lock CHRYSLER VOYAGER 2005 Service Manual

CARPETS AND FLOOR MATS
REMOVAL
(1) Remove front seats. (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL)
(2) Remove front center console.
(3) Remove heel blocker (plastic block below accel-
erator pedal).
(4) Remove the remaining seats. Refer to the Own-
er's Manual for the proper procedures.
(5) Remove front cowl panels and sill plates.
(6) Remove sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(7) Remove the cargo organizer, if equipped.
(8) Remove liftgate scuff plate. (Refer to 23 -
BODY/INTERIOR/LIFTGATE SCUFF PLATE -
REMOVAL)
(9) Remove lower B-pillar trim covers.
(10) Remove D-pillar trim covers.
(11) Remove Quarter trim panels.
(12) Remove floor escutcheons (Fig. 4).
(13) Remove the floor console trays. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE TRAY -
REMOVAL)
(14) Remove push pin fasteners attaching carpet to
floor in front seat and rear area.
(15) Roll carpet from under instrument panel to
center of sliding door.
(16) Roll and fold carpet forward away from rear
door opening.
(17) Extract carpet through sliding door opening
(Fig. 5).
INSTALLATION
(1) Insert carpet through sliding door opening.
(2) Roll carpet rearward toward rear door opening.
(3) Roll carpet under instrument panel.
(4) Install push pins fasteners through carpet and
grommet into floor to attach carpet to floor in front
seat area (Fig. 5).
(5) Install push pins fasteners in the rear area.
CAUTION: Ensure that the correct fasteners are
installed in the proper locations. Damage to the fuel
tank may result.
(6) Install floor escutcheons (Fig. 4).
(7) Install the floor console trays. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE TRAY -
INSTALLATION)
(8) Install Quarter trim panels.
(9) Install D-pillar trim covers.
(10) Install lower B-pillar trim covers.
(11) Install rear door sill plate.
(12) Install sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(13) Install front cowl panels and sill plates.
(14) Install the passenger seats. Refer to the Own-
er's Manual for proper procedures.
(15) Install front center console.
(16) Install heel blocker (plastic block below accel-
erator pedal).
(17) Install front seats. (Refer to 23 - BODY/
SEATS/SEAT - INSTALLATION)
Fig. 4 SEAT ESCUTCHEONS
1 - SEAT ESCUTCHEON
2 - FLOOR CARPET
Fig. 5 FLOOR CARPET
1 - CARPET LOCATOR GROMMET
2 - PUSH PIN
3 - CARPET
4 - CARPET GROMMET
5 - HEEL PROTECTOR PAD
6 - BODY ASSEMBLY
RSINTERIOR23-81

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

(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)

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
RSINTERIOR23-89

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
RSINTERIOR23-91

INSTALLATION
(1) Insert headlining through liftgate opening (Fig.
23), (Fig. 24), (Fig. 25), and (Fig. 26).
(2) Place headlining in position on roof.
(3) Connect wire connectors.
(4) Install left sun visor support.
(5) Install push in locking fasteners attaching
headlining to rear roof header and bows (Fig. 22).
(6) Install right sun visor support.
(7) Install sun visors and vanity mirrors.
(8) If equipped, install roof rail modules.
(9) If equipped, install coat hooks.
(10) Install dome lamp.
(11) If equipped, install reading lamp.
(12) If equipped, install overhead console.
(13) Install liftgate opening header trim.
(14) Install D-pillar trim covers. (Refer to 23 -
BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL -
INSTALLATION), and (Refer to 23 - BODY/INTERI-
OR/RIGHT D-PILLAR TRIM PANEL - INSTALLA-
TION).(15) Install C-pillar upper trim covers. (Refer to 23
- BODY/INTERIOR/C-PILLAR TRIM - INSTALLA-
TION).
(16) Install B-pillar upper trim covers. (Refer to 23
- BODY/INTERIOR/B-PILLAR UPPER TRIM -
INSTALLATION).
(17) Install A-pillar trim covers. (Refer to 23 -
BODY/INTERIOR/A-PILLAR TRIM - INSTALLA-
TION).
Fig. 23 HEADLINER WITH SIDE CURTAINS
1 - 4-WAY LOCATOR AT FRONT OF HEADLINER
2 - PUSH IN CLIPS ON SUN VISOR RETAINER RACKET AND
TWO SCREWS IN SUN VISOR SWIVEL BRACKET
3 - ONE SCREW IN OVER HEAD CONSOLE
4 - PUSH PINS ATTACHING HEADLINER TO OVERHEAD5-2WAYLOCATOR AT REAR OF HEADLINER
6 - COAT HANGER HOOKS
7 - 2-WAY LOCATORS
8 - WIRE HARNESS
23 - 92 INTERIORRS
HEADLINER (Continued)

INSTALLATION
(1) Place rear tub carpet insert into position on
weld studs (Fig. 30).
(2) Slip carpet edges under quarter trim panel.
(3) Install nuts attaching third row seat lower trim
cover (Fig. 29). Follow the tightening sequence.
(4) Fold third row seats in to floor well.
(5) Install two screws attaching front edge of floor
tub carpet.
(6) Place anchor molding into position push on
clips to lock (Fig. 28).
(7) Remove liftgate sill plate. (Refer to 23 - BODY/
INTERIOR/LIFTGATE SILL PLATE - INSTALLA-
TION).
(8) Close liftgate.
REAR HEADER TRIM
REMOVAL
(1) Disengage hidden clips holding trim to rear
header (Fig. 31).
(2) Separate rear header trim from vehicle.
INSTALLATION
(1) Place rear header trim in position on vehicle.
(2) Align guide pins on trim to holes in header.
(3) Engage hidden clips to hold trim to rear
header.
(4) Engage interlock tabs at D-pillar trim.
REAR HVAC LOUVER
REMOVAL
(1) Using a trim stick (C-4755), pry edge of louver
from bezel.
(2) Remove HVAC louver from bezel.
(3) Using a trim stick, pry lower edge of HVAC
bezel away from headlining (Fig. 32).
(4) Remove louver from vehicle.
Fig. 30 REAR FLOOR TUB CARPET INSERT
1 - REAR TUB
2- TAB ON SIDE OF CARPET IN WHEELHOUSE AREA
3 - REAR TUB CARPET
4 - LOAD THROUGH LIFTGATE OPENING
Fig. 31 REAR HEADER TRIM
1 - REAR HEADER
2 - GUIDE PINS
3 - CLIPS
Fig. 32 REAR HVAC LOUVER
1 - HEVAC DUCT
2 - REAR HEVAC LOUVER
3 - HEADLINING
4 - CLIP
23 - 96 INTERIORRS
REAR FLOOR TUB CARPETS INSERT - FOLD-IN-FLOOR (Continued)

INSTALLATION
(1) Place sill plate in position on vehicle.
(2) Engage hooks to hold outside edge of sill plate
to door sill.
(3) Align guide pins to holes in door sill.
(4) Engage hidden clips to hold sill plate to sliding
door opening sill.
(5) Engage interlock tabs at lower B-pillar and
quarter trim panel.
SUN VISOR
REMOVAL
All vehicles with driver and passenger side air
bags must have a colored coded five Bullet point air
bag warning label applied to the sun visor, verify
label availability and ensure the label is installed.
(1) Disengage sun visor from center support.
(2) Remove screws attaching sun visor to roof
header (Fig. 37).
(3) Remove sun visor from roof.
(4) If equipped, disconnect illuminated vanity mir-
ror wire connector from body harness.
(5) Remove sun visor from vehicle.
INSTALLATION
All vehicles with driver and passenger side air
bags must have a colored coded five Bullet point air
bag warning label applied to the sun visor, verify
label availability and ensure the label is installed.
(1) Place sun visor in position on vehicle.
(2) Connect illuminated vanity mirror wire connec-
tor into body harness.
(3) Place sun visor in position on roof.
(4) Install screws to hold sun visor to roof header
(Fig. 37).
(5) Engage sun visor into center support.
SUN VISOR SUPPORT
REMOVAL
(1) Disengage sun visor from support.
(2) Remove screw holding support to roof header
(Fig. 38).
(3) Remove sun visor support from vehicle.
INSTALLATION
(1) Place sun visor support in position on vehicle.
(2) Install screw holding support to roof header
(Fig. 38).
(3) Engage sun visor into support.
Fig. 36 SLIDING DOOR SILL PLATE
1 - HOOKS
2 - SILL PLATE
3 - CLIPS
4 - SLIDING DOOR SILL
5 - CLIPS
Fig. 37 SUN VISOR
1 - HEADLINING
2 - SUN VISOR
Fig. 38 SUN VISOR SUPPORT
1 - OVERHEAD CONSOLE
2 - SUN VISOR SUPPORT
3 - HEADLINING
RSINTERIOR23-99
SLIDING DOOR SILL PLATE (Continued)

SEAT BASE RISER - SECOND ROW - FOLD-IN-
FLOOR
REMOVAL............................134
INSTALLATION........................135
SEAT CUSHION COVER/FOAM -SECOND ROW
- FOLD-IN-FLOOR
REMOVAL............................136
INSTALLATION........................136
SEAT RECLINER/FORWARD FOLDING
MECHANISM -SECOND ROW -FOLD-IN-
FLOOR
REMOVAL............................137
INSTALLATION........................137
SEAT CUSHION SIDE SHIELD - SECOND ROW
- FOLD-IN-FLOOR
REMOVAL............................138
INSTALLATION........................138
SEAT GAS STRUT - SECOND ROW - FOLD-IN-
FLOOR
REMOVAL............................138
INSTALLATION........................139
SEAT PROP ROD - SECOND ROW - FOLD-IN-
FLOOR
REMOVAL............................139
INSTALLATION........................140
BUCKET SEAT BACK - QUAD BUCKET
REMOVAL............................140
INSTALLATION........................141
QUAD SEAT CUSHION
REMOVAL............................141
INSTALLATION........................141
QUAD BUCKET SEAT SIDE SHIELD/CUP
HOLDER
REMOVAL............................141
INSTALLATION........................142
QUAD BUCKET SEAT SIDE SHIELD - NO CUP
HOLDER
REMOVAL............................143
INSTALLATION........................143
QUAD BUCKET SEAT RISER
REMOVAL............................143
INSTALLATION........................143
BENCH SEAT BACK PANEL
REMOVAL............................143
INSTALLATION........................144
SEAT CUSHION COVER - QUAD BUCKET,
50/50 SPLIT, BENCH
REMOVAL............................144
INSTALLATION........................144
BENCH SEAT RISER - 50/50 SPLIT
REMOVAL............................145
INSTALLATION........................145
BENCH SEAT RISER - SECOND ROW
REMOVAL............................145
INSTALLATION........................145BENCH SEAT RISER - THIRD ROW
REMOVAL............................145
INSTALLATION........................145
SEAT BACK HINGE COVERS - QUAD BUCKET,
50/50 SPLIT, BENCH
REMOVAL............................146
INSTALLATION........................146
BENCH SEAT BACK HINGE
REMOVAL............................146
INSTALLATION
INSTALLATION......................146
SYNCHRONIZING CABLE ADJUSTMENT . . 147
BENCH SEAT BACK
REMOVAL............................147
INSTALLATION........................147
BENCH SEAT BACK COVER
REMOVAL............................148
INSTALLATION........................148
BENCH SEAT TRACK
REMOVAL............................148
INSTALLATION........................148
PLASTIC GROCERY BAG RETAINER
REMOVAL............................149
INSTALLATION........................149
UNDER SEAT STORAGE BIN
REMOVAL............................149
INSTALLATION........................149
UNDER SEAT STORAGE BIN GUIDE
REMOVAL............................150
INSTALLATION........................150
UNDER SEAT STORAGE BIN LOCK/LATCH
REMOVAL............................150
INSTALLATION........................150
LUMBAR SUPPORT
REMOVAL............................150
INSTALLATION........................150
SEAT RISER LATCH LOCKING LINK
REMOVAL............................151
INSTALLATION........................151
QUAD BUCKET SEAT SIDE SHIELD/CUP
HOLDER - FLAP AND SPRING ASSEMBLY
REMOVAL............................151
INSTALLATION........................151
BOTTOM OF SEAT CUSHION PAN PANEL-
THIRD ROW - FOLD-IN-FLOOR
REMOVAL............................152
INSTALLATION........................152
HEADREST SLEEVE - THIRD ROW - FOLD-IN-
FLOOR
REMOVAL............................152
INSTALLATION........................153
SEAT - THIRD ROW - FOLD-IN-FLOOR
REMOVAL............................153
INSTALLATION........................154
RSSEATS23 - 103