CHRYSLER VOYAGER 1996 Service Manual

(2) Engage hidden clips to hold molding to liftgate
upper frame (Fig. 66).
LIFTGATE UPPER FRAME SIDE MOLDINGS
REMOVAL
(1) Remove liftgate upper frame molding.
(2) Disengage hidden clips holding side moldings
to liftgate upper frame (Fig. 66).
(3) Remove liftgate upper frame side molding from
vehicle.
INSTALLATION
(1) Place liftgate upper frame side moldings in
position on vehicle.
(2) Engage hidden clips to hold side moldings to
liftgate upper frame (Fig. 66).
(3) Install liftgate upper frame molding.
LOWER B-PILLAR TRIM COVER
REMOVAL
(1) Slide lower seat belt cover rearward to expose
anchor bolt.
(2) Remove bolt holding lower seat belt anchor to
floor.
(3) Remove upper B-pillar trim cover.
(4) Remove access panel from B-pillar trim (Fig.
67).
(5) Remove screw holding lower trim cover to
B-pillar from below seat belt retractor.
(6) Disengage hidden clips holding lower trim
cover to B-pillar.
(7) Remove lower B-pillar trim cover from vehicle.
INSTALLATION
(1) Place lower B-pillar trim cover in position on
vehicle.
(2) Insert seat belt through hole in lower B-pillar
trim.
(3) Engage hidden clips to hold lower trim cover to
B-pillar.
(4) Install screw to hold lower trim cover to B-pil-
lar below seat belt retractor.
(5) Install access cover.
(6) Install upper B-pillar trim cover.
(7) Place seat belt anchor in position on floor so
webbing is pointed rearward and slightly outboard.
(8) Install bolt to hold lower seat belt anchor to
floor. Tighten all seat belt bolts to 39 N´m (29 in.
lbs.) torque.
(9) Verify that seat belt anchor does not interfere
with seat track travel.
LUGGAGE RACK CROSSBAR
REMOVAL
(1) Remove luggage rack front riser covers.
(2) Disengage lock and slide crossbar forward into
notch in front riser (Fig. 68).
(3) Remove crossbar from roof.
Fig. 67 Lower B-pillar Trim Cover
Fig. 68 Luggage Rack Crossbar
NSBODY 23 - 51
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place crossbar in position on roof.
(2) Engage crossbar into notch in front riser.
(3) Slide crossbar rearward into desired position.
(4) Install luggage rack front riser covers.
LUGGAGE RACK RISER COVER
REMOVAL
(1) Disengage lock tabs holding luggage rack front
riser cover to riser.
(2) Remove cover from riser (Fig. 69).
INSTALLATION
(1) Place cover in position on luggage rack riser.
(2) Engage lock tabs to holding luggage rack front
riser cover to riser.
LUGGAGE RACK SIDE RAIL
REMOVAL
(1) Remove luggage rack front riser covers.
(2) Remove crossbars.
(3) Remove screws attaching side rail to front riser
and roof panel (Fig. 70).
(4) Remove screws attaching side rail to center
riser and roof panel.
(5) Remove screws attaching side rail to rear riser
and roof panel (Fig. 71).
(6) Remove side rail from vehicle.
INSTALLATION
(1) Place side rail in position on vehicle.
(2) Install screws to attach side rail to rear riser
and roof panel.
(3) Install screws to attach side rail to center riser
and roof panel.
(4) Install screws to attach side rail to front riser
and roof panel.
(5) Install crossbars.
(6) Install luggage rack front riser covers.
OVERHEAD GRAB-HANDLES
REMOVAL
(1) Using a trim stick (C-4755), remove screw
access covers from grab-handle.
(2) Remove screws holding grab-handle to roof rail.
(3) Remove grab-handle from vehicle.
INSTALLATION
(1) Place grab-handle in position on vehicle.
(2) Install screws to hold grab-handle to roof rail.
(3) Install screw access covers into grab-handle.
QUARTER GLASS
REMOVAL
(1) Remove C-pillar trim.
(2) Open quarter glass to vent position.
(3) Remove screw attaching quarter window
retainer to vent motor arm.
(4) Disengage quarter window retainer from vent
motor arm.
Fig. 69 Luggage Rack Riser Cover
Fig. 70 Luggage Rack Front Riser
Fig. 71 Luggage Rack Rear Riser
23 - 52 BODYNS
REMOVAL AND INSTALLATION (Continued)

(5) Remove nuts holding quarter glass to C-pillar
(Fig. 72).
(6) Remove quarter glass from vehicle.
INSTALLATION
(1) Place quarter glass in position on vehicle.
(2) Install nuts to attach quarter glass to C-pillar.
(3) Engage quarter window retainer to vent motor
arm.
(4) Install screw holding quarter window retainer
to vent motor arm.
(5) Close quarter glass.
(6) Install C-pillar trim.
QUARTER TRIM BOLSTER
The speaker grille in the quarter trim bolster is
not removable. The trim bolster must removed to ser-
vice the speaker.
REMOVAL
(1) Disengage hidden clips holding trim bolster to
quarter trim panel (Fig. 73) and (Fig. 74).
(2) Disengage hook retainer holding front of trim
bolster to quarter trim panel, if applicable (Fig. 73).
(3) Remove quarter trim bolster from vehicle.
INSTALLATION
(1) Place quarter trim bolster in position on vehi-
cle.
(2) Engage hook retainer to hold front of trim bol-
ster to quarter trim panel, if applicable.
(3) Engage hidden clips to hold trim bolster to
quarter trim panel.
RADIATOR CLOSURE PANEL CROSSMEMBER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching hood latch to cross-
member and position latch out of the way.(3) Remove radiator sight shield.
(4) Remove engine air inlet resonator.
(5) Remove bolt holding air cleaner housing to
crossmember.
(6) Remove screw holding coolant recovery bottle
to crossmember.
(7) Remove bolts holding radiator isolators to
crossmember.
(8) Remove bolts holding ends of crossmember to
radiator closure panel (Fig. 75).
(9) Lift crossmember upward and away from radi-
ator closure panel.
(10) Remove crossmember from vehicle.
INSTALLATION
(1) Place radiator closure panel crossmember in
position on vehicle.
(2) Insert ends of crossmember between layered
metal sections of radiator closure panel at each side
of radiator.
Fig. 72 Quarter Glass
Fig. 73 Left Quarter Trim Bolster ± LWB Four Door
Fig. 74 Left Quarter Trim Bolster ± SWB and LWB
Three Door
NSBODY 23 - 53
REMOVAL AND INSTALLATION (Continued)

(3) Install bolts to hold ends of crossmember to
radiator closure panel (Fig. 75).
(4) Install bolts to hold radiator isolators to cross-
member.
(5) Install screw to hold coolant recovery bottle to
crossmember.
(6) Install bolt to hold air cleaner housing to cross-
member.
(7) Install engine air inlet resonator.
(8) Install radiator sight shield.
(9) Align hood latch by placing latch over netpierce
tabs. If alignment is required, flatten tabs.
(10) Install bolts to hold hood latch to crossmem-
ber.
(11) Verify hood latch operation and hood align-
ment.
RAIL LAMP MODULE
WITHOUT REAR HVAC
REMOVAL
(1) Pull coat hook open.
(2) Remove screw attaching rail lamp module to
roof rail.
(3) Remove rail lamp module from headlining (Fig.
76).
(4) Disconnect wire connector from body wiring
harness.
(5) Remove rail lamp module from vehicle.
INSTALLATION
(1) Position rail lamp module in vehicle.
(2) Connect wire connector to body wiring harness.
(3) Position rail lamp module to headlining.
(4) Install screw attaching module to roof rail
inside coat hook.
WITH REAR HVAC
REMOVAL
(1) Pull coat hook open.
(2) Remove screw attaching rail lamp module to
roof rail inside coat hook (Fig. 77).
(3) Remove screws attaching rail lamp module to
roof rail from behind grab handle.
(4) Remove rail lamp module from headlining.
(5) Disconnect wire connector from body wiring
harness.
(6) Remove rail lamp module from vehicle.
INSTALLATION
(1) Position rail lamp module to vehicle.
(2) Connect wire connector to body wiring harness.
(3) Position rail lamp module to headlining.
(4) Install screws to attach rail lamp module to
roof rail behind grab handle.
(5) Install screw to attach rail lamp module to roof
rail inside coat hook.
Fig. 75 Radiator Closure Panel CrossmemberFig. 76 Rail Lamp Module ± w/o Rear HVAC
Fig. 77 Rail Lamp Module ± w/Rear HVAC
23 - 54 BODYNS
REMOVAL AND INSTALLATION (Continued)

REAR HVAC LOUVER AND BEZEL
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. 78).
(4) Remove louver from vehicle.
INSTALLATION
(1) Place bezel in position in HVAC duct opening.
(2) Push inward on bezel until clips snap in place.
Verify that all four clips have been engaged to the
bezel and that the bezel is flush to the headlining
(3) Position HVAC louver to bezel.
(4) Snap both ends of the louver into HVAC bezel.
REAR HEADER TRIM
REMOVAL
(1) Disengage hidden clips holding trim to rear
header (Fig. 79).
(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.
RIGHT 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, if
equipped, anchor to quarter on short wheel base
vehicle.
(5) Remove quarter trim bolster on short wheel
base vehicle.
(6) Remove screws holding trim panel to attaching
bracket on short wheel base vehicle (Fig. 80).
(7) Disengage hidden clips holding trim to D-pillar
(Fig. 80), (Fig. 81), and (Fig. 82).
(8) Remove D-pillar trim panel from D-pillar.
(9) Disconnect speaker wire connector, if equipped.
(10) P
ass second rear seat belt, if equipped, through
slot in trim panel on short wheel base vehicle.
(11) Remove D-pillar trim from vehicle.
INSTALLATION
(1) Position D-pillar trim on vehicle.
(2) Pass second rear seat belt, if equipped, through
slot in trim panel on short wheel base vehicle.
(3) Connect speaker wire connector to speaker, if
equipped.
(4) Align locating pins on backside of trim panel to
mating holes in D-pillar.
(5) Engage hidden clips to hold trim to D-pillar.
(6) Install screws to hold trim panel to attaching
bracket on short wheel base vehicle.
(7) Install quarter trim bolster on short wheel base
vehicle.
(8) Install bolt to attach second rear seat belt, if
equipped, anchor to quarter on short wheel base
vehicle. Tighten all seat belt bolts to 39 N´m (29 in.
lbs.) torque.
(9) Install second rear seat belt turning loop on
long wheel base vehicle.
(10) Install liftgate sill plate.
(11) Install rear header trim cover.
Fig. 78 Rear HVAC Louver
Fig. 79 Rear Header Trim
NSBODY 23 - 55
REMOVAL AND INSTALLATION (Continued)

RIGHT QUARTER TRIM PANEL
REMOVAL
CAUTION: Disconnect the battery negative cable.
Damage to accessory feed circuit can result.
(1) Remove first rear seat.
(2) Remove second rear seat, if equipped.
(3) Remove sliding door sill trim panel.
(4) Remove quarter trim bolster.
(5) Remove C-pillar trim panel.
(6) Remove D-pillar trim panel.
(7) Remove first rear seat belt anchor.
(8) Remove second rear seat belt anchor on long
wheel base vehicle.
(9) Remove screws holding quarter trim to quarter
panel from bolster area.
(10) Remove screws holding rear edge of quarter
trim to attaching bracket.
(11) Disengage hidden clips holding front of quar-
ter trim to quarter panel rearward of sliding door
opening.
(12) Remove quarter trim from quarter panel.
(13) Disconnect wire connector from accessory
power outlet, if equipped.(14) Pass second rear seat belt through slot in trim
panel on long wheel base vehicle.
(15) Pass first rear seat belt through slot in trim
panel.
(16) Remove quarter trim panel from vehicle.
INSTALLATION
(1) Position quarter trim panel on vehicle.
(2) Pass first rear seat belt through slot in trim
panel.
(3) Pass second rear seat belt through access hole
in trim panel on long wheel base vehicle.
(4) Connect wire connector into accessory power
outlet, if equipped.
(5) Align locating pins on backside of trim panel to
mating holes in inner quarter panel.
(6) Engage hidden clips to hold front of quarter
trim to quarter panel rearward of sliding door open-
ing.
(7) Install screws to hold rear edge of quarter trim
to attaching bracket.
(8) Install screws to hold quarter trim to inner
quarter panel in bolster area.
(9) Install second rear seat belt anchor on long
wheel base vehicle. Tighten all seat belt bolts to 39
N´m (29 in. lbs.) torque.
Fig. 80 Right Quarter and D-Pillar Trim Panels ± SWB
23 - 56 BODYNS
REMOVAL AND INSTALLATION (Continued)

(10) Install first rear seat belt anchor.
(11) Install D-pillar trim panel.
(12) Install C-pillar trim panel.
(13) Install quarter trim bolster.
(14) Install sliding door sill trim panel.
(15) Install second rear seat, if equipped.
(16) Install first rear seat.
(17) Connect the battery negative cable.
ROOF APERTURE (RAP) MOLDING
The RAP molding is set with body side molding
tape. The temperature in the work area and the vehi-
cle should be at least 21É C (70É F) to avoid damag-
ing the RAP moldings.
REMOVAL
(1) Warm the affected stick-on molding and body
metal to approximately 38É C (100É 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-BriteyMolding
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
(1) If molding is to be reused;
(a) Remove tape residue from molding.
(b) Clean back of molding with MopartSuper
Kleen solvent, or equivalent.
(c) Wipe molding dry with lint free cloth.
(d) Apply new body side molding (two sided
adhesive) tape to back of molding.
(2) Clean body surface with MopartSuper 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.
SEAT BELT BUCKLE ± FRONT INBOARD
REMOVAL
(1) Remove screws holding front inboard side cover
to seat cushion frame.
(2) Remove side cover from vehicle.
(3) Remove bolt holding seat belt buckle to front
seat track (Fig. 83).
Fig. 81 Right Quarter and D-Pillar Trim Panels ± LWB without Rear A\C
NSBODY 23 - 57
REMOVAL AND INSTALLATION (Continued)

(4) Remove buckle from vehicle.INSTALLATION
For installation, reverse the above procedures.
Tighten seat belt anchor bolts to 39 N´m (29 ft. lbs.)
torque.
SEAT BELT BUCKLE FIRST REAR ± TWO
PASSENGER BENCH
REMOVAL
(1) Remove seat from vehicle. Refer to Owner's
Manual for proper procedures.
(2) Remove bolt attaching inboard seat belt/buckle
to seat frame (Fig. 84).
(3) Remove belt from seat.
INSTALLATION
For installation, reverse the above procedures.
Tighten all seat belt anchor bolts to 39 N´m (29 ft.
lbs.) torque.
SEAT BELT BUCKLE FIRST REAR QUAD BUCKET
REMOVAL
(1) Remove seat from vehicle. Refer to Owner's
Manual for proper procedures.
(2) Remove screws attaching inboard side cover to
seat cushion.
Fig. 82 Right Quarter and D-Pillar Trim Panels ± LWB with Rear A\C
Fig. 83 Seat Belt Buckle ± Front Inboard
23 - 58 BODYNS
REMOVAL AND INSTALLATION (Continued)

(3) Remove side cover from seat.
(4) Remove bolts attaching recliner bracket to seat
cushion.
(5) Remove recliner bracket from seat.
(6) Remove bolt attaching seat belt buckle to seat
track (Fig. 83).
(7) Remove buckle from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Tighten all seat belt anchor bolts to 39 N´m (29 ft.
lbs.) torque.
SEAT BELT BUCKLE SECOND REAR ± THREE
PASSENGER BENCH
REMOVAL
(1) Remove bolt attaching seat belt buckle to seat
rear frame rail (Fig. 85).
(2) Remove seat belt buckle from seat.
INSTALLATION
(1) Place seat belt buckle in position on seat.
(2) Install bolt to attach seat belt buckle to seat
rear frame rail. Tighten all seat belt bolts to 39 N´m
(29 ft. lbs.) torque.
SEAT BELT ± OUTBOARD FRONT
REMOVAL
(1) Remove shoulder harness height adjuster knob
by pulling it straight away from adjuster.
(2) Remove cover from seat belt turning loop.
(3) Remove bolt holding turning loop to shoulder
belt height adjuster (Fig. 86).
(4) Remove turning loop from B-pillar.
(5) Remove lower B-pillar trim cover or quarter
trim panel on three door left side.
(6) Remove bolt holding seat belt retractor to
B-pillar (Fig. 86).
(7) Lift retractor upward and disengage arrow
head retainer holding retractor to B-pillar.
(8) Remove seat belt from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Tighten all seat belt anchor bolts to 39 N´m (29 ft.
lbs.) torque.
SEAT BELT FIRST REAR ANCHOR BRACKET ± LWB
REMOVAL
(1) Remove lower quarter trim panel.
(2) Remove bolt holding first rear seat belt anchor
bracket to floor.
(3) Remove bracket from vehicle.
INSTALLATION
(1) Position bracket to vehicle.
(2) Install bolt holding first rear seat belt anchor
bracket to floor.
(3) Install lower quarter trim panel.
Fig. 84 Seat Belt Buckle First Rear ± Two Passenger
Bench
Fig. 85 Seat Belt Buckle Second Rear ± Three
Passenger Bench
Fig. 86 Seat Belt ± Outboard Front
NSBODY 23 - 59
REMOVAL AND INSTALLATION (Continued)

NOTE: The tightening specification for all seat belt
anchor bolts is 39 N´m (29 ft. lbs.) torque.
SEAT BELT FIRST REAR OUTBOARD ± LWB FOUR
DOOR
REMOVAL
(1) Remove first and second rear seats. Refer to
Owner's manual for proper procedures.
(2) Remove shoulder harness height adjuster knob
by pulling it straight away from adjuster.
(3) Slide floor anchor cover from over the anchor
bolt.
(4) Remove floor anchor bolt.
(5) Remove anchor from floor.
(6) Open clam shell cover from over seat belt turn-
ing loop.
(7) Remove bolt holding turning loop to shoulder
belt height adjuster.
(8) Remove turning loop from C-pillar.
(9) Remove lower quarter trim panel.
(10) Route seat belt webbing and turning loop
through access hole in lower quarter trim panel.
(11) Remove bolt holding seat belt retractor to
quarter panel.
(12) Lift retractor upward and disengage arrow
head retainer holding retractor to quarter panel.
(13) Remove seat belt from vehicle.
INSTALLATION
(1) Position seat belt to vehicle.
(2) Install arrow head retainer to quarter panel
and push downward to seat retainer.
(3) Install bolt holding seat belt retractor to quar-
ter panel.
(4) Route seat belt webbing and turning loop
through access hole in lower quarter trim panel.
(5) Install lower quarter trim panel.
(6) Position turning loop to C-pillar.
(7) Install bolt holding turning loop to shoulder
belt height adjuster.
(8) Close clam shell cover from over seat belt turn-
ing loop.
(9) Position anchor to floor.
(10) Install floor anchor bolt.
(11) Slide floor anchor cover over the anchor bolt.
(12) Install shoulder harness height adjuster knob
by pushing it straight onto adjuster.
(13) Install first and second rear seats. Refer to
Owner's manual for proper procedures.
NOTE: The tightening specification for all seat belt
anchor bolts is 39 N´m (29 ft. lbs.) torque.
SEAT BELT FIRST REAR OUTBOARD ± SWB FOUR
DOOR
REMOVAL
(1) Remove first and second rear seats. Refer to
Owner's manual for proper procedures.
(2) Remove shoulder harness height adjuster knob
by pulling it straight away from adjuster.
(3) Slide floor anchor cover from over the anchor
bolt.
(4) Remove floor anchor bolt (Fig. 87).
(5) Remove anchor from floor.
(6) Open clam shell cover from over seat belt turn-
ing loop.
(7) Remove bolt attaching turning loop to shoulder
belt height adjuster (Fig. 87).
(8) Remove turning loop from C-pillar.
(9) Remove lower quarter trim panel.
(10) Route seat belt webbing and turning loop
through access hole in lower quarter trim panel.
(11) Remove bolt holding seat belt retractor to
quarter panel (Fig. 87).
(12) Lift retractor upward and disengage arrow
head retainer holding retractor to quarter panel.
(13) Remove seat belt from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Tighten seat belt anchor bolts to 39 N´m (29 ft. lbs.)
torque.
Fig. 87 Seat Belt First Rear Outboard ± SWB Four
Door
23 - 60 BODYNS
REMOVAL AND INSTALLATION (Continued)