roof CHRYSLER VOYAGER 2001 Owner's Manual

ROOF PANEL/ROOF RAIL - SHORT WHEEL BASE ONLY
23 - 148 BODYRS
BODY (Continued)

SPECIFICATIONS -
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
All seat belt anchor bolts 39 29 Ð
Armrest shoulder bolt 29 21 Ð
Bench seat riser bolts 48 35 Ð
Bench seat track nuts 48 35 Ð
Quad bucket seat track to cushion frame bolts 40 30 Ð
Bucket seat back pivot bolts 33 24 Ð
Center seat to seat track bolts 24 17 Ð
Child seat module screws (bench seats) 7 Ð 62
Child seat module screws (quad seats) 13.5 10 Ð
Crossmember to radiator closure panel bolts 28 21 Ð
Door check strap to door end frame 12 Ð 105
Door latch to door end frame bolts 10 Ð 89
Floor latch to seat cushion frame bolts 27 19 Ð
Front cover to seat track screws 4 Ð 32
Front door hinge to hinge pillar bolts 34 25 Ð
Front door hinge to door nuts and bolts 34 25 Ð
Front door latch striker bolts 28 21 Ð
Front/quad seat cushion bolts 28.5 21 Ð
Front seat belt retractor bolts 38 28 Ð
Front seat riser to floor nuts 60 44 Ð
Front seat track cover screws 4 Ð 35
Front seat riser to seat track nuts 81 60 Ð
Front seatback pivot bolts 54 40 Ð
Front seatback recliner nut 12 Ð 105
Front seatback assist strap screws 2.5 Ð 22
Grocery bag holder screws 2 Ð 17
Hinge to liftgate bolts 33 24 Ð
Hood latch to bolts 13.5 10 Ð
Hood latch striker bolts 13.5 10 Ð
Hood hinge to hood bolts 13.5 10 Ð
Liftgate exterior handle outer screws 20 15 Ð
Liftgate exterior handle inner bolts 40 30 Ð
Lifgate hinge to roof header bolts 33 24 Ð
Liftgate latch bolts 16 12 Ð
Liftgate latch striker bolts 28 21 Ð
Liftgate lift motor link to liftgate 28 21 Ð
Liftgate spoiler bolts 9 Ð 80
Lifgate stabalizer wedge striker to D-pillar bolts 3 Ð 30
Luggage rack crossbar fasteners 4 Ð 35
RSBODY23 - 149
BODY (Continued)

(8) Install center roller channel end cover (Fig. 16).
(9) Install center stop on sliding door. (Refer to 23
- BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(10) Place upper roller stop bumper in position on
upper roller arm.
(11) Install screw to hold upper roller arm stop
bumper to upper roller arm (Fig. 14).
(12) Remove masking tape from body surfaces.
(13) Verify door operation and fit. Adjust as neces-
sary. (Refer to 23 - BODY/DOORS - SLIDING/SLID-
ING DOOR - ADJUSTMENTS)
SLIDING DOOR ADJUSTMENTS
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
PRELIMINARY CHECKS
(1) Close the sliding door, visually checking C-post
striker alignment entry into latch. Striker at this
point must not affect alignment. Striker should go
straight into the latching mechanism.
(2) On vehicles with left sliding doors, check the
fuel door blocker striker entry into latch. Striker at
this point must not affect alignment.
(3) Check C-post and B-post for door to aperture
gaps and door to door gaps. All gaps should be 5 mm
  1 mm.
(4) Check door for height using character lines as
a reference. Also check roof contour as a controlling
factor.
Using the procedures noted below, adjust the side
door in the order the individual steps are called out.
DOOR FLUSHNESS ADJUSTMENT
(1) Check sliding door flushness at the C-pillar
striker.
(2) Adjust the C-pillar striker in or out untill the
door is flush.
(3) Check upper B-pillar flushness to A-pillar
cover.
(4) Loosen one nut on upper hinge and adjust door
in or out untill the door is flush.
(5) Check flushness at upper C-pillar.
(6) If upper C-pillar flushness is out of specifica-
tion use a heavy rubber malet on the door assembly
until door is in spec.
DOOR GAP ADJUSTMENT - UP/DOWN
UP/DOWN ADJUSTMENT
(1) Visually inspect the sliding door for fitting low
at the top of the door by checking the alignment of
the top contour of the door to the quarter panel.(2) Fully open the sliding door.
(3) Verify that all center hinge bolts are tight.
(4) Adjust the rear of the sliding door up by turn-
ing the center hinge bolt clockwise (Fig. 19).
(5) Close the door and check the sliding door align-
ment.
(6) Fully open door and apply thread lock nut onto
the center hinge bolt. Tighten nut until till it butts
up against the welded nut on the center hinge.
Tighten nut to 15 N´m (130 in. lbs.). It may be nec-
essary to hold the center hinge bolt to prevent it
from turning while tightening nut.
(7) Verify alignment. Re-adjust as necessary.
DOOR GAP ADJUSTMENT - FORE/AFT
FORE/AFT ADJUSTMENT
(1) Check height of sliding door at the B-post and
C-post to determine which area is contributing the
greatest to the incorrect gaps.
(2) If the sliding door is high at the C-post;
(a) Open the door to mid-point of travel.
(b) Mark outline of center hinge on sliding door
to assist in making adjustments.
(c) Loosen center hinge bolts (Fig. 19).
(d) Move hinge fore or aft to position the sliding
door into the correct location.
(e) Tighten center hinge bolts.
(f) Verify alignment. Re-adjust as necessary.
(3) If the sliding door is low at the B-post;
(a) Remove access plug in the sliding door trim
panel.
(b) Open the door to mid-point of travel.
Fig. 19 Sliding Door Center Hinge
1 - ADJUSTING BOLT
2 - WELD NUT
RSDOORS - SLIDING23 - 171
SLIDING DOOR (Continued)

(5) Engage rigging cam to latch/lock control mech-
anism.
(6) Move clip on latch/lock control to bottom of slot
and engage linkage to latch/lock control.
(7) Verify sliding door operation. Adjust as neces-
sary.
(8) Install latch/lock cover.
(9) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(10) Install sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(11) Install sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
UPPER ROLLER
REMOVAL
(1) Open sliding door, do not latch open.
(2) Remove screw holding upper stop bracket to
upper roller bracket (Fig. 32).
(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. 33).
(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. (Refer to 23 - BODY/DOORS -
SLIDING/SLIDING DOOR - ADJUSTMENTS)
OUTSIDE HANDLE CABLE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate side door trim panel.
(Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
(4) Open the side door and remove the latch
assembly. Refer to the Power Side Doors section for
the procedure.
CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
Fig. 32 Sliding Door Upper Stop
1 - SLIDING DOOR
2 - UPPER STOP
3 - UPPER ROLLER ARM
Fig. 33 Sliding Door Upper Roller
1 - SLIDING DOOR UPPER ROLLER
2 - SLIDING DOOR
RSDOORS - SLIDING23 - 177
EXTERIOR HANDLE (Continued)

DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL.............................180
INSTALLATION..........................180
HINGE
REMOVAL.............................180
INSTALLATION..........................181
LATCH
REMOVAL.............................181
INSTALLATION..........................181
LATCH STRIKER
REMOVAL.............................181
INSTALLATION..........................181
LIFTGATE
REMOVAL.............................181INSTALLATION..........................182
LIFTGATE SPOILER
REMOVAL.............................182
INSTALLATION..........................182
LOCK CYLINDER
REMOVAL.............................182
INSTALLATION..........................182
SUPPORT CYLINDER
REMOVAL.............................183
INSTALLATION..........................183
TRIM PANEL
REMOVAL.............................183
INSTALLATION..........................183
EXTERIOR HANDLE
REMOVAL
(1) Remove liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the exterior handle electrical con-
nectors.
(3) Remove the two outer screws and the two inner
screws.
(4) Remove the exterior handle/license plate light
assembly.
INSTALLATION
(1) Route the exterior handle electrical connector
through the door and position handle.
(2) Install the two inner bolts and tighten to 40
N´m (30 ft. lbs.).
(3) Install the two out screws and tighten to 20
N´m (15 ft. lbs.).
(4) Connect the electrical connector.
(5) Install the trim panel. (Refer to 23 - BODY/
DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM
PANEL - INSTALLATION)
HINGE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device in
the full open position.(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 attaching liftgate hinge to roof
header.
(5) Disconnect VTSS switch from the body har-
ness.
(6) Remove bolts attaching hinge to liftgate (Fig.
1).
(7) Remove hinge from vehicle.
Fig. 1 Liftgate Hinge
1 - LIFTGATE
2 - HINGE
3 - REAR ROOF HEADER
23 - 180 DECKLID/HATCH/LIFTGATE/TAILGATERS

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 attaching hinge to liftgate (Fig. 1)
. Tighten bolts to 33 N´m (24 ft. lbs.) torque.
(5) Align hinge to marks on roof header.
(6) Install bolts attaching liftgate hinge to roof
header. Tighten outer two bolts to 33 N´m (24 ft. lbs.)
torque. The sheet medal screw at center 12 N´m (105
in. lbs.)
(7) Remove duct tape from roof and liftgate.
(8) Verify liftgate alignment. Refer to Liftgate
Remove and Installation for proper gap measure-
ments.
LATCH
REMOVAL
(1) Remove liftgate trim panel.
(2) Disengage outside handle link from clip on
latch.
(3) Disconnect wire connector from liftgate latch
(Fig. 2).
(4) Remove screws attaching latch to liftgate.
(5) Remove latch from vehicle.
INSTALLATION
(1) Engage like and place latch in position on vehi-
cle.
(2) Install screws attaching latch to liftgate.
Tighten to 10 N´m (95 lb.in.) torque.
(3) Connect wire connector to liftgate latch.
(4) Verify liftgate fit and operation. Adjust as nec-
essary.
(5) Install liftgate trim panel.
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. 3)
.
(4) Remove striker from vehicle.
INSTALLATION
(1) Place striker in position on vehicle.
(2) Align striker to outline mark on sill.
(3) Install screws attaching striker to sill. Tighten
screws to 28 N´m (21 ft. lbs.) torque.
(4) Verify liftgate alignment and operation.
LIFTGATE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Remove screws attaching liftgate wire connec-
tor to rear header.
Fig. 2 Liftgate Latch
1 - ELECTRICAL CONNECTOR
2 - LIFTGATE LATCH
3 - SCREW
4 - LIFTGATE
5 - LIFTGATE LOCK CYLINDER
Fig. 3 Liftgate Latch Striker
1 - LIFTGATE SILL
2 - LIFTGATE STRIKER
RSDECKLID/HATCH/LIFTGATE/TAILGATE23 - 181
HINGE (Continued)

(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 attaching support cylinders to
liftgate.
(8) Remove bolts attaching liftgate hinge to roof
header (Fig. 4) .
(9) With assistance, remove liftgate from vehicle.
INSTALLATION
(1) With assistance, place liftgate in position on
vehicle.
(2) Install bolts attaching liftgate hinge to roof
header. Tighten bolts to 33 N´m (24 ft. lbs.) torque.
(3) Install screws attaching support cylinders to
liftgate. Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(4) Remove lifting device from under liftgate.
(5) Connect liftgate wire harness into body wire
harness.
(6) Install screws attaching wire connector to rear
header.
(7) Connect rear window washer hose onto spray
nozzle.
(8) Install liftgate upper frame molding.
(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 SPOILER
REMOVAL
(1) Remove nuts (Fig. 5).
(2) Remove spoiler from vehicle.
INSTALLATION
(1)Place liftgate spoiler in position and install nuts.
(2) Tighten nuts to 9 N´m (80 in. lbs.) torque.
LOCK CYLINDER
REMOVAL
(1) Remove the liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the electrical connector.
(3) Disconnect the latch rod.
(4) Rotate plastic lock cylinder nut one quarter
turn and remove nut and spring washer.
(5) Remove the lock cylinder from the liftgate.
INSTALLATION
(1) Install lock cylinder into liftgate.
(2) Install the plastic lock cylinder lock nut, spring
washer and rotate one quarter turn.
(3) Connect the electrical connector.
(4) Connect the latch rod.
(5) Install the trim panel. (Refer to 23 - BODY/
DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM
PANEL - INSTALLATION)
(6) Verify lock cylinder operation.
Fig. 4 Liftgate
1 - HINGE
2 - ROOF
3 - NET HOLE OR SLOT
Fig. 5 Liftgate Spoiler
1 - RETAINER SEALER WASHER
2 - LIFT GATE SPOILER
23 - 182 DECKLID/HATCH/LIFTGATE/TAILGATERS
LIFTGATE (Continued)

EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL.............................184
INSTALLATION..........................184
COWL GRILLE
REMOVAL.............................190
INSTALLATION..........................190
EXTERIOR NAME PLATES - TAPE ATTACHED
REMOVAL.............................191
INSTALLATION..........................191
EXTERIOR NAME PLATES - ADHESIVE
ATTACHED
REMOVAL.............................191
INSTALLATION..........................191
FRONT FENDER
REMOVAL.............................191
INSTALLATION..........................191
FUEL FILL DOOR
REMOVAL.............................191
INSTALLATION..........................192
FUEL FILL DOOR BLOCKER LATCH
REMOVAL.............................192
INSTALLATION..........................192
FUEL FILL DOOR BLOCKER LATCH STRIKER
REMOVAL.............................193
INSTALLATION..........................193
FUEL FILL DOOR BLOCKER LOCKOUT LINK
REMOVAL.............................193INSTALLATION..........................193
GRILLE OPENING REINFORCEMENT
REMOVAL.............................194
INSTALLATION..........................194
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL.............................194
INSTALLATION..........................195
LUGGAGE RACK RISER
REMOVAL.............................195
INSTALLATION..........................195
LUGGAGE RACK CROSSBAR
REMOVAL.............................195
INSTALLATION..........................196
REAR QUARTER PANEL/FENDER AIR
EXHAUSTER
DESCRIPTION..........................196
REMOVAL.............................196
INSTALLATION..........................197
ROOF JOINT MOLDING
REMOVAL.............................197
INSTALLATION..........................197
SIDE VIEW MIRROR
REMOVAL.............................198
INSTALLATION..........................198
BODY SIDE MOLDINGS
REMOVAL
Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig.
5)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 38É C (100É F) using a suit-
able heat lamp or heat gun.
(2) If equipped, remove pop-rivets holding molding
edge to wheelhouse lip.
(3) Pull stick-on molding from painted surface.
(4) Remove adhesive tape residue from painted
surface of vehicle. Use a 3M Scotch-BriteŸ Molding
Adhesive and Stripe Removal Disc, or equivalent, to
clean adhesive residue from painted surfaces. These
products are available from automotive paint suppli-
ers. Refer to instructions supplied with the specific
product for proper usage.
INSTALLATION
Refer to (Fig. 1) , (Fig. 2), (Fig. 3), (Fig. 4) or (Fig.
5)for proper location of fasteners to hold the molding
to the wheelhouse lip and rocker panels.
(1) If molding is to be reused;
(a) Remove tape residue from molding.
(b) Clean back of molding with Moparž Super
Kleen, or equivalent.
(c) Wipe molding dry with lint free cloth.
(d) Apply a single coat of Moparž TPO Molding
Prep to tape side of molding and allow to dry thor-
oughly.
(e) Apply new body side molding (two sided
adhesive) tape to back of molding.
(2) Clean body surface with Moparž Super Kleen,
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 to rear,
inserting locator pins into hole in body panel.
23 - 184 EXTERIORRS

INSTALLATION
SHORT WHEELBASE
(1) Position the air exhauster to the hole in the
lower aperture panel (Fig. 18).
(2) Using hand pressure, press the air exhauster
into the opening in the lower aperture panel until
the snap features are fully engaged.
(3) Reinstall the rear fascia onto the body. (Refer
to 13 - FRAMES & BUMPERS/BUMPERS/REAR
FASCIA - INSTALLATION).
LONG WHEELBASE
NOTE: Models with the optional rear heater and air
conditioner do not have an air exhauster on the
right side of the vehicle, but have a plastic plug
installed in the right lower aperture panel. This plug
is installed using the same procedure used to
install the air exhauster onto the short wheelbase
model. Refer to SHORT WHEELBASE .
(1) Position the air exhauster to the hole in the
lower aperture panel (Fig. 19).
(2) Using hand pressure, press the air exhauster
into the opening in the lower aperture panel until
the snap features are fully engaged.
(3) Reinstall the quarter trim panel onto the inside
of the left or right quarter inner panel. (Refer to 23 -
BODY/INTERIOR/RIGHT QUARTER TRIM PANEL
- INSTALLATION) or (Refer to 23 - BODY/INTERI-
OR/LEFT QUARTER TRIM PANEL - INSTALLA-
TION).
ROOF JOINT MOLDING
REMOVAL
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.
(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-BriteŸ Molding
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
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.
(1) If molding is to be reused;
(a) Remove tape residue from molding.
(b) Clean back of molding with Moparž Super
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 Moparž Super 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.
RSEXTERIOR23 - 197
REAR QUARTER PANEL/FENDER AIR EXHAUSTER (Continued)

A-PILLAR LOWER EXTENSION
TRIM
REMOVAL
(1) Remove instrument panel side cover.
(2) Remove screw holding A-pillar extension to
door hinge pillar.
(3) Remove A-pillar extension trim from vehicle
(Fig. 1) .
INSTALLATION
(1) Place A-pillar extension trim in position on
vehicle.
(2) Install screw to hold A-pillar extension to door
hinge pillar.
(3) Install instrument panel side cover.
A-PILLAR TRIM
REMOVAL
(1) Remove the assist handle if equipped. (Refer to
23 - BODY/INTERIOR/ASSIST HANDLE - REMOV-
AL).
(2) Disengage hidden clips holding A-pillar trim
panel to A-pillar (Fig. 2).
(3) Remove A-pillar trim from vehicle.
INSTALLATION
(1) Position foot on A-pillar trim panel into instru-
ment panel top cover channel.
(2) Position A-pillar trim in vehicle.
(3) Align locator pins.
(4) Engage hidden clips.(5) Install the assist handle, if equipped. (Refer to
23 - BODY/INTERIOR/ASSIST HANDLE - INSTAL-
LATION)
ASSIST HANDLE
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.
B-PILLAR LOWER TRIM
REMOVAL
(1) Slide lower seat belt cover rearward to expose
anchor bolt.
(2) Remove bolt attaching lower seat belt anchor to
floor.
(3) Remove upper B-pillar trim cover.
(4) Remove access panel from B-pillar trim (Fig. 3)
.
Fig. 1 A-pillar Lower Extension Trim
1 - A-PILLAR LOWER EXTENSION TRIM
2 - IP SIDE COVER
Fig. 2 A-pillar Trim
1 - A-PILLAR
2 - CLIPS
RSINTERIOR23 - 209