2005 CHRYSLER CARAVAN mirror

INTERIOR
TABLE OF CONTENTS
page page
A-PILLAR LOWER EXTENSION TRIM
REMOVAL.............................79
INSTALLATION.........................79
A-PILLAR TRIM
REMOVAL.............................79
INSTALLATION.........................79
ASSIST HANDLE
REMOVAL.............................79
INSTALLATION.........................79
B-PILLAR LOWER TRIM
REMOVAL.............................79
INSTALLATION.........................80
B-PILLAR UPPER TRIM
REMOVAL.............................80
INSTALLATION.........................80
CARPETS AND FLOOR MATS
REMOVAL.............................81
INSTALLATION.........................81
CARPETS - FOLD-IN-FLOOR
REMOVAL.............................82
INSTALLATION.........................83
CARPET TRIM RING AND COVER - FOLD-IN-
FLOOR
REMOVAL.............................84
INSTALLATION.........................84
COWL TRIM
REMOVAL.............................88
INSTALLATION.........................88
C-PILLAR TRIM
REMOVAL.............................88
INSTALLATION.........................88
DOOR SILL TRIM PLATE
REMOVAL.............................89
INSTALLATION.........................89
FLOOR CONSOLE BASE TRAY
REMOVAL.............................89
INSTALLATION.........................89
FLOOR CONSOLE - FOLD-IN-FLOOR
REMOVAL.............................89
INSTALLATION.........................89
FLOOR CONSOLE KEY LOCK TUMBLER -
FOLD-IN-FLOOR
REMOVAL.............................90
INSTALLATION.........................90
FLOOR CONSOLE LID LATCH - FOLD-IN-
FLOOR
REMOVAL.............................90
INSTALLATION.........................90HEADLINER
REMOVAL.............................91
INSTALLATION.........................92
LEFT D-PILLAR TRIM PANEL
REMOVAL.............................94
INSTALLATION.........................94
LEFT QUARTER TRIM PANEL
REMOVAL.............................94
INSTALLATION.........................94
LIFTGATE SILL PLATE
REMOVAL.............................94
INSTALLATION.........................95
QUARTER TRIM BOLSTER
REMOVAL.............................95
INSTALLATION.........................95
REAR FLOOR TUB CARPETS INSERT -
FOLD-IN-FLOOR
REMOVAL.............................95
INSTALLATION.........................96
REAR HEADER TRIM
REMOVAL.............................96
INSTALLATION.........................96
REAR HVAC LOUVER
REMOVAL.............................96
INSTALLATION.........................97
RIGHT QUARTER TRIM PANEL
REMOVAL.............................97
INSTALLATION.........................97
REAR VIEW MIRROR
REMOVAL.............................97
INSTALLATION.........................97
RIGHT D-PILLAR TRIM PANEL
REMOVAL.............................97
INSTALLATION.........................98
SECOND ROW FLOOR TUB CARPET INSERT -
FOLD-IN-FLOOR
REMOVAL.............................98
INSTALLATION.........................98
SLIDING DOOR SILL PLATE
REMOVAL.............................98
INSTALLATION.........................99
SUN VISOR
REMOVAL.............................99
INSTALLATION.........................99
SUN VISOR SUPPORT
REMOVAL.............................99
INSTALLATION.........................99
23 - 78 INTERIORRS

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. (Refer to 23 -
BODY/INTERIOR/A-PILLAR TRIM - REMOVAL).
(6) Remove B-pillar upper trim covers (Fig. 20).
(Refer to 23 - BODY/INTERIOR/B-PILLAR UPPER
TRIM - REMOVAL).
(7) Remove C-pillar upper trim covers (Fig. 21).
(Refer to 23 - BODY/INTERIOR/C-PILLAR TRIM -
REMOVAL).
(8) Remove D-pillar trim covers. (Refer to 23 -
BODY/INTERIOR/RIGHT D-PILLAR TRIM PANEL -
REMOVAL) and (Refer to 23 - BODY/INTERIOR/
LEFT D-PILLAR TRIM PANEL - REMOVAL).
(9) Remove liftgate opening header trim.
(10) If equipped, remove overhead console screws.
(11) If equipped, remove reading lamps.
(12) Remove dome lamp.
(13) Remove push in locking fasteners attaching
headlining to rear roof header and roof bows (Fig.
22).(14) Remove wiring connections.
(15) Remove headlining from roof (Fig. 23), (Fig.
24), (Fig. 25), and (Fig. 26).
(16) Extract headlining through liftgate opening.
Fig. 20 HEADLINER AT B-PILLAR
1 - FRONT AND SLIDING DOOR WEATHERSTRIP SEAL
2 - B-PILLAR UPPER TRIM PANEL
Fig. 21 HEADLINER AT C-PILLAR
1 - SLIDING DOOR WEATHERSTRIP
2 - C-PILLAR UPPER TRIM PANEL
3 - REAR QUARTER WINDOW OPENING WEATHERSTRIP
Fig. 22 HEADLINER PUSH PINS
RSINTERIOR23-91

INSTALLATION
(1) Insert headlining through liftgate opening (Fig.
23), (Fig. 24), (Fig. 25), and (Fig. 26).
(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. 22).
(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.
(13) Install liftgate opening header trim.
(14) Install D-pillar trim covers. (Refer to 23 -
BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL -
INSTALLATION), and (Refer to 23 - BODY/INTERI-
OR/RIGHT D-PILLAR TRIM PANEL - INSTALLA-
TION).(15) Install C-pillar upper trim covers. (Refer to 23
- BODY/INTERIOR/C-PILLAR TRIM - INSTALLA-
TION).
(16) Install B-pillar upper trim covers. (Refer to 23
- BODY/INTERIOR/B-PILLAR UPPER TRIM -
INSTALLATION).
(17) Install A-pillar trim covers. (Refer to 23 -
BODY/INTERIOR/A-PILLAR TRIM - INSTALLA-
TION).
Fig. 23 HEADLINER WITH SIDE CURTAINS
1 - 4-WAY LOCATOR AT FRONT OF HEADLINER
2 - PUSH IN CLIPS ON SUN VISOR RETAINER RACKET AND
TWO SCREWS IN SUN VISOR SWIVEL BRACKET
3 - ONE SCREW IN OVER HEAD CONSOLE
4 - PUSH PINS ATTACHING HEADLINER TO OVERHEAD5-2WAYLOCATOR AT REAR OF HEADLINER
6 - COAT HANGER HOOKS
7 - 2-WAY LOCATORS
8 - WIRE HARNESS
23 - 92 INTERIORRS
HEADLINER (Continued)

INSTALLATION
(1) Place bezel in position in HVAC duct opening.
(2) Push inward on bezel until clips snap in place.
Verify that all four clips have been engaged to the
bezel and that the bezel is flush to the headlining
(3) Position HVAC louver to bezel.
(4) Snap both ends of the louver into HVAC bezel.
RIGHT QUARTER TRIM PANEL
REMOVAL
CAUTION: Disconnect the battery negative cable.
Damage to accessory feed circuit can result.
(1) Remove first row seat.
(2) Remove second row seat.
(3) Remove sliding door sill trim panel.
(4) Remove quarter trim bolster.
(5) Remove D-pillar trim panel.
(6) Remove first row seat belt anchor.
(7) Remove second row seat belt anchor.
(8) Remove screws attaching quarter trim to quar-
ter panel from bolster area.
(9) Remove screws attaching rear edge of quarter
trim to attaching bracket.
(10) Disengage hidden clips attaching front of
quarter trim to quarter panel rearward of sliding
door opening and at locators.
(11) Remove quarter trim from quarter panel.
(12) Disconnect speaker wire connector on LWB
quarter trim panel with rear air conditioning.
(13) Pass second row seat belt through slot in trim
panel on long wheel base vehicle.
(14) Pass first row seat belt through slot in trim
panel.
(15) Remove quarter trim panel from vehicle.
INSTALLATION
(1) Position quarter trim panel on vehicle.
(2) Pass first row seat belt through slot in trim
panel.
(3) Pass second row seat belt through access hole
in trim panel on long wheel base vehicle.
(4) Connect wire connector into speaker on LWB
with rear air conditioning.
(5) Align locating pins on backside of trim panel to
mating holes in inner quarter panel.
(6) Engage hidden clips attaching front of quarter
trim to quarter panel rearward of sliding door open-
ing and at locators.
(7) Install screws attaching rear edge of quarter
trim to attaching bracket.
(8) Install screws attaching quarter trim to inner
quarter panel in bolster area.(9) Install second row seat belt anchor on long
wheel base vehicle. Tighten all seat belt bolts to 39
N´m (29 ft. lbs.) torque.
(10) Install first row seat belt anchor.
(11) Install D-pillar trim panel.
(12) Install C-pillar trim panel.
(13) Install quarter trim bolster.
(14) Install sliding door sill trim panel.
(15) Install second row seat, if equipped.
(16) Install first row seat.
(17) Connect the battery negative cable.
REAR VIEW MIRROR
REMOVAL
(1) If equipped, disconnect mirror harness connec-
tor (Fig. 33).
(2) Loosen the mirror base set screw (Fig. 34).
(3) Slide the mirror base upward and off the
bracket.
INSTALLATION
(1) Position the mirror base at the bracket and
slide it downward onto the support bracket.
(2) Tighten the setscrew 1 N´m (15 in. lbs.) torque.
(3) If equipped, connect mirror harness connector.
RIGHT D-PILLAR TRIM PANEL
REMOVAL
(1) Remove rear header trim cover.
(2) Remove liftgate sill plate.
(3) Remove second row seat belt turning loop on
long wheel base vehicle.
Fig. 33 REAR VIEW MIRROR ASSEMBLY
1 - HEADLINER
2 - WIRE COVER
3 - MIRROR
4 - MIRROR ASSEMBLY
5 - WIRE CONNECTOR
6 - WINDSHIELD
RSINTERIOR23-97
REAR HVAC LOUVER (Continued)

(4) Remove bolt attaching second row seat belt,
anchor to quarter on short wheel base vehicle.
(5)
Disengage hidden clips attaching trim to D-pillar.
(6) Remove D-pillar trim panel from D-pillar.
(7) Disconnect speaker wire connector, if equipped.
(8) Pass second row seat belt, if equipped, through
slot in trim panel on short wheel base vehicle.
(9) Remove D-pillar trim from vehicle.
INSTALLATION
(1) Position D-pillar trim on vehicle.
(2) Pass second row seat belt, if equipped, through
slot in trim panel on short wheel base vehicle.
(3) Connect speaker wire connector to speaker, if
equipped.
(4) Align locating pins on backside of trim panel to
mating holes in D-pillar.
(5) Engage hidden clips attaching trim to D-pillar.
(6) Install screws attaching trim panel to attach-
ing bracket on short wheel base vehicle.
(7) Install quarter trim bolster on short wheel base
vehicle.
(8) Install bolt to attach second row seat belt, if
equipped, anchor to quarter on short wheel base
vehicle. Tighten all seat belt bolts to 39 N´m (29 ft.
lbs.) torque.
(9) Install second row seat belt turning loop on
long wheel base vehicle.
(10) Install liftgate sill plate.
(11) Install rear header trim cover.
SECOND ROW FLOOR TUB
CARPET INSERT - FOLD-IN-
FLOOR
REMOVAL
(1) Move both front seats to the full forward posi-
tion.(2) Fold second row seats into the floor well.
(3) Remove rear carpet ring and cover from vehi-
cle. (Refer to 23 - BODY/INTERIOR/REAR CARPET
RING AND COVER ASSEMBLY - REMOVAL).
(4) Remove second row seat from vehicle. Repeat
operation for other side, if necessary.
(5) Remove second row floor tub insert(s) from
vehicle (Fig. 35).
INSTALLATION
(1) Place second row floor tub insert(s) into posi-
tion (Fig. 35).
(2) Place seat(s) into position and install seat.
(Refer to 23 - BODY/SEATS/SEAT - INSTALLA-
TION). Repeat operation for other side, if necessary.
(3) Install rear carpet ring and cover position.
(Refer to 23 - BODY/INTERIOR/REAR CARPET
RING AND COVER - INSTALLATION).
(4) Open second row seats into the upright posi-
tion.
(5) Move both front seats to the normal position.
SLIDING DOOR SILL PLATE
REMOVAL
(1) Disengage hidden clips holding sill plate to
sliding door opening sill.
(2) Disengage hooks holding outside edge of sill
plate to door sill (Fig. 36).
(3) Remove sill plate from vehicle.
Fig. 34 REAR VIEW MIRROR
1 - MIRROR
2 - WINDSHIELD
Fig. 35 SECOND ROW FLOOR TUB INSERT
1 - WELD STUDS
2 - RIGHT TUB INSERT
3 - SECOND ROW SEAT TUB
4 - LEFT TUB INSERT
23 - 98 INTERIORRS
RIGHT D-PILLAR TRIM PANEL (Continued)

INSTALLATION
(1) Place sill plate in position on vehicle.
(2) Engage hooks to hold outside edge of sill plate
to door sill.
(3) Align guide pins to holes in door sill.
(4) Engage hidden clips to hold sill plate to sliding
door opening sill.
(5) Engage interlock tabs at lower B-pillar and
quarter trim panel.
SUN VISOR
REMOVAL
All vehicles with driver and passenger side air
bags must have a colored coded five Bullet point air
bag warning label applied to the sun visor, verify
label availability and ensure the label is installed.
(1) Disengage sun visor from center support.
(2) Remove screws attaching sun visor to roof
header (Fig. 37).
(3) Remove sun visor from roof.
(4) If equipped, disconnect illuminated vanity mir-
ror wire connector from body harness.
(5) Remove sun visor from vehicle.
INSTALLATION
All vehicles with driver and passenger side air
bags must have a colored coded five Bullet point air
bag warning label applied to the sun visor, verify
label availability and ensure the label is installed.
(1) Place sun visor in position on vehicle.
(2) Connect illuminated vanity mirror wire connec-
tor into body harness.
(3) Place sun visor in position on roof.
(4) Install screws to hold sun visor to roof header
(Fig. 37).
(5) Engage sun visor into center support.
SUN VISOR SUPPORT
REMOVAL
(1) Disengage sun visor from support.
(2) Remove screw holding support to roof header
(Fig. 38).
(3) Remove sun visor support from vehicle.
INSTALLATION
(1) Place sun visor support in position on vehicle.
(2) Install screw holding support to roof header
(Fig. 38).
(3) Engage sun visor into support.
Fig. 36 SLIDING DOOR SILL PLATE
1 - HOOKS
2 - SILL PLATE
3 - CLIPS
4 - SLIDING DOOR SILL
5 - CLIPS
Fig. 37 SUN VISOR
1 - HEADLINING
2 - SUN VISOR
Fig. 38 SUN VISOR SUPPORT
1 - OVERHEAD CONSOLE
2 - SUN VISOR SUPPORT
3 - HEADLINING
RSINTERIOR23-99
SLIDING DOOR SILL PLATE (Continued)

STATIONARY GLASS
TABLE OF CONTENTS
page page
WINDSHIELD
DESCRIPTION........................161
WARNING
WINDSHIELD SAFETY PRECAUTIONS....161
REMOVAL............................161
INSTALLATION........................162
SLIDING DOOR GLASS
REMOVAL............................163INSTALLATION........................163
QUARTER WINDOW
REMOVAL............................164
INSTALLATION........................164
LIFTGATE GLASS
REMOVAL............................164
INSTALLATION........................164
WINDSHIELD
DESCRIPTION
The windshield is attached to the window frame
with urethane adhesive. The urethane adhesive is
applied cold and seals the surface area between the
window opening and the glass. The primer adheres
the urethane adhesive to the windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
structural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficult
to cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.
WARNING
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVESTHAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
REMOVAL
WINDSHIELD REMOVAL ± EXTERIOR METHOD
The urethane adhesive holding the windshield to
the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
(1) Remove inside rear view mirror.
(2) Remove windshield wiper arms.
(3) Remove cowl cover.
RSSTATIONARY GLASS23 - 161

(4) Remove A-pillar trim panels.
(5) Place protective covers over instrument panel
and hood.
(6) Remove windshield molding. Using pliers, pull
outward on molding at the bottom of A-pillars.
(7) Using a sharp cold knife, cut urethane adhe-
sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 1). A power
cutting device can be used if available.
(8) Remove windshield from vehicle.
WINDSHIELD REMOVAL ± INTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Remove instrument panel top cover. Refer to
Group 8E, Instrument Panel and Systems.
(3) Remove A-pillar trim covers.
(4) Place protective covers over instrument panel
and hood.
(5) Using a reciprocating or oscillating power
knife, cut urethane adhesive holding the windshield
to the A-pillars, roof header and cowl pinch weld
fences. Refer to instructions provided with the equip-
ment being used.
(6) Remove windshield from vehicle.
INSTALLATION
The urethane adhesive holding the windshield to
the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment. If a door is slammed before
urethane bonding is cured, water leaks can result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.To avoid stressing the replacement windshield, the
urethane bonding material on the windshield fence
should be smooth and consistent to the shape of
the replacement windshield. The support spacers
should be cleaned and properly installed on weld
studs or repair screws at bottom of windshield
opening.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the compression spacers.
(2) Verify the glass lays evenly against the pinch
urethane adhesive remaining on the weld fence at
the sides, top and bottom of the replacement wind-
shield. If not, the pinch weld fence must be formed to
the shape of the new glass.
(3) Remove replacement windshield from wind-
shield opening.
(4) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 2).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(5) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.
(6) Install molding to perimeter of windshield.
(7) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of windshield and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.
(8) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying time.
(9) Using a razor knife, remove as much original
urethane as possible. Do not damage paint on wind-
shield fence.
(10) Apply pinch weld primer 19 mm (0.75 in.)
wide around the windshield fence. Allow at least
three minutes drying time.
(11) If a low viscosity urethane adhesive is used,
install compression spacers on the fence around the
windshield opening (Fig. 3).
(12) Apply a 10 mm (0.4 in.) bead of urethane on
center line of windshield fence.
(13) With the aid of a helper, position the wind-
shield over the windshield opening.
(14) Slowly lower windshield glass to windshield
opening fence. Guide the molding into proper position
as necessary. Push windshield inward until molding
is flush to roof line and A-pillars (Fig. 3).
(15) Clean access urethane from exterior with
MopartSuper Kleen or equivalent.
Fig. 1 CUT URETHANE AROUND WINDSHIELD
1 - COLD KNIFE
2 - WINDSHIELD
23 - 162 STATIONARY GLASSRS
WINDSHIELD (Continued)