2005 CHRYSLER CARAVAN Service Manual

differential clock reset height adjustment change wheel jump cable airbag off

Page 1801 of 2339

CHRYSLER CARAVAN 2005 Service Manual (7) Disengage clip holding door lock linkage to
door latch.
(8) Remove lock linkage from latch.
(9) Remove nuts holding outside door handle to
door outer panel.
(10) Remove outside door handle from ve

(7) Disengage clip holding door lock linkage to
door latch.
(8) Remove lock linkage from latch.
(9) Remove nuts holding outside door handle to
door outer panel.
(10) Remove outside door handle from vehicle.
INSTALLATION
If outside door handle replacement is necessary,
transfer lock cylinder from the original handle to the
new one.
(1) Place outside door handle in position on vehi-
cle.
(2) Install nuts attaching outside door handle to
door outer panel (Fig. 11). Tighten nuts to 6 N´m (50
in. lbs.).
(3) Insert lock linkage into door latch.
(4) Engage clip to hold door lock linkage to latch.
(5) Insert latch linkage into door latch.
(6) Engage clip to hold door latch linkage to latch.
(7) Install push-in fasteners to hold VTSS switch
harness to inner door reinforcement bar, if equipped.
(8) Connect VTSS switch connector into door har-
ness, if equipped.
(9) Verify door latch operation.
(10) Install sound shield and door trim panel.
WINDOW REGULATOR -
POWER
REMOVAL
(1) Remove watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(2) Remove inner belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - REMOVAL)
(3) Remove door glass. (Refer to 23 - BODY/DOOR
- FRONT/DOOR GLASS - REMOVAL).
(4) Disconnect wire connector from power window
motor.
(5) Loosen screws attaching front and rear window
guide rails to inner door panel.
(6) Remove screw heads on guide rails from key
hole slots in inner door panel.
(7) Loosen screws attaching motor/housing to inner
door panel.
(8) Remove regulator from inner door panel.
(9) Extract rear guide rail through inner door
panel rear access hole (Fig. 14).
(10) Extract front guide rail through front access
hole.
INSTALLATION
(1) Insert front guide rail through front access
hole.(2) Insert rear guide rail through rear access hole.
(3) Place window regulator in position on inner
door panel.
(4) Place screw heads on guide rails in position
through key hole slots in inner door panel.
(5) Tighten screws to attach front and rear guide
rails to inner door panel to 8.5±10.7 N´m (75±95 in
lbs). Tighten top screw first and bottom screw sec-
ond.
(6) Tighten screws to attach motor/housing to
inner door panel to 2.8 N´m (25 in lbs).
(7) Connect wire connector into power window
motor.
(8) Install door glass. (Refer to 23 - BODY/DOOR -
FRONT/DOOR GLASS - INSTALLATION)
(9) Verify door glass alignment and operation.
(10) Install inner belt molding (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - INSTALLATION)
(11) Install watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - INSTALLATION)
WINDOW REGULATOR -
MANUAL
REMOVAL
(1) Remove watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(2) Remove inner belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - REMOVAL)
(3) Remove door glass. (Refer to 23 - BODY/DOOR
- FRONT/DOOR GLASS - REMOVAL).
Fig. 14 FRONT DOOR POWER WINDOW
1 - POWER WINDOW MOTOR
2 - FRONT DOOR
3 - GUIDE RAILS
23 - 22 DOOR - FRONTRS
EXTERIOR HANDLE (Continued)

Page 1802 of 2339

CHRYSLER CARAVAN 2005 Service Manual (4) Loosen screws attaching front and rear window
guide rails to inner door panel. (Fig. 15).
(5) Remove screw heads on guide rails from key
hole slots in inner door panel.
(6) Loosen screws attaching

Page 1803 of 2339

CHRYSLER CARAVAN 2005 Service Manual DOORS - SLIDING
TABLE OF CONTENTS
page page
CENTER HINGE
REMOVAL.............................24
INSTALLATION.........................24
SLIDING DOOR STOP BUMPER BEZEL
REMOVAL..........................

DOORS - SLIDING
TABLE OF CONTENTS
page page
CENTER HINGE
REMOVAL.............................24
INSTALLATION.........................24
SLIDING DOOR STOP BUMPER BEZEL
REMOVAL.............................25
INSTALLATION.........................25
STOP BUMPER
REMOVAL.............................25
INSTALLATION.........................25
HOLD OPEN LATCH
REMOVAL.............................25
INSTALLATION.........................25
HOLD OPEN LATCH STRIKER
REMOVAL.............................26
INSTALLATION.........................26
LATCH / LOCK ASSEMBLY
REMOVAL.............................26
INSTALLATION.........................27
INSIDE HANDLE ACTUATOR
REMOVAL.............................27
INSTALLATION.........................27
CENTER STRIKER
REMOVAL.............................28
INSTALLATION.........................28
LOWER HINGE
REMOVAL.............................28
INSTALLATION.........................28
REAR LATCH STRIKER
REMOVAL.............................29
INSTALLATION.........................29
SLIDING DOOR
REMOVAL.............................29
INSTALLATION.........................29ADJUSTMENTS
SLIDING DOOR ADJUSTMENTS..........30
STABILIZER
REMOVAL.............................33
INSTALLATION.........................33
STABILIZER SOCKET
REMOVAL.............................33
INSTALLATION.........................33
TRIM PANEL
REMOVAL.............................34
INSTALLATION.........................34
INSIDE LATCH HANDLE
REMOVAL.............................34
INSTALLATION.........................34
BELLCRANK
REMOVAL.............................35
INSTALLATION.........................35
OUTSIDE HANDLE
REMOVAL.............................35
INSTALLATION.........................36
UPPER HINGE
REMOVAL.............................36
INSTALLATION.........................36
OUTSIDE HANDLE CABLE
REMOVAL.............................37
INSTALLATION.........................37
INSIDE HANDLE CABLE
REMOVAL.............................37
INSTALLATION.........................38
HOLD OPEN LATCH CABLE
REMOVAL.............................38
INSTALLATION.........................38
CENTER HINGE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Open sliding door to the mid point of its travel.
(2) Support sliding door on a suitable lifting
device.
(3) Mark outline of center hinge of inner door
panel to aid installation.(4) Remove bolts attaching center hinge to sliding
door.
(5) Remove center hinge from sliding door.
(6) Roll center hinge to rear of roller channel.
(7) Remove center hinge from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
23 - 24 DOORS - SLIDINGRS

Page 1804 of 2339

CHRYSLER CARAVAN 2005 Service Manual NOTE: Center hinge has an adjustable bolt for
up/down alignment. (Refer to 23 - BODY/DOORS -
SLIDING/SLIDING DOOR - ADJUSTMENTS)
(1) Place center hinge in position on vehicle.
(2) Roll center hinge fo

NOTE: Center hinge has an adjustable bolt for
up/down alignment. (Refer to 23 - BODY/DOORS -
SLIDING/SLIDING DOOR - ADJUSTMENTS)
(1) Place center hinge in position on vehicle.
(2) Roll center hinge forward in roller channel.
(3) Place center hinge in position on sliding door
and align marks.
(4) Install bolts attaching center hinge to sliding
door.
(5) Verify sliding door alignment and operation.
SLIDING DOOR STOP BUMPER
BEZEL
REMOVAL
(1) Using a trim stick (C-4755), disengage clips
attaching door stop bumper bezel to the door trim
panel.
(2) Remove bezel from vehicle (Fig. 1).
INSTALLATION
(1) Place door stop bumper bezel into position (Fig.
1).
(2) Engage clips attaching door stop bumper bezel
to the door trim panel.
STOP BUMPER
REMOVAL
(1) Remove door stop bumper bezel.
(2) Loosen screws attaching rear of stop bumper to
door inner panel (Fig. 1).
(3) Remove screw attaching front of door stop
bumper to door inner panel.
(4) Remove door stop bumper from vehicle.
INSTALLATION
(1) Place stop bumper in position on vehicle.
(2) Install screw attaching front of stop bumper to
door inner panel (Fig. 1).
(3) Tighten screws attaching rear of stop bumper
to door inner panel.
(4) Install door stop bumper bezel.
HOLD OPEN LATCH
REMOVAL
(1) Open sliding door.
(2) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(3) Remove nuts attaching hold open latch to lower
roller arm (Fig. 2).
(4) Remove hold open latch from lower arm.
(5) Disconnect cable from hold open latch.
(6) Remove hold open latch from vehicle.
INSTALLATION
(1) Place hold open latch in position on vehicle.
(2) Connect cable to hold open latch.
(3) Place hold open latch in position on lower arm.
(4) Install nuts attaching the hold open latch to
lower roller arm. Tighten nuts to 5 N´m (45 in. lbs.)
torque.
(5) Install sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(6) Verify sliding door operation.
Fig. 1 SLIDING DOOR STOP BUMPER
1 - DOOR STOP BUMPER
2 - DOOR STOP BUMPER BEZEL
3 - SLIDING DOOR
Fig. 2 SLIDING DOOR HOLD OPEN LATCH
1 - SLIDING DOOR HOLD OPEN LATCH - MANUAL DOOR
2 - LOWER ROLLER ARM
RSDOORS - SLIDING23-25
CENTER HINGE (Continued)

Page 1805 of 2339

CHRYSLER CARAVAN 2005 Service Manual HOLD OPEN LATCH STRIKER
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Open sliding door, do not latch open.
(2) Remove sliding doo

HOLD OPEN LATCH STRIKER
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Open sliding door, do not latch open.
(2) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(3) Remove two bolts attaching sliding door hold
open latch striker to door sill (Fig. 3).
(4) Remove hold open latch striker from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Place hold open latch striker in position on
vehicle.
(2) Install two bolts attaching sliding door hold
open latch striker to door sill.
(3) Install sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(4) Verify sliding door operation.
LATCH / LOCK ASSEMBLY
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
(4) Disengage external cable from latch/lock
assembly (Fig. 4).
(5) Remove foam block.
(6) Remove inside door handle assembly (Refer to
23 - BODY/DOORS - SLIDING/INSIDE LATCH
HANDLE - REMOVAL).
(7) Disengage inside cable from latch/lock assem-
bly.
(8) Disengage link from bellcrank.
(9) Disengage hold open latch cable from lower
hinge.
(10) Remove bolts attaching latch/lock control to
sliding door (Fig. 5).
(11) If equipped, lower latch and disconnect wire
connector from power door lock motor.
(12) Remove latch/lock from door.
Fig. 3 SLIDING DOOR HOLD OPEN LATCH STRIKER
1 - POWER DOOR LOWER TRACK
2 - POWER DOOR HOLDING STRIKER
3 - MANUAL DOOR HOLDING STRIKER
4 - MANUAL DOOR LOWER TRACK
Fig. 4 SLIDING DOOR LATCH/LOCK ASSEMBLY
1 - SLIDING DOOR
2 - LATCH LOCK ASSEMBLY
23 - 26 DOORS - SLIDINGRS

Page 1806 of 2339

CHRYSLER CARAVAN 2005 Service Manual INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Position latch/lock locking lever in unlocked
position.
(2) If equipped, engage

INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Position latch/lock locking lever in unlocked
position.
(2) If equipped, engage wire connector into power
door lock motor (Fig. 4).
(3) Place latch/lock in position on door (Fig. 5).
CAUTION: REPLACE BOLTS IF INSTALLING NEW
LATCH.
(4) Insert bolt into slots in sliding door inner
panel.
(5) Tighten bolts attaching latch/lock assembly to
sliding door.
(6) Engage inside cable into latch/lock assembly.
(7) Install inside door handle assembly (Refer to
23 - BODY/DOORS - SLIDING/INSIDE LATCH
HANDLE - INSTALLATION).
(8) Install foam block.
(9) Engage external cable to latch/lock assembly.
(10) Engage link rod to bellcrank.
(11) Engage hold open latch cable from lower
hinge.
(12) Engage clip to hold bellcrank link to latch/lock
control.
(13) Verify sliding door operation.(14) Install latch/lock cover.
(15) Insure that enough adhesive remains to
securely retain the watershield. Replace as necessary.
(16) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(17) Install sliding door stop bumper.(Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(18) Install sliding door trim panel.(Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove latch/lock assembly. (Refer to 23 -
BODY/DOORS - SLIDING/LATCH/LOCK CONTROL
- REMOVAL).
(2) Remove lock actuator three attaching screws
(Fig. 6).
(3) Remove lock actuator.
INSTALLATION
(1) Place lock actuator into position on latch/lock
assembly.
(2) Insall attaching screws (Fig. 6).
(3) Install latch/lock assembly. (Refer to 23 -
BODY/DOORS - SLIDING/LATCH / LOCK CON-
TROL - INSTALLATION).
Fig. 5 REMOVING SLIDING DOOR LATCH/LOCK
ASSEMBLY
1 - WIRE HARNESS
2 - LATCH/LOCK ASSEMBLY
3 - BELLCRANK LINK ROD
4 - LINK AND SLEEVE ASSEMBLY
Fig. 6 LOCK ACTUATOR
1 - INSIDE HANDLE ACTUATOR
2 - LATCH/LOCK ASSEMBLY
3 - THREE ATTACHING SCREWS
RSDOORS - SLIDING23-27
LATCH / LOCK ASSEMBLY (Continued)

Page 1807 of 2339

CHRYSLER CARAVAN 2005 Service Manual CENTER STRIKER
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove bolts attaching stop bumper. Remove
stop bumper from door.
(3) Remove sc

CENTER STRIKER
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove bolts attaching stop bumper. Remove
stop bumper from door.
(3) Remove screws attaching center striker assem-
bly to door end frame (Fig. 7).
(4) Remove center striker assembly from door
through access hole.
INSTALLATION
(1) Place center striker in position on door through
access hole (Fig. 7).
(2) Install screws to attach center striker to door
end frame.
(3) Install bolts attaching stop bumper.
(4) Install sliding door trim panel (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION).
LOWER HINGE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Open sliding door.
(2) Mark outline of roller arm on sliding door to
aid installation (Fig. 8).(3) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(4) Remove screws attaching open latch to lower
roller arm.
(5) Remove open latch from lower arm.
(6) Support sliding door on a suitable lifting device
with a padded upper surface. The door must be
moveable with lifting device in place.
(7) Remove hold open latch striker.
(8) Remove bolts attaching lower roller arm to
sliding door.
(9) Remove roller arm from sliding door.
(10) Disengage roller arm from lower channel.
(11) Remove roller arm from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Place roller arm into position (Fig. 8).
(2) Engage roller arm to lower channel.
(3) Install roller arm to sliding door.
(4) Install bolts attaching lower roller arm to slid-
ing door.
(5) Install hold open latch striker.
(6) Install screws attaching open latch to lower
roller arm.
(7) Install sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(8) Check sliding door for proper operation.
Fig. 7 SLIDING DOOR CENTER STRIKER
ASSEMBLY
1 - STRIKER BOLT ASSEMBLY
2 - SLIDING DOORFig. 8 SLIDING DOOR LOWER ROLLER ARM
1 - POWER LOWER ROLLER ARM
2 - MANUAL LOWER ROLLER ARM
23 - 28 DOORS - SLIDINGRS

Page 1808 of 2339

CHRYSLER CARAVAN 2005 Service Manual REAR LATCH STRIKER
REMOVAL
(1) Open sliding door.
(2) Mark outline of striker on C-pillar door jamb
face to aid installation.
(3) Remove screws attaching striker to C-pillar
(Fig. 9).
(4) Remove strik

REAR LATCH STRIKER
REMOVAL
(1) Open sliding door.
(2) Mark outline of striker on C-pillar door jamb
face to aid installation.
(3) Remove screws attaching striker to C-pillar
(Fig. 9).
(4) Remove striker from vehicle.
INSTALLATION
(1) Place striker in position on vehicle.
(2) Align striker to outline marks on C-pillar.
(3) Install screws attaching striker to C-pillar.
Tighten screws to 28 N´m (21 ft. lbs.) torque.
(4) Verify sliding door alignment and operation.
SLIDING DOOR
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Apply masking tape to outside surface of quar-
ter panel below the center roller channel, rearward of
the door opening.
(2) Release sliding door latch and open door.
(3) Apply masking tape to door jamb area, rear-
ward of the upper roller channel.
(4) Remove screw attaching upper stop bumper to
upper roller arm (Fig. 10).
(5) Remove upper stop from upper roller arm.(6) Remove center stop from sliding door. (Refer to
23 - BODY/DOORS - SLIDING/STOP BUMPER -
REMOVAL)
(7) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(8) Remove hold open latch striker (Refer to 23 -
BODY/DOORS - SLIDING/HOLD OPEN LATCH
STRIKER - REMOVAL).
(9) Open quarter glass.
(10) Remove center roller channel end cover (Fig.
11).
(11) Support sliding door on a suitable lifting
device with a padded upper surface. The door must
be moveable with lifting device in place.
CAUTION: Do not allow the center hinge roller to
contact the quarter glass. Glass can break.
(12) Slide door rearward until the upper sliding
door hinge roller disengages from the upper channel
(Fig. 12).
(13) Continue moving the door rearward until the
lower rollers exit the lower track.
(14) Continue moving door rearward till center
hinge roller exits the channel (Fig. 13)
(15) Remove sliding door from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Place sliding door in position on lifting device.
(2) Engage center hinge roller into channel and
move door forward (Fig. 13).
Fig. 9 SLIDING DOOR LATCH STRIKER
1 - LATCH STRIKER
2 - SLIDING DOOR
Fig. 10 SLIDING DOOR UPPER STOP
1 - UPPER STOP PLATE
2 - SLIDING DOOR
3 - UPPER SLIDING DOOR HINGE
RSDOORS - SLIDING23-29

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