system again.
To further check for a disconnected drain hose:
(1) Remove A-pillar trim, sun visors, and map
lamps/mini console.
(2) Remove sunroof opening trim lace. Refer to
Sunroof Opening Trim Lace.
NOTE: Care must be taken not to fold or kink the
headliner upon removal.
(3) Lower headliner as necessary to gain access to
sunroof housing drain tubes. Refer to Headlining
Removal and Installation for proper procedures.
(4) Repair as necessary.
DRAIN TUBE
REMOVAL
FRONT HOSES
NOTE: Front A-pillars are filled with sound deaden-
ing foam and the front drain tubes are sealed into
the pillars.
(1) Move glass panel to the fully closed position.
(2) Disconnect negative battery cable.
(3) Remove headliner (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL).
(4) Disconnect the drain hose from the sunroof
housing (Fig. 1).
(5) Drain any liquid from hose connection, repair
as necessary.
REAR HOUSING HOSE
(1) Move glass panel to the fully closed position.
(2) Disconnect negative battery cable.
(3) Remove headliner (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL).
(4) Remove third seat or seats from vehicle.
(5) Remove second seat belt lower anchor.
(6) Remove third seat lower anchor.
(7) Remove quarter trim bolster.
(8) Remove trim panel screws.
(9) Remove quarter trim panel
(10) Disconnect the drain hose from the sunroof
housing. (Fig. 1).
(11) Drain any liquid from hose connection, if nec-
essary, and remove tube.
23 - 116 SUNROOFRS
SUNROOF (Continued)
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DISTRIBUTION - REAR
TABLE OF CONTENTS
page page
AIR OUTLETS
DESCRIPTION.........................52
REMOVAL.............................52
INSTALLATION.........................52
A/C DISTRIBUTION DUCT
REMOVAL.............................53
INSTALLATION.........................53
BLOWER MOTOR
DESCRIPTION.........................53
OPERATION...........................54DIAGNOSIS AND TESTING - BLOWER
MOTOR .............................54
REMOVAL.............................56
INSTALLATION.........................56
REAR HEATER-A/C HOUSING
REMOVAL.............................56
INSTALLATION.........................58
REAR HEATER DISTRIBUTION DUCT
REMOVAL.............................59
INSTALLATION.........................59
AIR OUTLETS
DESCRIPTION
Based upon the system mode selected, conditioned
air can exit the rear heater-A/C unit housing through
one or a combination of the two main housing out-
lets: air conditioner, or heater. Once the conditioned
air exits the unit housing, it is directed through
molded plastic ducts to the various outlets in the
vehicle interior. These outlets and their locations are
as follows:
²Floor Outlets- Three floor outlets with fixed
vanes are located in the right quarter trim panel,
near the floor. These outlets distribute air from the
rear heater distribution duct to the intermediate and
rear seat occupants. The floor outlets are integral to
the right quarter trim panel and, if faulty or dam-
aged, the quarter trim panel must be replaced.
²Overhead Outlets- Four (two right side and
two left side) fully adjustable outlets along the roof
rails distribute air from the rear A/C distribution
duct and the headliner ducts to the intermediate and
rear seat occupants. The headliner ducts are integral
to the headliner panel. Each overhead outlet is
housed in a headliner bezel. The two forward head-
liner bezels also feature a courtesy lamp, a fold-away
coat hook, and a fold-away assist handle. The over-
head outlets can be removed from the headliner
bezels individually for service replacement.
REMOVAL
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the thumb wheel end of
the overhead outlet away from the pivot pin in the
headliner bezel until one end of the outlet is released
(Fig. 1).(2) Pull the opposite end of the overhead outlet
away from its pivot pin in the headliner bezel until
that end of the outlet is released.
(3) Remove the overhead outlet from the opening
in the headliner bezel.
INSTALLATION
(1) Position the overhead outlet into the opening in
the headliner bezel.
(2) Slide the non-thumb wheel end of the outlet
onto the pivot pin in the headliner bezel. Using hand
pressure, push the thumb wheel end outboard onto
the pivot pin until it fully seats.
Fig. 1 Overhead Outlet
1 - HEADLINER BEZEL
2 - OVERHEAD OUTLET
3 - TRIM STICK
4 - COURTESY LAMP
5 - COAT HOOK
6 - ASSIST HANDLE
24 - 52 DISTRIBUTION - REARRS
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A/C COMPRESSOR
DESCRIPTION
All vehicles use the Nippondenso 10S20 compres-
sor. This compressor use an aluminum swash plate,
teflon coated pistons and aluminum sleeveless cylin-
der walls. This compressor includes an integral high
pressure relief valve. The compressor is secured low
in the right front corner of the engine compartment
to a mounting bracket on the cylinder block (2.4L
engine), or directly to the cylinder block (3.3L and
3.8L engines) is integral to the compressor. This com-
pressor cannot be repaired. If faulty or damaged, the
entire compressor must be replaced. The compressor
clutch, pulley, and clutch coil are available for service
replacement.
OPERATION
The compressor is driven by the engine through an
electric clutch, drive pulley and belt arrangement.
The compressor is lubricated by refrigerant oil that is
circulated throughout the refrigerant system with the
refrigerant. The compressor draws in low-pressure
refrigerant vapor from the evaporator through its
suction port. It then compresses the refrigerant into
a high-pressure, high-temperature refrigerant vapor.
The compressor pumps high-pressure refrigerant
vapor to the condenser through the compressor dis-
charge port. The mechanical high pressure relief
valve is designed to vent refrigerant from the system
to protect against damage to the compressor or other
system components, caused by condenser air flow
restrictions or an overcharge of refrigerant. The valve
only vents enough refrigerant to reduce the system
pressure, then re-seats itself. The valve opens at a
discharge pressure of 3445 to 4135 kPA (500 to 600
psi) or above, and closes when a minimum discharge
pressure of 2756 kPa (400 psi) is reached.
DIAGNOSIS AND TESTING - COMPRESSOR
NOISE DIAGNOSIS
Excessive noise while the air conditioning compres-
sor is operating can be caused by loose compressor
mounts, a loose compressor clutch, or high operating
pressures in the refrigerant system. Verify compres-
sor drive belt condition, proper compressor mounting,
correct refrigerant charge level, and compressor head
pressure before compressor repair is performed.
With the close tolerances within the compressor, it
is possible to experience a temporary lockup. The
longer the compressor is inactive, the more likely the
condition is to occur. This condition is the result of
normal refrigerant migration within the refrigerant
system caused by ambient temperature changes. Therefrigerant migration may wash the refrigerant oil
out of the compressor.
NOTE: Prior to a vehicle being removed from ser-
vice or stored for more than two weeks, the com-
pressor should be operated to ensure adequate
refrigerant oil distribution throughout the system
components. Turn on the air conditioner for a min-
imum of five minutes with outside air and the high-
est blower speed selected.
BELT NOISE
If the compressor drive belt slips at initial start-up,
it does not necessarily mean the compressor has
failed. The following procedure can be used to iden-
tify a compressor drive belt noise problem.
A. Start the vehicle and run at idle.
B. Turn the air conditioner On and listen for belt
squeal.
C. If belt squeal is heard, turn the air conditioner
Off immediately.
If the belt squeal stops when the air conditioner is
turned Off, perform the following repair procedures.
(1) Using an appropriate sized oil filter wrench or
a strap wrench, grasp the outer diameter of the com-
pressor clutch hub. While facing the compressor,
rotate the hub clockwise, then counterclockwise. If
the hub rotates, proceed to the next step. If the hub
will not rotate, the compressor is internally damaged,
and must be replaced.
(2) Turn the hub clockwise five complete revolu-
tions and remove the tool.
(3) Start the vehicle and run at idle.
(4) Turn the air conditioner On. Observe the com-
pressor and the system for normal operation, noting
cooling performance and noise levels. Operate for five
minutes before turning the air conditioner Off. If
acceptable cooling performance is observed during
compressor operation, the compressor does not need
to be replaced.
(5) Inspect the drive belt for wear, damage, and
proper tension. (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - DIAGNOSIS AND TEST-
ING).
RSPLUMBING - FRONT24-63
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