CHRYSLER VOYAGER 1996 Service Manual

to support the hood, install bottom bolts to hold hood
to hinge finger tight.
(2) Install top bolts to hold hood to hinge finger
tight.
(3) Position bolts at marks and tighten bolts. The
hood should be aligned to 4 mm (0.160 in.) gap to the
front fenders and flush across the top surfaces along
fenders.
(4) Verify hood operation and alignment.
HOOD HINGE
REMOVAL
(1) Remove hood.
(2) Remove wiper unit. Refer to Group 8K, Wind-
shield Wipers and Washers, for procedure.
(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 bolts attaching body half of hood hinge
to front fender flange and remove hinge from vehicle
(Fig. 45).
INSTALLATION
(1) If necessary, paint new hinge before installa-
tion.
(2) Place body half of hood hinge in position on
vehicle.
(3) Install bolts to hold hood hinge to front fender
flange.
(4) Install wiper unit. Refer to Group 8K, Wind-
shield Wipers and Washers, for proper procedures.
(5) Install hood.
(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.
HOOD LATCH
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts holding hood latch to radiator clo-
sure panel crossmember (Fig. 46).
(3) Remove hood latch from crossmember.
(4) Disconnect hood release cable from hood latch
(Fig. 47).
(5) Remove hood latch from vehicle.
INSTALLATION
(1) Position hood latch on vehicle.
(2) Connect hood release cable from hood latch.
(3) Position hood latch on crossmember.
(4) Align hood latch by placing latch over net-
pierced tabs. If alignment is required, flatten tabs.
(5) Install bolts attaching hood latch to radiator
closure panel crossmember.
(6) Verify hood operation and alignment. Adjust as
necessary.
Fig. 44 HoodFig. 45 Hood Hinge
Fig. 46 Hood Latch
NSBODY 23 - 41
REMOVAL AND INSTALLATION (Continued)

(7) Tighten attaching bolts to 11 to 16 N´m (100 to
140 in. lbs.) torque.
HOOD LATCH STRIKER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts holding striker to inside of hood
(Fig. 44).
(3) Remove hood latch striker from vehicle.
INSTALLATION
(1) Position hood latch striker on vehicle.
(2) Install bolts to hold hood latch striker to hood.
(3) Align hood latch striker to engage smoothly
into hood latch.
(4) Verify hood operation and alignment. Adjust as
necessary.
(5) Tighten attaching bolts to 11 to 16 N´m (100 to
140 in. lbs.) torque.
HOOD RELEASE CABLE
REMOVAL
(1) Remove hood latch.
(2) Disengage cable end from hood latch locking
mechanism.
(3) Slide cable case end sideways in keyhole slot of
hood latch while pinching barb on cable case closed.
(4) Remove cable from latch (Fig. 47).
(5) Remove hood release handle from instrument
panel.
(6) Disengage rubber grommet cable insulator
from hole in dash panel.
(7) Attach a suitable length of mechanic's wire to
latch end of cable to assist cable installation.
(8) Route cable back from latch through engine
compartment toward dash panel near power brake
booster (Fig. 48).
(9) Remove attaching clips from cable case.
(10) From inside vehicle, pull cable through dash
panel until mechanic's wire is exposed.
(11) Disconnect cable from mechanic's wire.(12) Remove hood release cable from vehicle.
INSTALLATION
(1) Place hood release cable in position under
instrument panel.
(2) Attach latch end of hood release cable to
mechanic's wire protruding through dash panel.
(3) Route cable forward through engine compart-
ment toward latch by pulling on mechanic's wire
(Fig. 48).
(4) Disconnect mechanic's wire from cable.
(5) Engage rubber grommet cable insulator into
hole in dash panel.
(6) Install hood release handle into instrument
panel.
(7) Place cable in position on latch.
(8) Slide cable case end sideways into keyhole slot
of hood latch.
(9) Engage cable end into hood latch locking mech-
anism.
(10) Install hood latch.
(11) Install attaching clips to cable case and install
clips into original holes in strut tower, fender, head-
lamp area, and radiator closure panel crossmember.
HOOD RELEASE HANDLE
REMOVAL
(1) Remove lower steering column cover and knee
blocker reinforcement. Refer to Group 8E, Instru-
ment Panel and Systems for proper procedures.
(2) Remove hood latch cable.
(3) Remove screws holding hood latch release han-
dle to instrument panel brace (Fig. 49).
(4) Remove hood latch release handle from vehicle.
INSTALLATION
(1) Position hood latch release handle on vehicle.
(2) Install screws to hold hood latch release handle
to instrument panel brace.
Fig. 47 Hood Release Cable End Attachment
Fig. 48 Hood Release Cable Routing
23 - 42 BODYNS
REMOVAL AND INSTALLATION (Continued)

(3) Install hood latch cable.
(4) Install lower steering column cover and knee
blocker reinforcement.
JACK STORAGE COVER
LONG WHEEL BASE
REMOVAL
(1) Depress latch handle at top of jack storage
cover (Fig. 50).
(2) Pull outward at top of cover to disengage latch.
(3) Remove jack storage cover from vehicle.
INSTALLATION
(1) Place jack storage cover in position on vehicle.
(2) Align guide pins.
(3) Push inward at top of cover to engage latch
and fastener.
SHORT WHEEL BASE
REMOVAL
(1) Open quarter panel bin storage cover.
(2) Lift upward and rearward on jack storage cover
retaining latch to disengage (Fig. 51).
(3) Remove jack storage cover from vehicle.
INSTALLATION
(1) Position jack storage cover to vehicle.
(2) Snap storage cover latch into position on quar-
ter trim panel.
(3) Close quarter trim panel bin storage cover.
LEFT D-PILLAR TRIM PANEL
REMOVAL
(1) Remove rear header trim cover.
(2) Remove liftgate sill plate.
(3) Remove second rear seat belt turning loop on
long wheel base vehicle.
(4) Remove bolt holding second rear seat belt
lower anchor to quarter on short wheel base vehicle.
(5) Remove jack storage cover.
(6) Remove screws holding trim panel to D-pillar
(Fig. 52), (Fig. 53), and (Fig. 54).
(7) Disengage hidden clips holding trim to D-pillar.
(8) Disconnect speaker wire connector, if equipped.
(9) Pass seat belt through slot in D-pillar trim
panel on short wheel base vehicle.
(10) Remove D-pillar trim from vehicle.
INSTALLATION
(1) Pass seat belt through slot in D-pillar trim
panel on short wheel base vehicle.
(2) Position D-pillar trim panel on vehicle.
Fig. 49 Hood Release Handle
Fig. 50 Jack Storage Cover ± LWB
Fig. 51 Jack Storage Cover ± SWB
NSBODY 23 - 43
REMOVAL AND INSTALLATION (Continued)

(3) Connect speaker wire connector to speaker, if
equipped.
(4) Align locating pins on backside of trim panel to
mating holes in inner quarter panel.
(5) Engage hidden clips to hold trim to D-pillar.
(6) Install screws to hold trim to D-pillar.
(7) Install jack storage cover.
(8) Install bolt to hold second rear seat belt lower
anchor to quarter on short wheel base vehicle.
Tighten all seat belt bolts to 39 N´m (29 in. lbs.).
(9) Install second rear seat belt turning loop on
long wheel base vehicle.
(10) Install liftgate sill plate.
(11) Install rear header trim cover.
LEFT QUARTER TRIM PANEL
REMOVAL
CAUTION: Disconnect the negative cable clamp
from battery post. Damage to accessory feed circuit
can result.
(1) Remove first rear seat.
(2) Remove second rear seat, if equipped.
(3) Remove front door sill plate on three door vehi-
cle.(4) Remove sliding door sill plate on four door
vehicle.
(5) Remove left quarter trim bolster.
(6) Remove upper left B-pillar trim on three door
vehicle.
(7) Remove C-pillar trim panel.
(8) Remove left D-pillar trim panel.
(9) Remove first rear seat belt anchor.
(10) Remove second rear seat belt anchor on long
wheel base vehicle.
(11) Remove left front seat belt opening bezel from
quarter trim on three door vehicle.
(12) Remove screws holding quarter trim to quar-
ter panel in B-pillar area on three door vehicle (Fig.
52) and (Fig. 54).
(13) Remove screws holding quarter trim to quar-
ter panel from bolster area (Fig. 52), (Fig. 53), and
(Fig. 54).
(14) Remove screws holding rear edge of quarter
trim to attaching bracket or inner quarter trim
panel.
(15) Remove screws holding top of trim panel to
inner sheet metal between B-pillar and C-pillar on
three door vehicle.
(16) Disconnect wire connector from accessory
power outlet, if equipped.
(17) Remove quarter trim from quarter panel.
Fig. 52 Left Quarter and D-Pillar Trim Panels ± LWB 3 Door
23 - 44 BODYNS
REMOVAL AND INSTALLATION (Continued)

(18) Pass front seat belt and turning loop through
slot in quarter trim panel on three door vehicle.
(19) Pass first rear seat belt through slot in quar-
ter trim panel.
(20) Pass second rear seat belt, if equipped,
through slot in quarter trim panel on long wheel
base vehicle.
(21) Remove quarter trim panel from vehicle.
INSTALLATION
(1) Position quarter trim panel on vehicle.
(2) Pass second rear seat belt, if equipped, through
slot in quarter trim panel on long wheel base vehicle.
(3) Pass first rear seat belt through slot in quarter
trim panel.
(4) Pass front seat belt through slot in quarter
trim panel on three door vehicle.
(5) Connect wire connector into accessory power
outlet, if equipped.
(6) Align locating pins on backside of trim panel to
mating holes in inner panels.
(7) Position quarter trim panel on inner quarter
panel.
(8) Install screws to hold top of trim panel to inner
sheet metal between B-pillar and C-pillar on three
door vehicle.(9) Install screws to hold rear edge of quarter trim
to attaching bracket or inner quarter panel.
(10) Install screws to hold quarter trim to inner
quarter panel in bolster area.
(11) Install screws to hold quarter trim to inner
quarter panel in B-pillar area on three door vehicle.
(12) Install left front seat belt opening bezel into
quarter trim on three door vehicle.
(13) Install second rear seat belts anchor on long
wheel base vehicle. Tighten all seat belt bolts to 39
N´m (28 in. lbs.) torque.
(14) Install first rear seat belt anchor.
(15) Install left D-pillar trim panel.
(16) Install C-pillar trim panel.
(17) Install upper left B-pillar trim on three door
vehicle.
(18) Install left quarter trim bolster.
(19) Install front door sill plate on three door vehi-
cle.
(20) Install sliding door sill plate on four door
vehicle.
(21) Install second rear seat, if equipped.
(22) Install first rear seat.
(23) Connect the battery negative cable.
Fig. 53 Left Quarter and D-Pillar Trim Panels ± LWB Four Door
NSBODY 23 - 45
REMOVAL AND INSTALLATION (Continued)

LIFTGATE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Remove screws holding liftgate wire connector
to rear header.
(3) Disconnect liftgate wire harness from body
wire harness.
(4) Remove liftgate upper frame molding.
(5) Disconnect rear window washer hose from
spray nozzle.
(6) Support liftgate on a suitable lifting device.
(7) Remove screws holding support cylinders to
liftgate.
(8) Remove bolts holding liftgate hinge to roof
header (Fig. 55).
(9) With assistance, remove liftgate from vehicle.
INSTALLATION
(1) With assistance, place liftgate in position on
vehicle.
(2) Install bolts to hold liftgate hinge to roof
header.
(3) Install screws to hold support cylinders to lift-
gate.
(4) Remove lifting device from under liftgate.(5) Connect liftgate wire harness into body wire
harness.
(6) Install screws to holding wire connector to rear
header.
(7) Connect rear window washer hose onto spray
nozzle.
(8) Install liftgate upper frame molding.
Fig. 54 Left Quarter and D-Pillar Trim Panels ± SWB
Fig. 55 Liftgate
23 - 46 BODYNS
REMOVAL AND INSTALLATION (Continued)

(9) Verify liftgate alignment. The liftgate should
have a gap to adjacent panels and fit flush across the
gaps. The gap is;
²7 mm (0.280 in.) to the fascia,
²6 mm (0.240 in.) to the roof,
²4 mm (0.160 in.) to the aperture.
LIFTGATE CHMSL ACCESS PANEL
REMOVAL
(1) Using a trim stick (C-4755), disengage clips
holding CHMSL access panel to liftgate trim panel.
(2) Remove access panel from vehicle.
INSTALLATION
(1) Place access panel in position on vehicle.
(2) Engage clips to hold CHMSL access panel to
liftgate trim panel.
LIFTGATE HINGE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device.
(3) Apply several layers of duct tape on the outside
of to roof across the gap to the lift gate to hold the
liftgate in position.
(4) Remove bolts holding liftgate hinge to roof
header.
(5) Remove bolts holding hinge to liftgate (Fig. 56).
(6) Remove hinge from vehicle.
INSTALLATION
(1) If necessary, paint replacement hinge before
installation.
(2) Place hinge in position on vehicle.
(3) Align hinge to marks on liftgate.
(4) Install bolts to hold hinge to liftgate (Fig. 56).
(5) Align hinge to marks on roof header.(6) Install bolts to hold liftgate hinge to roof
header.
(7) Remove duct tape from roof and liftgate.
(8) Support liftgate on a suitable lifting device.
(9) Verify liftgate alignment. Refer to Liftgate
Remove and Installation for proper gap measure-
ments.
LIFTGATE LATCH
REMOVAL
(1) Remove liftgate trim panel.
(2) Disengage outside handle link from clip on
latch.
(3) Disconnect wire connector from liftgate ajar
switch (Fig. 57).
(4) Remove screws holding latch to liftgate.
(5) Remove latch from vehicle.
INSTALLATION
(1) Place latch in position on vehicle.
(2) Install screws to hold latch to liftgate.
(3) Pull downward on outside handle link and
engage link to clip on latch.
(4) Connect wire connector to liftgate ajar switch.
(5) Verify liftgate fit and operation. Adjust as nec-
essary.
(6) Install liftgate trim panel.
LIFTGATE LATCH STRIKER
REMOVAL
(1) Open liftgate.
(2) Mark outline of striker on sill to aid installa-
tion.
(3) Remove screws attaching striker to sill (Fig.
58).
(4) Remove striker from vehicle.
Fig. 56 Liftgate Hinge
Fig. 57 Liftgate Latch
NSBODY 23 - 47
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place striker in position on vehicle.
(2) Align striker to outline mark on sill.
(3) Install screws to attach striker to sill.
(4) Verify liftgate alignment and operation.
LIFTGATE LOCK CYLINDER
REMOVAL
NOTE: Do not remove E-clip.
(1) Remove outside liftgate handle.
(2) Remove lock cylinder clip from handle (Fig. 59).
(3) Remove lock cylinder and arm from handle.
INSTALLATION
(1) Install lock cylinder clip into liftgate handle.
(2) Push lock cylinder into handle until clip
engages groove in lock cylinder with an audible click
(Fig. 60).
(3) Install outside liftgate handle.
(4) Verify lock cylinder operation.
LIFTGATE OUTSIDE HANDLE
REMOVAL
(1) Remove liftgate trim panel.
(2) Remove power lock motor.
(3) Disengage outside handle link from clip on lift-
gate latch.
(4) Disconnect VTSS switch from back of lock cyl-
inder, if equipped.
(5) Disengage lock link, if equipped.
(6) Remove nut attaching outside liftgate handle to
liftgate (Fig. 61).
(7) Disengage retaining groove holding handle to
liftgate.
(8) Remove outside liftgate handle and links from
vehicle.
INSTALLATION
(1) Position outside liftgate handle and links on
vehicle.
(2) Engage retaining groove to hold handle to lift-
gate by pushing handle to the right for centering.
(3) Install nut to attach outside liftgate handle to
liftgate.
Fig. 58 Liftgate Latch Striker
Fig. 59 Lock Cylinder Removal
Fig. 60 Lock Cylinder Installation
23 - 48 BODYNS
REMOVAL AND INSTALLATION (Continued)

(4) Connect VTSS switch from back of lock cylin-
der, if equipped.
(5) Engage outside handle link to clip on liftgate
latch.
(6) Install lock link, if equipped.
(7) Install power lock motor.
(8) Verify liftgate operation. Adjust as necessary.
(9) Install liftgate trim panel.
LIFTGATE PROP ASSEMBLY
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device.
(3) Pull liftgate opening weatherstrip from D-pillar
flange next to prop assembly end pivot.
(4) Remove bolt holding end pivot to D-pillar (Fig.
62).
(5) Remove bolt holding prop assembly to liftgate.
(6) Remove prop assembly from vehicle.
INSTALLATION
For installation, reverse the above procedures.
LIFTGATE SILL PLATE
REMOVAL
(1) Disengage hidden clips holding sill plate to lift-
gate door opening sill (Fig. 63).
(2) Remove sill plate from vehicle.
INSTALLATION
(1) Place sill plate in position on vehicle.
(2) Align locator rib into recess in liftgate sill.
(3) Engage hidden clips to hold sill plate to liftgate
door opening sill.
LIFTGATE STABILIZER WEDGE
REMOVAL
(1) Open liftgate.
(2) Mark outline of stabilizer wedge on liftgate to
aid installation.
(3) Remove rivets attaching wedge to liftgate (Fig.
64).
(4) Remove wedge from vehicle.
INSTALLATION
(1) Position stabilizer wedge on vehicle.
(2) Align stabilizer wedge to outline previously
made on liftgate.
(3) Install rivet to hold wedge to liftgate.
(4) Verify liftgate fit and operation. Adjust as nec-
essary.
LIFTGATE STABILIZER WEDGE STRIKER
REMOVAL
(1) Open liftgate.
Fig. 61 Liftgate Outside HandleFig. 62 Liftgate Prop Assembly
Fig. 63 Liftgate Sill Plate
NSBODY 23 - 49
REMOVAL AND INSTALLATION (Continued)

(2) Remove screws attaching stabilizer wedge
striker to D-pillar (Fig. 65).
(3) Retrieve shims from between wedge striker and
D-pillar, if necessary.
(4) Remove wedge striker from vehicle.
INSTALLATION
(1) Position wedge striker on vehicle.
(2) Install any shims previously retrieved from
between wedge striker and D-pillar or add shims to
ensure proper contact.
(3) Install screws attaching stabilizer wedge
striker to D-pillar (Fig. 65).
LIFTGATE TRIM PANEL
REMOVAL
(1) Remove liftgate upper frame molding.
(2) Remove upper frame side moldings.
(3) Remove screws holding assist handle to liftgate
and fasteners around the perimeter of the lower trim
panel.(4) If equipped, using a trim stick (C-4755), pry
courtesy lamps from liftgate trim.
(5) Disconnect wire connector from lamp.
(6) Remove CHMSL cover and fasteners holding
the trim panel.
(7) Disengage hidden clips holding trim panel to
liftgate from around perimeter or liftgate (Fig. 66).
(8) Remove liftgate trim panel from vehicle.
INSTALLATION
(1) Place liftgate trim panel in position on vehicle.
(2) Engage hidden clips to hold trim panel to lift-
gate and fasteners around perimeter of liftgate (Fig.
66).
(3) Install fasteners into trim brackets and install
CHMSL cover.
(4) Connect wire connector into lamp.
(5) Install courtesy lamps into liftgate trim.
(6) Install screws to hold assist handle to liftgate.
(7) Install upper frame side moldings.
(8) Install liftgate upper frame molding.
LIFTGATE UPPER FRAME MOLDING
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Disengage hidden clips holding molding to lift-
gate upper frame (Fig. 66).
(3) Remove liftgate upper molding from vehicle.
INSTALLATION
(1) Place liftgate upper molding in position on
vehicle.
Fig. 64 Liftgate Wedge
Fig. 65 Liftgate Wedge Striker
Fig. 66 Liftgate Trim
23 - 50 BODYNS
REMOVAL AND INSTALLATION (Continued)