2005 CHRYSLER CARAVAN lock

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. 96).
(2) Remove retainer.
50/50 SPLIT BENCH SEAT
(1) Remove the screws. (Fig. 97)
(2) Pull top of retainer away from the seat back
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. 98).
(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. 96 PLASTIC GROCERY BAG RETAINER
1 - ATTACHING SCREWS
2 - ATTACHING SCREWS
Fig. 97 PLASTIC GROCERY BAG RETAINER - 50/50
SPLIT
1 - SEAT BACK
2 - ATTACHING SCREWS
3 - SEAT BACK PANEL
4 - GROCERY BAG RETAINER
5 - ATTACHMENT HOOKS
Fig. 98 STORAGE BIN
1 - PASS. SIDE BUCKET SEAT
2 - UNDER SEAT STORAGE BIN
3 - RISER
4 - LOCK TAB
RSSEATS23 - 149

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. 99).
(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. 99). 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. 100).
(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. 100).
(3) Verify under seat storage bin latch operation.
LUMBAR SUPPORT
REMOVAL
(1) Remove screw attaching lumbar handle to seat
back (Fig. 101).
(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. 99 UNDER SEAT STORAGE BIN GUIDE
1 - STORAGE BIN TRACK GUIDE
2 - RISER
Fig. 100 UNDER SEAT STORAGE BIN LOCK/LATCH
1 - UNDER SEAT STORAGE BIN
2 - LOCK/LATCH
Fig. 101 LUMBAR HANDLE
1 - LUMBAR HANDLE
23 - 150 SEATSRS

SEAT RISER LATCH LOCKING
LINK
REMOVAL
(1) Remove seat as necessary to access latch lock-
ing link.
NOTE: If the seat is locked in the seated position
and cannot be tilted forward, it can be released by
reaching into the escutcheons with a hook tool or a
finger from the rear. Pulling the latch toward the
rear of the vehicle will unlock the seat latch allow-
ing the seat to tilt forward.
(2) Using a flat bladed tool pry plastic latch lock-
ing link free from both pins (Fig. 102).
(3) Remove link from seat.
INSTALLATION
(1) Place latch locking link into position (Fig. 102).
(2) Press latch locking link onto pins lock and seat
fully.
(3) Place seat into position and verify proper oper-
ation.
QUAD BUCKET SEAT SIDE
SHIELD/CUP HOLDER - FLAP
AND SPRING ASSEMBLY
REMOVAL
(1) Inspect the flap retaining tabs on cup holder
for damage (Fig. 103).(2) If cracked or broken, replace quad bucket seat
side shield with cup holder. (Refer to 23 - BODY/
SEATS/SEAT SIDE SHIELD - REMOVAL).
(3) If flap retaining tabs are not damaged replace
flap and spring assembly.
INSTALLATION
(1) Ensure the spring is position into mounting tab
(Fig. 104).
(2)
Hold flap and spring assembly in the horizontal
position and snap into cup holder flap retaining tabs.
(3) Verify cup holder flap operation several times
to ensure proper operation. Flap should fold down-
ward with little effort and spring back to a horizontal
position when released.
Fig. 102 SEAT RISER LATCH LOCKING LINK
1 - LATCH LOCKING LINK
2 - FLAT BLADED TOOL
3 - SEAT RISER
Fig. 103 CUP HOLDER FLAP RETAINING TABS
1 - FLAP RETAINING TABS
Fig. 104 FLAP AND SPRING ASSEMBLY
1 - CUP HOLDER FLAP
2 - SPRING IN MOUNTING TAB
RSSEATS23 - 151

BOTTOM OF SEAT CUSHION
PAN PANEL-THIRD ROW -
FOLD-IN-FLOOR
REMOVAL
(1) Fold the third row seat with back down.
(2) Remove handle from cushion.
(3) Using a trim tool, remove bottom side of the
cushion pan panel (Fig. 105).
INSTALLATION
(1) Place bottom side of the cushion pan panel into
position (Fig. 106).
(2) Press on back of cushion pan panel to seat the
fasteners.
(3) Install handle on cushion.
(4) Place seat in the up right position.
HEADREST SLEEVE - THIRD
ROW - FOLD-IN-FLOOR
REMOVAL
(1) Remove headrest (Fig. 107).
(2) Using a trim tool remove sleeve by prying
sleeve away from the seat back frame to unlock it
(Fig. 108)
(3) Pull headrest sleeve upward and out the top of
the seat back frame and remove from seat.
Fig. 105 THIRD ROW CUSHION PAN & COVER
Fig. 106 THIRD ROW CUSHION PAN & COVER
Fig. 107 HEADREST
1 - HEADREST
2 - DEPRESS TAB
Fig. 108 REMOVING HEADREST SLEEVES
1 - HEADREST SLEEVES
2 - TRIM TOOL
23 - 152 SEATSRS

INSTALLATION
(1) Place headrest sleeve into position and push
downward until sleeve locks into position (Fig. 109).
(2) Install headrest (Fig. 107).
SEAT - THIRD ROW - FOLD-IN-
FLOOR
REMOVAL
(1) Fold third row seat into floor well.
(2) Using a trim stick, unclip anchor molding (Fig.
110).
(3) Remove third row seat attaching bolts (Fig.
111).
(4) Raise seats to the upright position.
(5) Remove the rear seat lower trim cover (Fig.
112).
(6) Remove rear attaching bolts (Fig. 113).
(7) Remove rear seat from vehicle.
Fig. 109 HEADREST SLEEVES
1 - SLEEVES
Fig. 110 ANCHOR MOLDING
1 - 2-WAY CLIPS INTO SEAT FRAME
2 - 4-WAY LOCATING PINS (2)
3 - FRONT SEAT ANCHOR MOLDING
Fig. 111 THIRD ROW SEATS
1 - ATTACHING BOLTS
RSSEATS23 - 153
HEADREST SLEEVE - THIRD ROW - FOLD-IN-FLOOR (Continued)

(3) Fold the rear seat into the floor well.
(4) Install attaching bolts (Fig. 116). Tighten bolts
to 54 N´m (40 ft. lbs.) torque.
(5) Place the rear seat lower trim cover into posi-
tion and press clips into the lock position (Fig. 117).
(6) Raise third row seat into upright position.
(7) Install lower trim cover with plastic nuts and
tighten them in sequence (Fig. 118).
SEAT BACK COVER/FOAM -
THIRD ROW - FOLD-IN-FLOOR
REMOVAL
(1) Remove seat back panel.
(2) Disengage J-straps (Fig. 119).
(3) Remove seat cover and foam from seat back
frame (Fig. 120).
(4) Separate cover and foam.
Fig. 116 THIRD ROW SEATS
1 - ATTACHING BOLTS
Fig. 117 ANCHOR MOLDING
1 - 2-WAY CLIPS INTO SEAT FRAME
2 - 4-WAY LOCATING PINS (2)
3 - FRONT SEAT ANCHOR MOLDING
Fig. 118 REAR SEAT TRIM COVER
1 - PLASTIC NUTS ON WELD STUDS
2 - LOWER TRIM COVER
Fig. 119 THIRD ROW SEAT BACK
1 - J-STRAPS
RSSEATS23 - 155
SEAT - THIRD ROW - FOLD-IN-FLOOR (Continued)

(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)

(16) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place until urethane cures.
(17) Install A-pillar trim panels.
(18) Install cowl cover and wipers.
(19) Install inside rear view mirror.
(20) After urethane has cured, remove tape strips
and water test windshield to verify repair.SLIDING DOOR GLASS
REMOVAL
The temperature of the vehicle should be at least
21É C (70É F) before removing the stationary quarter/
sliding door glass. Butyl sealer becomes more pliable
at high temperatures.
(1) Remove interior trim as necessary to gain
access attaching locations on back of glass.
(2) Remove nuts holding stationary glass to fence.
(3)
Using razor knife, cut butyl sealer holding glass
to fence from between the mounting studs (Fig. 4).
(4) Push glass from opening.
INSTALLATION
The temperature of the vehicle should be at least
21É C (70É F) before removing the stationary quarter/
sliding door glass. Butyl sealer becomes more pliable
at high temperatures.
The stationary glass fence should be cleaned of all
old butyl sealer.
(1) Applya6mm(0.25 in.) butyl tape around
perimeter of glass assembly encapsulation track.
Ensure that the butyl tape is wrapped around the
mounting studs.
(2) Place the glass into the opening and insert
mounting studs through holes in fence.
(3) Install nuts to hold stationary glass to fence.
CAUTION: Tighten nuts to 3.4 N´m (30 in. lbs.)
torque in the sequence indicated. Do not over
torque, or glass breakage may result (Fig. 4).
(4) Water test before installing interior trim.
(5) Install interior trim. (Refer to 23 - BODY/
DOORS - SLIDING/TRIM PANEL - INSTALLATION)
(6) Verify alignment and flushness.
Fig. 2 WORK SURFACE SET UP AND MOLDING
INSTALLATION
1 - WINDSHIELD AND MOLDINGS
2 - BLOCKS
Fig. 3 LOWER WINDSHIELD INTO POSITION
1 - WINDSHIELD
2 - COMPRESSION SPACERS
Fig. 4 SLIDING DOOR STATIONARY GLASS
1 - NUMBERS INDICATE THE TIGHTENING SEQUENCE
2-6mmBEAD OF BUTYL TAPE
3 - BODY SIDE/SLIDING DOOR GLASS
RSSTATIONARY GLASS23 - 163
WINDSHIELD (Continued)