wheel bolts CHRYSLER VOYAGER 2001 Service Manual

(2) Install andlightly tightenthe three remain-
ing wheel mounting nuts, securing the wheel cover in
place (Fig. 25).
(3) Tighten all five wheel mounting nuts in the
proper sequence (Fig. 28). Tighten wheel nuts to a
torque of 135 N´m (100 ft. lbs.).
WHEEL MOUNTING STUDS -
FRONT
REMOVAL
CAUTION: If a wheel mounting stud needs to be
replaced in the hub and bearing assembly, the
studs MUST NOT be hammered out of the hub
flange. If a stud is removed by hammering it out of
the bearing flange, damage to the hub and bearing
assembly will occur leading to premature bearing
failure.
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the front wheel and tire assembly from
the vehicle.
(3) Remove the two adapter mounting bolts secur-
ing both the disc brake caliper adapter to the steer-
ing knuckle (Fig. 29).
(4) Remove the disc brake caliper and adapter as
an assembly from the steering knuckle (Fig. 29).
Hang the assembly out of the way using wire or a
bungee cord. Use care not to overextend the brake
hose when doing this.
(5) Remove brake rotor from hub by pulling it
straight off wheel mounting studs (Fig. 29).
(6) On the wheel mounting stud to be removed,
install a wheel mounting (lug) nut far enough so the
threads on the stud are even with end of nut. Install
Remover, Special Tool C-4150A on hub and bearing
assembly flange and wheel stud (Fig. 30).
(7) Tighten down on special tool, pushing wheel
stud out of the hub flange. When shoulder of wheel
stud is past flange, remove special tool from hub and
bearing. Remove nut from stud and remove stud
from hub flange.
Fig. 26 Two Wheel Mounting Nuts Installed
1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
Fig. 27 Wheel Cover Installation Over Two Nuts
1 - RETAINING TABS
2 - VALVE STEM
3 - BOLT-ON WHEEL COVER
Fig. 28 Nut Tightening Sequence
RSTIRES/WHEELS22-15
WHEEL COVER (Continued)

INSTALLATION
(1) Install replacement wheel stud into flange of
hub and bearing assembly. Install washers on wheel
stud, then install a wheel mounting (lug) nut on stud
with flat side of lug nut against washers as shown
(Fig. 31).
(2) Tighten the nut, pulling the wheel stud into
the flange of the hub and bearing. When the head ofthe stud is fully seated against the rear of the hub
flange, remove nut and washers from stud.
(3) Install the brake rotor back on the hub and
bearing (Fig. 29).
(4) Install brake caliper and adapter back over
brake rotor aligning adapter with mounting holes on
steering knuckle (Fig. 29).
(5) Install the two adapter mounting bolts securing
the adapter to the steering knuckle. Tighten the
mounting bolts to 169 N´m (125 ft. lbs.) torque.
(6) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting lug nuts in proper
sequence until all nuts are torqued to half specifica-
tion, then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(7) Lower vehicle to the ground.
WHEEL MOUNTING STUDS -
REAR
REMOVAL
CAUTION: If a wheel attaching stud needs to be
replaced in the hub and bearing assembly the studs
MUST NOT be hammered out of the hub flange. If a
stud is removed by hammering it out of the bearing
flange, damage to the hub and bearing assembly
will occur leading to premature hub and bearing
failure.
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
Fig. 29 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
Fig. 30 Wheel Stud Removal (Typical)
1 - WHEEL MOUNTING (LUG) NUT
2 - HUB AND BEARING ASSEMBLY
3 - SPECIAL TOOL C-4150A
4 - STEERING KNUCKLE
5 - WHEEL STUD
Fig. 31 Installing Wheel Stud (Typical)
1 - WASHERS
2 - HUB AND BEARING ASSEMBLY
3 - WHEEL MOUNTING (LUG) NUT
4 - STEERING KNUCKLE
22 - 16 TIRES/WHEELSRS
WHEEL MOUNTING STUDS - FRONT (Continued)

INSTALLATION
(1) Position check strap on door through speaker
hole.
(2) Install nuts to attach check strap to door end
frame. Tighten nuts to 12 N´m (105 in. lbs.) torque.
(3) Install bolts to attach check strap to A-pillar.
(4) Install door speaker, if equipped.
(5) Install front door trim panel.
DOOR
REMOVAL
(1) Remove front wheelhouse splash shield. (Refer
to 23 - BODY/EXTERIOR/LF WHEELHOUSE
SPLASH SHIELD - REMOVAL)
(2) Disengage clips attaching door harness wire
connector to inner fender brace.
(3) Disconnect positive lock slide on the side of the
wire connectors (Fig. 3).
(4) Depress lock tab attaching wire connector
halves together.
(5) Disconnect door harness from body wiring har-
ness.
Fig. 3 Front Door Wire Connectors
1 - LOCK TAB
2 - POSITIVE LOCK
3 - BODY HARNESS CONNECTOR
4 - FRONT FENDER
5 - DOOR HARNESS CONNECTOR
6 - BODY HARNESS
Fig. 1 Front Door Applique
1 - GLASS RUN WEATHERSTRIP
2 - CLIPS
3 - APPLIQUE
4 - FRONT DOOR
Fig. 2 Front Door Check Strap
1 - FRONT DOOR
2 - DOOR CHECK STRAP
RSDOOR - FRONT23 - 153
CHECK STRAP (Continued)

(6) Remove bolts attaching door check strap to
A-pillar (Fig. 4).
(7) Support door on suitable lifting device.
(8) Remove bolts attaching lower hinge to door end
frame (Fig. 5).
(9) Steady door on lifting device and remove bolts
attaching upper hinge to door end frame.
(10) Remove door from vehicle.
INSTALLATION
NOTE: If new hinge pins are to be used, verify that
the knurling on the hinge pin is aligned with the
knurling on in the door hinge prior to driving in the
pin. Also, verify that the hinge pin is fully seated to
the door hinge and a new retaining clip is installed.
(1) Support door on suitable lifting device.(2) Position door to vehicle. Verify net pierce nub-
bin is engaged if reusing original hinges.
(3) Steady door on lifting device and install bolts
attaching upper hinge to door end frame. Tighten
bolts to 34 N´m (25 ft. lbs.) torque.
(4) Install bolts attaching door check strap to
A-pillar. Tighten bolts to 12 N´m (105 in. lbs.) torque.
(5) Install bolts attaching lower hinge to door end
frame. Tighten bolts to 34 N´m (25 ft. lbs.) torque.
Align door to achieve equal spacing to surrounding
body panels. Panels should be flush across all gaps.
(6) Connect door harness into body wiring harness.
(7) Connect positive lock slide on the side of the
wire connectors.
(8) Connect clips attaching door harness wire con-
nector to inner fender brace.
(9) Install front wheelhouse splash shield.
(10) Verify door operation and alignment. Adjust
as necessary.
Fig. 4 Front Door ± Hinge Pin Removal
1 - FRONT DOOR
2 - CLIP
3 - A-PILLAR
4 - HINGE PIN
5 - CLIP
6 - DOOR CHECK STRAP
Fig. 5 Front Door ± Hinge Bolt Removal
1 - FRONT DOOR
2 - UPPER HINGE
3 - CHECK STRAP
4 - LOWER HINGE
23 - 154 DOOR - FRONTRS
DOOR (Continued)

(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.
GRILLE OPENING
REINFORCEMENT
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 hood cable.
(6) Remove hood prop rod.
(7) Remove screw attaching coolant recovery bottle
to crossmember.
(8) Remove bolts attaching radiator isolators to
crossmember.
(9) Remove bolts attaching ends of crossmember to
radiator closure panel (Fig. 14) .
(10) Lift crossmember upward and away from
radiator closure panel.
(11) 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.
(3) Align with paint breaks around bolt heads.
(4) Install bolts attaching ends of crossmember to
radiator closure panel (Fig. 14) . Tighten bolts to 19
N´m (14 ft. lbs.) torque.
(5) Install bolts attaching radiator isolators to
crossmember.
(6) Install screw attaching coolant recovery bottle
to crossmember.
(7) Install bolt attaching air cleaner housing to
crossmember.
(8) Install engine air inlet resonator.
(9) Install radiator sight shield.
(10) Install hood prop rod.
(11) Align hood latch by placing latch over net
pierce tabs. If alignment is required, flatten tabs.
(12) Install bolts attaching hood latch to cross-
member. Tighten bolts to 13.5 N´m (10 ft. lbs.)
torque.
(13) Verify hood latch operation and hood align-
ment.
FRONT WHEELHOUSE
SPLASH SHIELD
REMOVAL
(1) Hoist and support vehicle on safety stands.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE)
(2) Remove front wheel. Refer to section 22, Tires/
Wheels, for recommended procedures.
(3) Remove push-in fasteners holding splash shield
to frame rail forward of suspension.
(4) Remove push-in fasteners holding splash shield
to frame rail rearward of suspension.
(5) Remove screws holding wheelhouse splash
shield to front fender.
(6) Remove splash shield from vehicle (Fig. 15).
Fig. 14 Radiator Closure Panel Crossmember
1 - RADIATOR CLOSURE PANEL CROSSMEMBER
2 - FRONT FASCIA
23 - 194 EXTERIORRS
FUEL FILL DOOR BLOCKER LOCKOUT LINK (Continued)

INSTALLATION
LONG WHEEL BASE
(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
(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 row seat belt turning loop on
long wheel base vehicle.
(4) Remove bolt attaching second row seat belt
lower anchor to quarter on short wheel base vehicle.
(5) Remove jack storage cover.
(6) Remove screws attaching trim panel to D-pil-
lar.
(7) Disengage hidden clips attaching trim to D-pil-
lar.
(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.
(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 attaching trim to D-pillar.
(6) Install screws attaching trim to D-pillar.
(7) Install jack storage cover.
(8) Install bolt attaching second row seat belt
lower anchor to quarter on short wheel base vehicle.
Tighten all seat belt bolts to 39 N´m (29 ft. lbs.).
(9) Install second row seat belt turning loop on
long wheel base vehicle.
(10) Install liftgate sill plate.
(11) Install rear header trim cover.
LIFTGATE SCUFF PLATE
REMOVAL
(1) Disengage hidden clips holding sill plate to lift-
gate door opening sill (Fig. 11) .
(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.
QUARTER TRIM BOLSTER
REMOVAL
The speaker grille in the quarter trim bolster is
not removable. The trim bolster must removed to ser-
vice the speaker.
(1) Disengage hidden clips attaching trim bolster
to quarter trim panel.
(2) Disengage hook retainer attaching front of trim
bolster to quarter trim panel, if applicable.
(3) Remove quarter trim bolster from vehicle.
INSTALLATION
The speaker grille in the quarter trim bolster is
not removable. The trim bolster must removed to ser-
vice the speaker.
(1) Place quarter trim bolster in position on vehi-
cle.
(2) Engage hook retainer attaching front of trim
bolster to quarter trim panel, if applicable.
(3) Engage hidden clips attaching trim bolster to
quarter trim panel.
Fig. 11 Liftgate Sill Plate
1 - LIFTGATE SILL PLATE
2 - LIFTGATE SILL
23 - 214 INTERIORRS
JACK STORAGE COVER (Continued)

RIGHT QUARTER TRIM PANEL
REMOVAL
CAUTION: Disconnect the battery negative cable.
Damage to accessory feed circuit can result.
(1) Remove first row seat.
(2) Remove second row 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 row seat belt anchor.
(8) Remove second row seat belt anchor on long
wheel base vehicle.
(9) Remove screws attaching quarter trim to quar-
ter panel from bolster area.
(10) Remove screws attaching 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 row seat belt through slot in trim
panel on long wheel base vehicle.
(15) Pass first row 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 row seat belt through slot in trim
panel.
(3) Pass second row 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 attaching front of quarter
trim to quarter panel rearward of sliding door open-
ing.
(7) Install screws attaching rear edge of quarter
trim to attaching bracket.
(8) Install screws attaching quarter trim to inner
quarter panel in bolster area.
(9) Install second row seat belt anchor on long
wheel base vehicle. Tighten all seat belt bolts to 39
N´m (29 ft. lbs.) torque.
(10) Install first row 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 row seat, if equipped.
(16) Install first row seat.
(17) Connect the battery negative cable.
LEFT QUARTER TRIM PANEL
REMOVAL
CAUTION: Disconnect the negative cable clamp
from battery post. Damage to accessory feed circuit
can result.
(1) Remove first row seat.
(2) Remove second row seat, if equipped.
(3)
Remove front door sill plate on three door vehicle.
(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 row seat belt anchor.
(10) Remove second row 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 attaching quarter trim to
quarter panel in B-pillar area on three door vehicle.
(13) Remove screws attaching quarter trim to
quarter panel from bolster area.
(14)
Remove screws attaching rear edge of quarter
trim to attaching bracket or inner quarter trim panel.
(15) Remove screws attaching 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.
(18) Pass front seat belt and turning loop through
slot in quarter trim panel on three door vehicle.
(19) Pass first row seat belt through slot in quar-
ter trim panel.
(20) Pass second row 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 row seat belt, if equipped, through
slot in quarter trim panel on long wheel base vehicle.
(3) Pass first row seat belt through slot in quarter
trim panel.
RSINTERIOR23 - 215

(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 attaching top of trim panel to
inner sheet metal between B-pillar and C-pillar on
three door vehicle.
(9) Install screws attaching rear edge of quarter
trim to attaching bracket or inner quarter panel.
(10) Install screws attaching quarter trim to inner
quarter panel in bolster area.
(11) Install screws attaching 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 row seat belts anchor on long
wheel base vehicle. Tighten all seat belt bolts to 39
N´m (28 in. lbs.) torque.
(14) Install first row 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 vehicle.
(20) Install sliding door sill plate on four door
vehicle.
(21) Install second row seat, if equipped.
(22) Install first row seat.
(23) Connect the battery negative cable.
REAR HEADER TRIM
REMOVAL
(1) Disengage hidden clips holding trim to rear
header (Fig. 12).
(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.
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. 13) .
(4) Remove louver from vehicle.INSTALLATION
(1) Place bezel in position in HVAC duct opening.
Fig. 12 REAR HEADER TRIM
1 - REAR HEADER
2 - GUIDE PINS
3 - CLIPS
Fig. 13 Rear HVAC Louver
1 - HEVAC DUCT
2 - REAR HEVAC LOUVER
3 - HEADLINING
4 - CLIP
23 - 216 INTERIORRS
LEFT QUARTER TRIM PANEL (Continued)

(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 VIEW MIRROR
REMOVAL
(1) If equipped, disconnect mirror harness connec-
tor (Fig. 14).
(2) Loosen the mirror base set screw (Fig. 15).
(3) Slide the mirror base upward and off the
bracket.
INSTALLATION
(1) Position the mirror base at the bracket and
slide it downward onto the support bracket.
(2) Tighten the setscrew 1 N´m (15 in. lbs.) torque.
(3) If equipped, connect mirror harness connector.
RIGHT D-PILLAR TRIM PANEL
REMOVAL
(1) Remove rear header trim cover.
(2) Remove liftgate sill plate.
(3) Remove second row seat belt turning loop on
long wheel base vehicle.
(4) Remove bolt attaching second row 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 attaching trim panel to attach-
ing bracket on short wheel base vehicle.
(7) Disengage hidden clips attaching trim to D-pil-
lar.
(8) Remove D-pillar trim panel from D-pillar.
(9) Disconnect speaker wire connector, if equipped.
(10) Pass second row seat belt, if equipped,
through slot in trim panel on short wheel base vehi-
cle.
(11) Remove D-pillar trim from vehicle.
INSTALLATION
(1) Position D-pillar trim on vehicle.
(2) Pass second row 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 attaching trim to D-pillar.
(6) Install screws attaching trim panel to attach-
ing bracket on short wheel base vehicle.
(7) Install quarter trim bolster on short wheel base
vehicle.
(8) Install bolt to attach second row seat belt, if
equipped, anchor to quarter on short wheel base
vehicle. Tighten all seat belt bolts to 39 N´m (29 ft.
lbs.) torque.
(9) Install second row seat belt turning loop on
long wheel base vehicle.
(10) Install liftgate sill plate.
(11) Install rear header trim cover.
Fig. 14 Rear View Mirror Assembly
1 - HEADLINER
2 - WIRE COVER
3 - MIRROR
4 - MIRROR ASSEMBLY
5 - WIRE CONNECTOR
6 - WINDSHIELD
Fig. 15 Rear View Mirror
1 - MIRROR
2 - WINDSHIELD
RSINTERIOR23 - 217
REAR HVAC LOUVER (Continued)