roof CHRYSLER VOYAGER 1996 User Guide

BODY COMPONENT SERVICE
INDEX
page page
DIAGNOSIS AND TESTING
WATER LEAKS.......................... 23
WIND NOISE........................... 24
SERVICE PROCEDURES
HEAT STAKING......................... 24
REMOVAL AND INSTALLATION
A-PILLAR LOWER EXTENSION TRIM........ 25
A-PILLAR TRIM PANEL................... 25
COWL COVER.......................... 25
COWL TRIM............................ 25
FLOOR CARPET........................ 26
FRONT DOOR APPLIQUE................. 28
FRONT DOOR CHECK STRAP.............. 28
FRONT DOOR FRAME CLOSEOUT MOLDINGS . 29
FRONT DOOR GLASS RUN WEATHER-STRIP . . 30
FRONT DOOR GLASS.................... 29
FRONT DOOR HINGE.................... 30
FRONT DOOR INNER BELT MOLDING....... 31
FRONT DOOR LATCH STRIKER............ 32
FRONT DOOR LATCH.................... 31
FRONT DOOR LOCK CYLINDER............ 32
FRONT DOOR OUTER BELT MOLDING....... 33
FRONT DOOR OUTSIDE HANDLE........... 33
FRONT DOOR REFLECTOR............... 34
FRONT DOOR SILL PLATE................ 34
FRONT DOOR TRIM PANEL................ 34
FRONT DOOR WEATHER-STRIP............ 36
FRONT DOOR WINDOW CRANK............ 36
FRONT DOOR WINDOW REGULATOR....... 36
FRONT DOOR.......................... 27
FRONT SEAT........................... 37
FRONT WHEELHOUSE SPLASH SHIELD..... 37
FUEL FILL DOOR BLOCKER LATCH STRIKER . . 38
FUEL FILL DOOR BLOCKER LATCH......... 38
FUEL FILL DOOR BLOCKER LOCKOUT LINK . . 38
FUEL FILLER HOUSING ± WITH BLOCKER
LATCH .............................. 39
GRILLE............................... 39
HEADLINING........................... 39
HOOD HINGE.......................... 41
HOOD LATCH STRIKER................... 42
HOOD LATCH.......................... 41
HOOD RELEASE CABLE.................. 42
HOOD RELEASE HANDLE................. 42
HOOD................................ 40
JACK STORAGE COVER.................. 43
LEFT D-PILLAR TRIM PANEL............... 43
LEFT QUARTER TRIM PANEL.............. 44
LIFTGATE CHMSL ACCESS PANEL.......... 47
LIFTGATE HINGE........................ 47LIFTGATE LATCH STRIKER................ 47
LIFTGATE LATCH........................ 47
LIFTGATE LOCK CYLINDER............... 48
LIFTGATE OUTSIDE HANDLE.............. 48
LIFTGATE PROP ASSEMBLY............... 49
LIFTGATE SILL PLATE.................... 49
LIFTGATE STABILIZER WEDGE STRIKER..... 49
LIFTGATE STABILIZER WEDGE............. 49
LIFTGATE TRIM PANEL................... 50
LIFTGATE UPPER FRAME MOLDING........ 50
LIFTGATE UPPER FRAME SIDE MOLDINGS . . . 51
LIFTGATE............................. 46
LOWER B-PILLAR TRIM COVER............ 51
LUGGAGE RACK CROSSBAR.............. 51
LUGGAGE RACK RISER COVER............ 52
LUGGAGE RACK SIDE RAIL............... 52
OVERHEAD GRAB-HANDLES.............. 52
QUARTER GLASS....................... 52
QUARTER TRIM BOLSTER................ 53
RADIATOR CLOSURE PANEL CROSSMEMBER . 53
RAIL LAMP MODULE..................... 54
REAR HEADER TRIM..................... 55
REAR HVAC LOUVER AND BEZEL.......... 55
RIGHT D-PILLAR TRIM PANEL.............. 55
RIGHT QUARTER TRIM PANEL............. 56
ROOF APERTURE (RAP) MOLDING.......... 57
SEAT BELT BUCKLE FIRST REAR QUAD
BUCKET............................. 58
SEAT BELT BUCKLE FIRST REAR ± TWO
PASSENGER BENCH................... 58
SEAT BELT BUCKLE SECOND REAR ± THREE
PASSENGER BENCH................... 59
SEAT BELT BUCKLE ± FRONT INBOARD..... 57
SEAT BELT FIRST REAR ANCHOR BRACKET ±
LWB ................................ 59
SEAT BELT FIRST REAR OUTBOARD ± LWB
FOUR DOOR.......................... 60
SEAT BELT FIRST REAR OUTBOARD ± SWB
FOUR DOOR.......................... 60
SEAT BELT LEFT FIRST REAR OUTBOARD ±
LWB THREE DOOR..................... 61
SEAT BELT LEFT FIRST REAR OUTBOARD ±
SWB THREE DOOR.................... 61
SEAT BELT SECOND REAR OUTBOARD ±
SWB ................................ 61
SEAT BELT SECOND RIGHT REAR OUTBOARD
±LWB ............................... 62
SEAT BELT ± OUTBOARD FRONT........... 59
SECOND RIGHT REAR OUTBOARD SEAT BELT
± LWB W/REAR HVAC................... 62
23 - 22 BODYNS

INSTALLATION
(1) Insert link into clip on fuel fill door.
(2) Engage clip to hold link to fuel fill door.
(3) Insert lockout link through grommet in panel
between inner and outer quarter panel.
(4) Close fuel fill door.
(5) Install fuel filler housing to outer quarter
panel.
(6) Verify that all clips on fuel filler housing are
fully engaged to outer quarter panel.
(7) Engage fuel filler lockout link into clip on fuel
fill blocker latch arm.
(8) Install water shield patch covering access hole
in C-pillar.
(9) Install left quarter trim panel.
FUEL FILLER HOUSING ± WITH BLOCKER LATCH
REMOVAL
(1) Remove left quarter trim panel.
(2) Remove water shield patch covering access hole
in C-pillar.
(3) Disengage latch release link from clip on fuel
fill blocker latch arm (Fig. 38).
(4) Open fuel fill door.
(5) Remove screws holding fuel fill neck to fuel
filler housing.
(6) Position fuel fill neck out of the way.
(7) Reaching inside fuel filler housing, release clips
holding housing to quarter panel (Fig. 40).
(8) Remove fuel fill door from vehicle.
(9) Disengage clip holding link to fuel fill door
(Fig. 39).
(10) Remove link from fuel fill door.
INSTALLATION
(1) Install spring to housing and door
(2) Snap door into housing.
(3) Insert lockout link into clip on fuel fill door.
(4) Engage clip to hold link to fuel fill door.(5) Insert lockout link through grommet in panel
between inner and outer quarter panel.
(6) Close fuel fill door.
(7) Install fuel filler housing to outer quarter
panel.
(8) Verify that all clips on fuel filler housing are
fully engaged to outer quarter panel.
(9) Place fuel fill neck in position.
(10) Install screws to hold fuel fill neck to fuel
filler housing.
(11) Engage latch release link into clip on fuel fill
blocker latch arm.
(12) Verify fuel fill blocker latch operation.
(13) Install water shield patch to cover access hole
in C-pillar.
(14) Install left quarter trim panel.
GRILLE
REMOVAL
(1) Remove front fascia. Refer to Group 13, Frame
and Bumpers, for proper procedures.
(2) Disengage clips holding grille to front fascia
(Fig. 41).
(3) Remove plastic rivets holding grille to fascia.
(4) Remove grille from fascia.
INSTALLATION
(1) Position grille on fascia.
(2) Install plastic rivets to hold grille to fascia.
(3) Install clips to hold grille to fascia along bot-
tom of grille.
(4) Install front fascia. Refer to Group 13, Frame
and Bumpers, for proper procedure.
HEADLINING
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.
Fig. 39 Fuel Filler Lockout LinkFig. 40 Fuel Filler Housing and Door
NSBODY 23 - 39
REMOVAL AND INSTALLATION (Continued)

(5) Remove A-pillar trim covers.
(6) Remove B-pillar upper trim covers.
(7) Remove C-pillar upper trim covers.
(8) Remove D-pillar upper trim covers.
(9) Remove rear door opening header trim.
(10) If equipped, remove overhead console.
(11) If equipped, remove reading lamp.
(12) Remove dome lamp.
(13) Remove push-in locking fasteners holding
headlining to rear roof header (Fig. 42) or (Fig. 43).
(14) Remove headlining from roof.
(15) Extract headlining through rear door opening.
INSTALLATION
(1) Insert headlining through rear door opening.
(2) Place headlining in position on roof.
(3) Install left sun visor support.(4) Install push-in locking fasteners to hold head-
lining to rear roof header (Fig. 42) or (Fig. 43).
(5) Install right sun visor support.
(6) Install sun visors and vanity mirrors.
(7) If equipped, install roof rail modules.
(8) If equipped, install coat hooks.
(9) Install dome lamp.
(10) If equipped, install reading lamp.
(11) If equipped, install overhead console.
(12) Install rear door opening header trim.
(13) Install D-pillar upper trim covers.
(14) Install C-pillar upper trim covers.
(15) Install B-pillar upper trim covers.
(16) Install A-pillar trim covers.
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 holding hood to hinge and
loosen the bottom bolts until they can be removed by
hand (Fig. 44).
(4) With assistance from a helper at the opposite
side of the vehicle to support the hood, remove bot-
tom bolts holding hood to hinge.
(5) Remove the hood from the vehicle.
INSTALLATION
(1) Place hood in position on vehicle. With assis-
tance from a helper at the opposite side of the vehicle
Fig. 41 Grille
Fig. 42 Headlining ± SWB
Fig. 43 Headlining ± LWB
23 - 40 BODYNS
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)

(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)

(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)

(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)

(5) If necessary, install screw from inside ash
receiver bezel on left sliding door trim panel.
(6) Install sliding door upper frame molding.
SLIDING DOOR UPPER ROLLER
REMOVAL
(1) Open sliding door, do not latch open.
(2) Remove screw holding upper stop bracket to
upper roller bracket (Fig. 127).
(3) Remove stop bracket from vehicle.
(4) Place a padded block between the open sliding
door and the roof rail.
(5) Mark outline of upper roller bracket on sliding
door.
(6) Remove bolts holding upper roller to sliding
door (Fig. 128).
(7) Remove upper roller from door.
(8) Slide roller out of rear end of roof rail channel.
(9) Remove upper roller from vehicle.
INSTALLATION
(1) Place upper roller in position on vehicle.
(2) Slide roller into rear end of roof rail channel.
(3) Place upper roller in position on door.
(4) Align outline marks on sliding door to upper
roller bracket
(5) Install bolts to hold upper roller to sliding door.
(6) Remove padded block from between sliding
door and roof rail.
(7) Place stop bracket in position on vehicle.
(8) Install screw to hold upper stop bracket to
upper roller bracket.(9) Verify sliding door alignment and operation.
Adjust as necessary.
SLIDING DOOR WEATHER-STRIP
REMOVAL
(1) Open sliding door.
(2) Remove door opening sill plate.
(3) Loosen B-pillar trim covers.
(4) Loosen quarter panel trim panels.
(5) From splice at the bottom center of door open-
ing, pull weather-strip from pinch flange around door
opening.
INSTALLATION
For installation, reverse the above procedures.
STICK-ON BODY SIDE MOLDING
REMOVAL
Refer to (Fig. 129), (Fig. 130), (Fig. 131), (Fig. 132)
or (Fig. 133) for proper location of fasteners holding
the molding to the wheelhouse lip and rocker panels.
(1) Warm the affected stick-on molding and body
metal to approximately 38ÉC (100ÉF) using a suitable
heat lamp or heat gun.
Fig. 126 Sliding Door Trim Panel Screws
Fig. 127 Sliding Door Upper Stop
Fig. 128 Sliding Door Upper Roller
NSBODY 23 - 75
REMOVAL AND INSTALLATION (Continued)