Chrysler Town, Dodge Caravan. Manual - part 448

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. 19).

(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 to

remove 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. 20).

(1) Remove the air exhauster from the hole in the

lower aperture panel.

Fig. 19 AIR EXHAUSTER - SWB

1 - LOWER APERTURE PANEL
2 - AIR EXHAUSTER

Fig. 20 AIR EXHAUSTER - LWB

1 - AIR EXHAUSTER
2 - PLUG
3 - LOWER APERTURE PANEL

23 - 56

EXTERIOR

LUGGAGE RACK CROSSBAR (Continued)

INSTALLATION

SHORT WHEELBASE

(1) Position the air exhauster to the hole in the

lower aperture panel (Fig. 19).

(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

(1) Position the air exhauster to the hole in the

lower aperture panel (Fig. 20).

(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 21° C (70° F) to avoid damag-
ing the RAP moldings.

(1) Warm the affected stick-on molding and body

metal to approximately 38° C (100° 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-Brite™ 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 21° C (70° 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 Mopar

t Super

Kleen solvent, or equivalent.

adhesive) tape to back of molding.
(2) Clean body surface with Mopar

t Super 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. 21).

(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. 21).

(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)

EXTERIOR

23 - 57

REAR QUARTER PANEL/FENDER AIR EXHAUSTER (Continued)

SIDE VIEW MIRROR GLASS

REMOVAL

WARNING: ALWAYS WEAR EYE AND HAND PRO-
TECTION WHEN SERVICING THE MIRROR ASSEM-
BLY. FAILURE TO OBSERVE THESE WARNINGS
MAY RESULT IN PERSONAL INJURY FROM BRO-
KEN GLASS.

(1) Carefully pull/pry the broken glass holder from

the mirror assembly.

(2) Disconnect the heated mirror electrical connec-

tors from the terminals on the mirror glass holder, if
equipped.

INSTALLATION

CAUTION: It is important to make sure the motor is
square to the glass holder (attaching fingers) prior
to glass holder attachment, otherwise the glass
holder could be installed incorrectly causing poor
retention and possible repeat failure.

(1) Position the new mirror glass holder to the

mirror assembly.

NOTE: Position the mirror glass holder so that the
moisture drain hole on the mirror glass holder
assembly is facing downward.

(2) Align the mirror glass holder’s attaching fin-

gers to the mirror motor housing.

NOTE: Ensure that the protective rubber cover of
the mirror motor housing is positioned correctly
around the bottom of the fingers area.

(3) Using one hand, firmly press the mirror glass

holder assembly into place while at the same time
supporting the housing assembly from the backside
with the other hand.

NOTE: Pressure must be applied equally over the
center portion of the mirror to engage the mirror
glass holder’s attaching fingers to the correspond-
ing fingers on the housing assembly. One or more
clicks may be heard when finger engagement takes
place.

(4) Verify retention of the mirror glass holder

assembly by gently pulling outward on the mirror
glass holder.

Fig. 21 SIDE VIEW MIRROR

1 - MIRROR
2 - MIRROR TRIM COVER
3 - A-PILLAR
4 - BOLTS

23 - 58

EXTERIOR

SIDE VIEW MIRROR (Continued)

HOOD

TABLE OF CONTENTS

page

HINGE

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 59

HOOD

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 60

LATCH

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 60

LATCH RELEASE CABLE

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 61

LATCH STRIKER

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 61

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

HOOD

23 - 59

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