2005 CHRYSLER CARAVAN Service Manual

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Page 1849 of 2339

CHRYSLER CARAVAN 2005 Service Manual (29) Remove both the left and right power mirrors:
(a) Using a trim stick or equivalent, gently pry
out on mirror trim cover.
(b) Open door and remove the three torx retain-
ing screws.
(c) Disconnect

(29) Remove both the left and right power mirrors:
(a) Using a trim stick or equivalent, gently pry
out on mirror trim cover.
(b) Open door and remove the three torx retain-
ing screws.
(c) Disconnect the wire connector and remove
mirror from the vehicle.
(30) Feed power mirror wire harness inboard
through the A-pillar.
(31) Loosen the left side roll down bolt (Fig. 8).
(32) Remove the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt (Fig.
8).
(33) With the help of an assistant remove the
instrument panel from vehicle. Lift the instrument
panel up off the HVAC so you won't damage the seal-
ing surface of the distribution duct.
(34) If the instrument panel is being replaced,
transfer all parts to the new instrument panel
assembly.
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OCCUPANT
CLASSIFICATION SYSTEM, SEAT BELT TEN-
SIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTESFOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH ON VEHICLES EQUIPPED WITH THE OCCU-
PANT CLASSIFICATION SYSTEM (OCS), ONLY THE
OCCUPANT CLASSIFICATION MODULE (OCM) AND
THE SEAT CUSHION TRIM MAY BE SERVICED SEP-
ARATELY. ALL OTHER COMPONENTS OF THE PAS-
SENGER SIDE FRONT SEAT CUSHION ASSEMBLY
MUST BE SERVICED ONLY AS A COMPLETE FAC-
TORY-CALIBRATED, ASSEMBLED AND TAMPER-EV-
IDENT SERVICE REPLACEMENT PACKAGE. THIS
PACKAGE INCLUDES THE FRAME, SPRINGS, PAD,
BLADDER, SENSOR, FOAM, WIRING AND A CALI-
BRATED OCM. WHEN INSTALLING THIS PACKAGE
ALWAYS REPLACE ALL OF THE EXISTING COMPO-
NENTS WITH THE NEW COMPONENTS AS A UNIT.
DO NOT ATTEMPT TO SEPARATE OR DISCONNECT
ANY OF THE NEW OCS COMPONENTS IN THE SER-
VICE REPLACEMENT PACKAGE FROM EACH
OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF
THE REPLACED COMPONENTS IN THIS OR ANY
OTHER VEHICLE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN FAILURE OF
THE PASSENGER AIRBAG TO DEPLOY WHEN
REQUIRED, OR IN PASSENGER AIRBAG DEPLOY-
MENT WHEN NOT REQUIRED.
(1) With the help of an assistant place the instru-
ment panel into vehicle on roll down bolts. As you
roll the instrument panel up, lift the instrument
panel up so the duct work does not bind or bend and
you can set it down on the HVAC housing to get the
proper seal at the distribution duct. Get one bolt
started in the dash panel.
(2) Start the locator screw and install the right
side A-pillar retaining bolts (Fig. 5). There are two 13
mm bolts and one 10 mm bolt.
(3) Install the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt (Fig.
8).
(4) Tighten the right and left side cowl side roll
down bolt.
(5) Feed power mirror wire harness outboard
through the A-pillar.
(6) Install both the left and right power mirrors:
(a) Connect the wire connector and install the
mirror onto the vehicle.
(b) Install the three torx retaining screws.
(c) Using a firm push, snap the mirror trim
cover into place.
Fig. 9 INSTRUMENT PANEL LOWER
REINFORCEMENT
1 - LOWER RIGHT REINFORCEMENT
2 - STEERING WHEEL ASSEMBLY
23 - 70 INSTRUMENT PANELRS
INSTRUMENT PANEL ASSEMBLY (Continued)

Page 1850 of 2339

CHRYSLER CARAVAN 2005 Service Manual (7) Place steering column cover plate into position
(Fig. 8).
(8) Install six instrument panel steering column
cover plate attaching screws.
(9) Install the screws attaching the instrument
panel reinf

(7) Place steering column cover plate into position
(Fig. 8).
(8) Install six instrument panel steering column
cover plate attaching screws.
(9) Install the screws attaching the instrument
panel reinforcement (Fig. 9).
(10) Place brake pedal support bracket into posi-
tion and install three nuts attaching to instrument
panel.
(11) Place steering column into position and install
four nuts retaining the steering column to the dash
panel steering column mounting bracket and lower
column to the floor (Fig. 7).
(12) Connect the Occupant Restraint Controller
(ORC) harness connector.
(13) Connect the steering column wiring. There
are seven connectors and clip the harness to the col-
umn.
(14) Connect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.
(c) Five harness connectors.
(d) Driver airbag connector.
(15) Place steering column bearing shroud and
steering column shroud into position and install four
steering column shroud retaining screws (Fig. 6).
(16) Place fixed shroud into position and install
two steering column fixed shroud retaining screws
(Fig. 6).
(17) Install two screws to the hood release handle.
(18) Install the inflatable knee blocker. (Refer to
23 - BODY/INSTRUMENT PANEL/KNEE BLOCKER
- INSTALLATION).
(19) Install the lower steering column cover and
end cap. (Refer to 23 - BODY/INSTRUMENT PAN-
EL/LOWER STEERING COLUMN COVER AND
END CAP - INSTALLATION).
(20) Install the cluster bezel. (Refer to 23 - BODY/
INSTRUMENT PANEL/CLUSTER BEZEL -
INSTALLATION).
(21) Install over steering column cover. (Refer to
23 - BODY/INSTRUMENT PANEL/STEERING COL-
UMN OPENING COVER - INSTALLATION).
(22) Install the right end cover. Position over
retaining slots and firmly snap into place.
(23) Connect the right side wire connectors to the
HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(24) Install the glove box:
(a) Install glove box into the vehicle. Line up the
hinges and firmly snap together.(b) Push in on sides of glove box bin and raise
door.
(25) Install two screws to each right and left cowl
trim covers.
(26) Connect the wire connectors to the Passenger
Airbag.
(27) Install the screws attaching the instrument
panel frame to the dash panel below windshield
opening.
(28) Install screws attaching instrument panel
frame to the dash panel below windshield opening
(Fig. 4).
(29) Install the instrument panel top cover and
silencer. (Refer to 23 - BODY/INSTRUMENT PAN-
EL/INSTRUMENT PANEL TOP PAD - INSTALLA-
TION).
(30) Install both left and right side A-pillar trim
covers.
(31) Install bolts attaching the lower supports to
the floor pan (Fig. 3).
(32) Install bolts attaching the lower supports to
the instrument panel frame.
(33) Install the lower console:
(a) Install lower console to vehicle.
(b) Connect the auxiliary power outlet.
(c) Install the six retaining screws.
(34) Connect the battery negative cable.
INSTRUMENT PANEL CENTER
BEZEL
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Insert the trim stick (special tool #C-4755) or
equivalent between access cover and center bezel
gently pry outward.
(3) Carefully pry the access cover from the instru-
ment panel (Fig. 10).
(4) Remove the two center bezel attaching screws.
(5) Using a trim stick or equivalent, gently pry out
on the edge of the instrument panel center bezel and
pull outward.
(6) Disconnect the wire connectors to the accessory
switches and HVAC control.
(7) Remove the instrument panel center bezel from
the vehicle.
RSINSTRUMENT PANEL23-71
INSTRUMENT PANEL ASSEMBLY (Continued)

Page 1851 of 2339

CHRYSLER CARAVAN 2005 Service Manual INSTALLATION
(1) Place center bezel near opening and connect
the wire connectors to the accessory switches and
HVAC control.
(2) Position the center bezel over the retaining
slots and firmly snap the

Page 1852 of 2339

CHRYSLER CARAVAN 2005 Service Manual LOWER CONSOLE
REMOVAL
(1) Remove screws attaching the lower console to
floor bracket and instrument panel (Fig. 13).
(2) Slide lower console rearward from around
instrument panel supports.
(3) Disconn

LOWER CONSOLE
REMOVAL
(1) Remove screws attaching the lower console to
floor bracket and instrument panel (Fig. 13).
(2) Slide lower console rearward from around
instrument panel supports.
(3) Disconnect the auxiliary power outlet wire con-
nector (if equipped).
(4) Remove lower console from vehicle.
INSTALLATION
(1) Connect the auxiliary power outlet wire con-
nector (if equipped).
(2) Install the lower console into the vehicle (Fig.
13).
(3) Slide console forward around instrument panel
supports.
(4) Install the screws attaching lower console to
floor bracket and instrument panel.
LOWER INSTRUMENT PANEL
REMOVAL
When servicing the lower instrument panel, refer
to Body, Instrument Panel, and then the appropriate
removal procedure.
(1) Remove the right end cover.
(2) Remove the lower steering column cover (Fig.
14).
(3) Remove the center bezel.
(4) Remove the lower console.
(5) Remove the cup holder and track.
(6) Remove the glove box.
(7) Remove the glove box latch striker.
(8) Remove the glove box lamp.
(9) Remove the eighteen screws holding the lower
instrument panel to the reinforcement frame (Fig.
15).
(10) Remove the lower instrument panel from
vehicle.
INSTALLATION
When servicing the lower instrument panel, refer
to Body, Instrument Panel, and then the appropriate
removal procedure.
(1) Install the lower instrument panel into the
vehicle (Fig. 15).
(2) Install the eighteen screws holding the lower
instrument panel to the reinforcement frame.
(3) Install the glove box lamp.
(4) Install the glove box latch striker.
(5) Install the glove box.
(6) Install the cup holder and track.
(7) Install the lower console.
(8) Install the center bezel.
(9) Install the lower steering column cover (Fig.
14).
(10) Install the right end cover.
Fig. 12 INSTRUMENT PANEL TOP COVER
1 - INSTRUMENT PANEL TOP COVER
2 - INSTRUMENT PANEL SILENCER PAD
3 - INSTRUMENT PANEL
Fig. 13 INSTRUMENT PANEL FLOOR CONSOLE
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL FLOOR CONSOLE
RSINSTRUMENT PANEL23-73
INSTRUMENT PANEL TOP COVER (Continued)

Page 1853 of 2339

CHRYSLER CARAVAN 2005 Service Manual LOWER STEERING COLUMN
COVER
REMOVAL
(1) Use trim stick to gently pry rt edge of steering
column cover from lower rt panel just enough to dis-
engage belt loops (Fig. 16).
(2) Pull lower steering col

Page 1854 of 2339

CHRYSLER CARAVAN 2005 Service Manual (3) Place the lower steering column cover into posi-
tion and push spring clips into position.
(4) Install the two screws attaching the lower
steering column cover to instrument panel.
BLOCKER- INFLAT

Page 1855 of 2339

CHRYSLER CARAVAN 2005 Service Manual OVER STEERING COLUMN
COVER
REMOVAL
(1) Taking a firm grasp of the over steering col-
umn cover front edge, give a quick upward pulling
motion to disengage the cover from the instrument
panel (Fig. 18)

Page 1856 of 2339

CHRYSLER CARAVAN 2005 Service Manual INSTRUMENT PANEL TOP PAD
ASSEMBLY
REMOVAL
(1)Remove the instrument cluster (Fig. 19). (Refer to 8
- ELECTRICAL/INSTRUMENT CLUSTER - REMOVAL)
(2) Remove the message center (Fig. 19). (Refer to
8 - ELEC

INSTRUMENT PANEL TOP PAD
ASSEMBLY
REMOVAL
(1)Remove the instrument cluster (Fig. 19). (Refer to 8
- ELECTRICAL/INSTRUMENT CLUSTER - REMOVAL)
(2) Remove the message center (Fig. 19). (Refer to
8 - ELECTRICAL/MESSAGE CENTER - REMOVAL)
(3) Remove the radio (Fig. 19). (Refer to 8 - ELEC-
TRICAL/AUDIO/RADIO - REMOVAL)
(4) Remove the headlamp switch (Fig. 19). (Refer
to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/HEADLAMP SWITCH - REMOVAL)
(5) Remove the lower console (Fig. 19). (Refer to 23
- BODY/INSTRUMENT PANEL/LOWER CONSOLE
- REMOVAL)
(6) Remove the lower panel. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER INSTRUMENT
PANEL TRIM - REMOVAL)
(7) Remove the instrument panel assembly. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL)
(8) Remove the instrument panel speakers.
(9) Remove the glove box light.
(10) Remove the two passenger air bag mounting
bolts (Fig. 20).
(11) Loosen the three passenger air bag support
bracket bolts to the hydro-form rail (Fig. 20).
(12) Remove the 16 screws along the upper edge of
the pad & panel assembly.(13) Remove the 19 screws along the lower edge of
the pad & panel assembly.
(14) Remove the pad and panel assembly (Fig. 19).
INSTALLATION
(1) Position the pan & panel assembly onto the
instrument panel support structure (Fig. 19).
(2) Install the 19 screws along the lower edge of
the pad & panel assembly (Fig. 19).
(3) Install the 16 screws along the upper edge of
the pad & panel assembly.
(4) Install and tighten the two passenger air bag
mounting screws (Fig. 20).
(5) Tighten the three passenger air bag support
bracket bolts to the hydro-form tube (Fig. 20).
(6) Install the glove box light.
(7) Install the instrument panel speakers.
(8) Install the instrument panel assembly. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION)
(9) Install the lower panel. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER INSTRUMENT
PANEL TRIM - INSTALLATION)
(10) Install the lower console. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER CONSOLE -
INSTALLATION)
(11) Install the headlamp switch. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP SWITCH - INSTALLATION)
(12) Install the radio. (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - INSTALLATION)
(13)
Install the message center. (Refer to 8 - ELEC-
TRICAL/MESSAGE CENTER - INSTALLATION)
(14) Install the instrument cluster. (Refer to 8 -
ELECTRICAL/INSTRUMENT CLUSTER - INSTAL-
LATION)
Fig. 19 INSTRUMENT PANEL ASSEMBLY
1 - INSTRUMENT CLUSTER
2 - TOP COVER
3 - PAD AND PANEL ASSEMBLY
4 - LOWER CONSOLE
5 - LOWER PANEL
6 - RADIO
7 - HEADLAMP SWITCH
Fig. 20 AIRBAG MOUNTING HARDWARE
1 - AIR BAG SCREWS (2)
2 - ELECTRICAL CONNECTOR
3 - AIR BAG SUPPORT BRACKET BOLTS (3)
4 - HYDRO-FORM INSTRUMENT PANEL SUPPORT RAIL
RSINSTRUMENT PANEL23-77

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