2005 CHRYSLER CARAVAN body

(6) Remove outboard cowl grille/fender bracket
screw and antenna right side only.
(7) Remove fender bolt to lower rocker panel.
(8) Remove fender bolt to lower cowl.
(9) Support/remove hood.
(10) Pull fascia away from fender.
(11) Remove bolts attaching fender to upper rail.
(12) Remove fender from vehicle (Fig. 8).
INSTALLATION
(1) Place fender in position on vehicle.
(2) From inside engine compartment, start the
center upper rail bolt. install all the bolts attaching
fender to upper rail and tighten.
(3) Install fender to lower cowl panel bolt.
(4) Install fender to rocker panel bolt.
(5) Place fascia into position.
(6) Install hood/remove support.
(7) Install outboard cowl grille/fender bracket
screw and install antenna right side only.
(8) Install fender to fascia nuts.
(9) Install inner splash shield.
(10) Install mud guard.
(11) Install headlamp assembly. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - INSTALLATION)
(12) Check fender for flush and gap. (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS).
FUEL FILL DOOR
REMOVAL
(1) Remove left quarter trim panel.
(2) Remove water shield patch covering access hole
in C-pillar.
(3) Disengage latch release link from clip on fuel
fill blocker latch arm (Fig. 12).
(4) Open fuel fill door.
(5) Remove screws holding fuel fill neck to fuel
filler housing.
(6) Position fuel fill neck out of the way.
(7) Reaching inside fuel filler housing, release clips
holding housing to quarter panel (Fig. 9).
(8) Remove fuel fill door from vehicle.
(9) Disengage clip holding link to fuel fill door
(Fig. 13).
(10) Remove link from fuel fill door.
INSTALLATION
(1) Install spring to housing and door
(2) Snap door into housing.
(3) Insert lockout link into clip on fuel fill door.
(4) Engage clip to hold link to fuel fill door.
(5) Insert lockout link through grommet in panel
between inner and outer quarter panel.
(6) Close fuel fill door.
(7) Install fuel filler housing to outer quarter
panel.
(8) Verify that all clips on fuel filler housing are
fully engaged to outer quarter panel.
(9) Place fuel fill neck in position.
(10) Install screws to hold fuel fill neck to fuel
filler housing.
Fig. 8 FENDER
1 - FASTENERS
2 - FENDER
3 - FASTENERS
Fig. 9 FUEL FILLER HOUSING AND DOOR
1 - FUEL FILLER HOUSING W/LATCH
2 - CLIP
3 - FUEL FILLER HOUSING DOOR
4 - CLIPS
5 - FIX CLIP
23 - 52 EXTERIORRS
FRONT FENDER (Continued)

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. 21).
(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. 22).
(1) Remove the air exhauster from the hole in the
lower aperture panel.
Fig. 21 AIR EXHAUSTER - SWB
1 - LOWER APERTURE PANEL
2 - AIR EXHAUSTER
Fig. 22 AIR EXHAUSTER - LWB
1 - AIR EXHAUSTER
2 - PLUG
3 - LOWER APERTURE PANEL
RSEXTERIOR23-59
LUGGAGE RACK CROSSBAR (Continued)

INSTALLATION
SHORT WHEELBASE
(1) Position the air exhauster to the hole in the
lower aperture panel (Fig. 21).
(2) Using hand pressure, press the air exhauster
into the opening in the lower aperture panel until
the snap features are fully engaged.
(3) Reinstall the rear fascia onto the body. (Refer
to 13 - FRAMES & BUMPERS/BUMPERS/REAR
FASCIA - INSTALLATION).
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 installed using the same procedure used to
install the air exhauster onto the short wheelbase
model. Refer to SHORT WHEELBASE.
(1) Position the air exhauster to the hole in the
lower aperture panel (Fig. 22).
(2) Using hand pressure, press the air exhauster
into the opening in the lower aperture panel until
the snap features are fully engaged.
(3) Reinstall the quarter trim panel onto the inside
of the left or right quarter inner panel. (Refer to 23 -
BODY/INTERIOR/RIGHT QUARTER TRIM PANEL
- INSTALLATION) or (Refer to 23 - BODY/INTERI-
OR/LEFT QUARTER TRIM PANEL - INSTALLA-
TION).
ROOF JOINT MOLDING
REMOVAL
The RAP molding is set with body side molding
tape. The temperature in the work area and the vehi-
cle should be at least 21É C (70É F) to avoid damag-
ing the RAP moldings.
(1) Warm the affected stick-on molding and body
metal to approximately 38É C (100É F) using a suit-
able heat lamp or heat gun.
(2) Pull stick-on molding from painted surface.
(3) Remove adhesive tape residue from painted
surface of vehicle. Use a 3M Scotch-BriteŸ Molding
Adhesive and Stripe Removal Discs, or equivalent, to
clean adhesive residue from painted surfaces. The
adhesive removal discs are available from automotive
paint suppliers. Refer to instructions supplied with
the discs for proper usage.
INSTALLATION
The RAP molding is set with body side molding
tape. The temperature in the work area and the vehi-
cle should be at least 21É C (70É F) to avoid damag-
ing the RAP moldings.
(1) If molding is to be reused;
(a) Remove tape residue from molding.
(b) Clean back of molding with MopartSuper
Kleen solvent, or equivalent.
(c) Wipe molding dry with lint free cloth.
(d) Apply new body side molding (two sided
adhesive) tape to back of molding.
(2) Clean body surface with MopartSuper Kleen
solvent, or equivalent. Wipe surface dry with lint free
cloth.
(3) Remove protective cover from tape on back of
molding.
(4) Apply molding to body from front of vehicle to
rear.
(5) Using a roller tool, roll molding onto body
panel with enough force to assure adhesion and not
bend roof panels.
SIDE VIEW MIRROR
REMOVAL
(1) Using a trim stick C-4755 or equivalent, lift up
the end of the instrument panel top pad enough to
gain access to the mirror electrical connector, if
equipped. (Refer to 23 - BODY/INSTRUMENT PAN-
EL/INSTRUMENT PANEL TOP COVER -
REMOVAL)
(2) Disconnect the electrical connector, if equipped.
(3) Using a trim stick or equivalent, remove the
trim cover (Fig. 23).
(4) Remove the bolts.
(5) Remove the mirror from the pillar.
INSTALLATION
(1) Route the mirror wire harness, if equipped,
through the a-pillar and place side view mirror in
position on vehicle (Fig. 23).
(2) Install the bolts and tighten to 10 N´m (85 in.
lbs.).
(3) Install the mirror trim cover.
(4) Connect the electrical connector, if equipped.
(5) Install the instrument panel top cover, if
equipped with the electric mirror. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION)
23 - 60 EXTERIORRS
REAR QUARTER PANEL/FENDER AIR EXHAUSTER (Continued)

HOOD
TABLE OF CONTENTS
page page
HINGE
REMOVAL.............................62
INSTALLATION.........................62
HOOD
REMOVAL.............................62
INSTALLATION.........................63
LATCH
REMOVAL.............................63INSTALLATION.........................63
LATCH RELEASE CABLE
REMOVAL.............................63
INSTALLATION.........................64
LATCH STRIKER
REMOVAL.............................64
INSTALLATION.........................64
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
23 - 62 HOODRS

INSTRUMENT PANEL
ASSEMBLY
REMOVAL
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 MINUTES
FOR 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) Disconnect and isolate the battery negative
cable.
(2) Remove the lower console:
(a) Remove five retaining screws.
(b) Pull rearward and disconnect the auxiliary
power outlet.(c) Remove lower console from vehicle.
(3) Remove the bolts attaching the lower supports
to the instrument panel frame (Fig. 3).
(4) Remove the bolts attaching the lower supports
to the floor pan.
(5) Remove the both left and right side A-pillar
trim covers using a trim stick (special tool #C-4755)
or equivalent gently pry out on the trim covers and
remove.
(6) Remove the instrument panel top cover. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP PAD - REMOVAL).
(7) Disconnect the wire connectors from the Pas-
senger Airbag.
(8) Remove the two screws to each right and left
cowl trim covers.
(9) Remove screws attaching instrument panel
frame to the dash panel below windshield opening
(Fig. 4).
(10) Remove the glove box:
(a) Push in on sides of glove box bin and lower
door.
(b) Pivot glove box downward and disengage
hinge hooks from instrument panel.
(c) Remove glove box from vehicle.
(11) Disconnect the antenna lead connector from
behind the glove box.
(12) Disconnect the right side wire connectors from
the HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
Fig. 3 FLOOR TO CENTER STACK BRACKETS
1 - DASH PANEL OCCUPANT BRACKET
2 - FLOOR BRACKET NUT
3 - FLOOR TO CENTER STACK BRACKET (RIGHT)
4 - BRACKET ATTACHING SCREW(S)
5 - FLOOR TO CENTER STACK BRACKET (LEFT)
RSINSTRUMENT PANEL23-67

(13) Remove the right end cover by pulling out-
board.
(14) Remove the right side A-pillar retaining bolts
(Fig. 5). There are two 13 mm bolts and one 10 mm
bolt.
(15) Loosen the right side cowl side roll down bolt.
(16) Remove over steering column cover. (Refer to
23 - BODY/INSTRUMENT PANEL/STEERING COL-
UMN OPENING COVER - REMOVAL).
(17) Remove the cluster bezel. (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
REMOVAL).
(18) Remove the lower steering column cover and
end cap. (Refer to 23 - BODY/INSTRUMENT PAN-
EL/LOWER STEERING COLUMN COVER -
REMOVAL)
(19) Remove the inflatable knee blocker. (Refer to
23 - BODY/INSTRUMENT PANEL/INFLATABLE
KNEE BLOCKER - REMOVAL)(20) Remove the two screws to the hood release
handle.
(21) Remove the two steering column fixed shroud
retaining screws (Fig. 6).
(22) Remove the four steering column shroud
retaining screws. Separate the steering column bear-
ing shroud and steering column shroud and remove
from vehicle (Fig. 6).
(23) Disconnect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.
(c) Five harness connectors.
(d) Driver airbag connector.
(24) Disconnect the steering column wiring. There
are seven connectors and then unclip the harness
from the column.
(25) Disconnect the Occupant Restraint Controller
(ORC) harness connector.
Fig. 4 INSTRUMENT PANEL REMOVAL
1 - INSTRUMENT PANEL
2 - SIX ATTACHING SCREWS
3 - 13 mm BOLT - TWO ON EACH SIDE4 - ROLL DOWN BRACKET
5 - 10 mm BOLT - STARTING BOLT ONE EACH SIDE
23 - 68 INSTRUMENT PANELRS
INSTRUMENT PANEL ASSEMBLY (Continued)

(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)

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)