CHRYSLER VOYAGER 2005 Service Manual

CARPETS - FOLD-IN-FLOOR
REMOVAL
(1) Remove floor mats.
(2) Remove front seats. (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL)
(3) Remove instrument panel lower console. (Refer
to 23 - BODY/INSTRUMENT PANEL/STORAGE
BIN - REMOVAL).
(4) Remove the floor console base tray and discon-
nect wire connector from the base tray.(Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE BASE TRAY -
REMOVAL)
(5) Remove heel blocker (plastic block below accel-
erator pedal).
(6) Remove winch plug (spare tire winch) (Fig. 6).
(7) Remove front cowl panels and sill plates.
(8) Remove kick plate and heel pad at gas pedal
(9) Remove seat belt anchors at the passenger side
B-pillar and driver side C-pillars
(10) Fold in floor second and third row seats. Refer
to the Owner's Manual for the proper procedures.
(11) Remove front carpet trim ring and cover (Fig.
7)(Refer to 23 - BODY/INTERIOR/CARPETS ANDFLOOR MATS - REMOVAL). (Refer to 23 - BODY/
INTERIOR/CARPETS TRIM RING AND COVER
REMOVAL).
Fig. 6 ACCESS TO WINCH
1 - WINCH PLUG
2 - ACCESS HOLE TO WINCH
Fig. 7 FRONT TRIM RING AND COVER ASSEMBLY
1 - FORWARD 4-WAY LOCATOR
2 - REARWARD 2-WAY LOCATOR
3 - LOAD FLOOR PLUG (8)4 - WELD STUD NUTS (10)
5 - TRIM RING COVER
23 - 82 INTERIORRS

(12) Remove sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(13) Remove lower B-pillar trim covers.
(14) Remove push pin fasteners attaching carpet to
floor in front seat area.
(15) Roll carpet from under instrument panel to
center of sliding door.
(16) Pull carpet out from under the quarter trim
panel (Fig. 8).
(17) Using a trim stick, release clips attaching
third row carpet cover, and remove (Fig. 9).
(18) Remove rear carpet screws attaching rear of
carpet.
(19) Roll and fold carpet forward away from rear
door opening.
(20) Remove carpet through sliding door opening.
INSTALLATION
(1) Place carpet through sliding door opening into
position.
(2) Roll carpet rearward towards the rear door
opening.
Fig. 8 FRONT FLOOR CARPET
FRONT CARPET
Fig. 9 ANCHOR MOLDING
1 - 2-WAY CLIPS INTO SEAT FRAME
2 - 4-WAY LOCATING PINS (2)
3 - FRONT SEAT ANCHOR MOLDING
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CARPETS - FOLD-IN-FLOOR (Continued)

(3) Roll carpet forward under instrument panel
(Fig. 8).
(4) Install push pins fasteners through carpet and
grommet into floor to attach carpet to floor in front
seat area.
(5) Pull wire harnesses through the carpet as
needed.
(6) Smooth out the carpet and allowing weld studs
to go all the way through the carpet.
(7) Install rear push pins fasteners attaching rear
of carpet.
(8) Place third row carpet cover into position and
press clips into position (Fig. 9).
(9) Slide the carpet under the quarter trim panel
into position.
(10) Install lower B-pillar trim covers.
(11) Install sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION).
(12) Install front carpet trim ring and cover (Fig.
7). (Refer to 23 - BODY/INTERIOR/CARPETS TRIM
RING AND COVER - INSTALLATION)
(13) Install seat belt anchors at the passenger side
B-pillar and driver side C-pillars
(14) Install kick plate and heel pad at the gas
pedal
(15) Install winch plug (spare tire winch) (Fig. 6).
(16) Install front cowl panels and sill plates.
(17) Install heel blocker (plastic block below accel-
erator pedal).
(18) Install the floor console base tray and discon-
nect wire connector from the base tray. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE BASE TRAY -
INSTALLATION).
(19) Install instrument panel lower console. (Refer
to 23 - BODY/INSTRUMENT PANEL/STORAGE
BIN - INSTALLATION).
(20) Install front seats. (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL).
(21) Install floor mats.CARPET TRIM RING AND
COVER - FOLD-IN-FLOOR
REMOVAL
(1) Move front seats to the full forward position.
(2) Fold the second row seats into the floor.
(3) Remove the load floor plugs (Fig. 10).
(4) Remove the ten weld nuts.
(5) Open door covers (Fig. 11).
(6) Remove the four inter weld nuts (Fig. 12).
(7) Raise the front trim ring and cover up off of
the weld studs and remove from vehicle.
INSTALLATION
(1) Place front trim ring and cover assembly into
position.
(2) Open door covers (Fig. 11).
(3) Install the four inter weld nuts (Fig. 12).
(4) Close door covers.
(5) Install the ten weld nuts (Fig. 10).
(6) Install the eight load floor plugs.
(7) Open the second row seats into position.
(8) Move front seats to the position.
23 - 84 INTERIORRS
CARPETS - FOLD-IN-FLOOR (Continued)

Fig. 10 FRONT TRIM RING AND COVER ASSEMBLY
1 - FORWARD 4-WAY LOCATOR
2 - REARWARD 2-WAY LOCATOR
3 - LOAD FLOOR PLUG (8)4 - WELD STUD NUTS (10)
5 - TRIM RING COVER
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CARPET TRIM RING AND COVER - FOLD-IN-FLOOR (Continued)

Fig. 11 DOOR COVER
1 - PROP ROD
2 - DOOR COVER ASSEMBLY3 - FINGER END OF PROP ROD AND PLACE INTO BRACKET
23 - 86 INTERIORRS
COWL TRIM (Continued)

Fig. 12 FRONT COVER ASSEMBLY
1 - SEATS IN THE FOLD-IN-FLOOR POSITION
2 - INTER WELD NUTS (4)3 - ISO DOOR
4 - TEATHER STRAP TO OPEN MID & REAR DOORS
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COWL TRIM (Continued)

COWL TRIM
REMOVAL
(1) Remove door sill plate.
(2) Disengage hidden clips holding cowl trim to
cowl panel (Fig. 13).
(3) Remove cowl trim from vehicle.
INSTALLATION
(1) Place cowl trim panel in position on vehicle
(Fig. 1).
(2) Engage hidden clips attaching cowl trim to
cowl panel.
(3) Install door sill plate.
C-PILLAR TRIM
REMOVAL
(1) Remove quarter trim panel.
(2) Remove seat belt turning loop from height
adjuster.
(3) Remove screw attaching C-pillar trim panel to
C-pillar (Fig. 14).
(4) Disengage hidden clips attaching trim to upper
C-pillar.
(5) Remove upper C-pillar trim from vehicle.
INSTALLATION
(1) Place upper C-pillar trim in position on vehicle
(Fig. 14).
(2) Engage hidden clips attaching trim to upper
C-pillar.
(3) Install screw attaching C-pillar trim panel to
C-pillar.
(4) Install seat belt turning loop onto height
adjuster. Tighten all seat belt bolts to 39 N´m (29 ft.
lbs.) torque.
(5) Install quarter trim panel.
Fig. 13 COWL TRIM
1 - INSTRUMENT PANEL
2 - CLIPS
3 - COWL TRIM
4 - COWLFig. 14 C-PILLAR
1 - C-PILLAR TRIM PANEL
2 - C-PILLAR
23 - 88 INTERIORRS

DOOR SILL TRIM PLATE
REMOVAL
(1) Using trim stick (C-4755), disengage hidden
clips holding door sill plate from door sill.
(2) Remove sill plate from vehicle (Fig. 15).
INSTALLATION
(1) Place sill plate in position on vehicle (Fig. 15).
(2) Align interlock tabs at front and rear to mating
trim.
(3) Engage hidden clips to hold door sill plate to
door sill.
FLOOR CONSOLE BASE TRAY
REMOVAL
(1) Remove the floor carpet. (Refer to 23 - BODY/
INTERIOR/CARPETS AND FLOOR MATS -
REMOVAL)
(2) Disconnect the electrical connector.
(3) Remove the four screws and remove the base
tray.
INSTALLATION
(1) Place the base tray into position and connect
the wire connector.
(2) Install the four screws attaching base tray.
(3) Install the floor console.
FLOOR CONSOLE - FOLD-IN-
FLOOR
REMOVAL
(1) Open floor console door and storage bin can be
lifted out of the console (Fig. 16).
(2) The floor console inner mat is just laying in the
bottom of the console. It can be removed by pulling
the mat upwards and out.
(3) The power outlet cover is snap into the console.
It can be removed by pulling upward on the inner
edge of the power cover to release it.
(4) The cell phone holder can be removed by com-
pressing the two legs towards each other and remov-
ing phone holder from the console housing (Fig. 17).
INSTALLATION
(1) Compress the legs on the cell phone holder and
place into position (Fig. 17).
(2) Place power outlet cover into position and snap
into position.
(3) Set mat into console housing and lay into posi-
tion.
(4) Set storage bin into console housing and close
door. (Fig. 16).
Fig. 15 DOOR SILL PLATE
1 - CLIPS
2 - SLIDING DOOR SILL TRIM PLATE
3 - FRONT DOOR SILL TRIM PLATE
Fig. 16 FLOOR CONSOLE
1 - POWER OUTLET COVER
2 - FLOOR CONSOLE INNER MAT
3 - STORAGE BIN
4 - FLOOR CONSOLE
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FLOOR CONSOLE KEY LOCK
TUMBLER - FOLD-IN-FLOOR
REMOVAL
(1) The key lock tumbler may be removed by
depressing the tab on the lock cylinder with a stiff
wire, to release the lock tumbler.
(2) Pull key and lock tumbler from the lock cylin-
der.
INSTALLATION
(1) Place lock tumbler and key into the lock cylin-
der and push tumbler in until it lock into position.
FLOOR CONSOLE LID LATCH -
FOLD-IN-FLOOR
REMOVAL
(1) Open floor console door and remove the three
screws attaching door to the hinge.
(2) Remove the six screws attaching inner door
panel, and separate inner panel from outer (Fig. 18).
(3) Remove two screws attaching lock cylinder to
door, and remove lock cylinder.
(4) Remove lock latch and handle as necessary
(Fig. 19).
INSTALLATION
(1) Place lock latch and door release handle into
position (Fig. 19).(2) Place lock cylinder into position. Install two
screws attaching lock cylinder (Fig. 18).
(3) Place the inner and outer door panels together.
Install six screws attaching door panels.
(4) Place door panel into position, and install the
three screws attaching door to the hinge.
Fig. 17 CELL PHONE HOLDER
1 - COMPRESS LEGS TO RELEASE
2 - CELL PHONE HOLDER
3 - FLOOR CONSOLE
Fig. 18 DOOR LATCH
1 - LOCK LATCH
2 - CONSOLE DOOR RELEASE HANDLE
3 - LOCK CYLINDER
Fig. 19 FLOOR CONSOLE DOOR
1 - INNER DOOR PANEL
2 - LOCK LATCH
3 - CONSOLE DOOR RELEASE HANDLE
4 - OUTER DOOR PANEL
23 - 90 INTERIORRS
FLOOR CONSOLE - FOLD-IN-FLOOR (Continued)

HEADLINER
REMOVAL
(1) Remove sun visors and vanity mirrors.
(2) Remove sun visor center supports.
(3) If equipped, remove coat hooks.
(4) If equipped, remove roof rail modules.
(5) Remove A-pillar trim covers. (Refer to 23 -
BODY/INTERIOR/A-PILLAR TRIM - REMOVAL).
(6) Remove B-pillar upper trim covers (Fig. 20).
(Refer to 23 - BODY/INTERIOR/B-PILLAR UPPER
TRIM - REMOVAL).
(7) Remove C-pillar upper trim covers (Fig. 21).
(Refer to 23 - BODY/INTERIOR/C-PILLAR TRIM -
REMOVAL).
(8) Remove D-pillar trim covers. (Refer to 23 -
BODY/INTERIOR/RIGHT D-PILLAR TRIM PANEL -
REMOVAL) and (Refer to 23 - BODY/INTERIOR/
LEFT D-PILLAR TRIM PANEL - REMOVAL).
(9) Remove liftgate opening header trim.
(10) If equipped, remove overhead console screws.
(11) If equipped, remove reading lamps.
(12) Remove dome lamp.
(13) Remove push in locking fasteners attaching
headlining to rear roof header and roof bows (Fig.
22).(14) Remove wiring connections.
(15) Remove headlining from roof (Fig. 23), (Fig.
24), (Fig. 25), and (Fig. 26).
(16) Extract headlining through liftgate opening.
Fig. 20 HEADLINER AT B-PILLAR
1 - FRONT AND SLIDING DOOR WEATHERSTRIP SEAL
2 - B-PILLAR UPPER TRIM PANEL
Fig. 21 HEADLINER AT C-PILLAR
1 - SLIDING DOOR WEATHERSTRIP
2 - C-PILLAR UPPER TRIM PANEL
3 - REAR QUARTER WINDOW OPENING WEATHERSTRIP
Fig. 22 HEADLINER PUSH PINS
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