CHRYSLER VOYAGER 2001 Service Manual

EXTERIOR HANDLE
REMOVAL
(1) Roll door glass up.
(2) Remove the watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(3) Through access hole at rear of inner door
panel, disconnect Vehicle Theft Security System
(VTSS) switch connector from door harness, if
equipped.
(4) Disengage push in fasteners attaching VTSS
switch harness to inner door reinforcement bar, if
equipped.
(5) Disengage clip holding door latch linkage to
door latch.
(6) Remove latch linkage from latch.
(7) Disengage clip holding door lock linkage to
door latch.
(8) Remove lock linkage from latch.
(9) Remove nuts holding outside door handle to
door outer panel (Fig. 19).
(10) Remove outside door handle from vehicle.
INSTALLATION
If outside door handle replacement is necessary,
transfer lock cylinder from the original handle to the
new one.
(1) Place outside door handle in position on vehi-
cle.
(2) Install nuts attaching outside door handle to
door outer panel (Fig. 19) .(3) Insert lock linkage into door latch.
(4) Engage clip to hold door lock linkage to latch.
(5) Insert latch linkage into door latch.
(6) Engage clip to hold door latch linkage to latch.
(7) Install push-in fasteners to hold VTSS switch
harness to inner door reinforcement bar, if equipped.
(8) Connect VTSS switch connector into door har-
ness, if equipped.
(9) Verify door latch operation.
(10) Install sound shield and door trim panel.
Fig. 19 Front Door Outside Handle
1 - VTA SWITCH
2 - LOCK LINKAGE
3 - LATCH LINKAGE
4 - FRONT DOOR OUTSIDE HANDLE
RSDOOR - FRONT23 - 161

DOORS - SLIDING
TABLE OF CONTENTS
page page
CENTER HINGE
REMOVAL.............................162
INSTALLATION..........................162
CENTER STOP TRIM COVER
REMOVAL.............................163
INSTALLATION..........................163
STOP BUMPER
REMOVAL.............................163
INSTALLATION..........................163
HOLD OPEN LATCH
REMOVAL.............................163
INSTALLATION..........................164
HOLD OPEN LATCH STRIKER
REMOVAL.............................164
INSTALLATION..........................164
LATCH / LOCK CONTROL
REMOVAL.............................164
INSTALLATION..........................165
LOWER ROLLER ARM
REMOVAL.............................166
INSTALLATION..........................167
LOWER ROLLER ARM BRACKET
REMOVAL.............................167
INSTALLATION..........................167
REAR LATCH
REMOVAL.............................168
INSTALLATION..........................168
CENTER LATCH STRIKER
REMOVAL.............................168
INSTALLATION..........................168
REAR LATCH STRIKER
REMOVAL.............................169
INSTALLATION..........................169
SLIDING DOOR
REMOVAL.............................169INSTALLATION..........................170
ADJUSTMENTS.........................171
STABILIZER
REMOVAL.............................173
INSTALLATION..........................173
STABILIZER SOCKET
REMOVAL.............................173
INSTALLATION..........................173
TRIM PANEL
REMOVAL.............................174
INSTALLATION..........................174
INSIDE LATCH HANDLE
REMOVAL.............................174
INSTALLATION..........................174
INSIDE LATCH HANDLE BELLCRANK
REMOVAL.............................175
INSTALLATION..........................175
INSIDE LATCH RELEASE MECHANISM
REMOVAL.............................175
INSTALLATION..........................176
EXTERIOR HANDLE
REMOVAL.............................176
INSTALLATION..........................176
UPPER ROLLER
REMOVAL.............................177
INSTALLATION..........................177
OUTSIDE HANDLE CABLE
REMOVAL.............................177
INSTALLATION..........................178
INSIDE HANDLE CABLE
REMOVAL.............................178
INSTALLATION..........................178
HOLD OPEN LATCH CABLE
REMOVAL.............................179
INSTALLATION..........................179
CENTER HINGE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Open sliding door to the mid point of its travel.
(2) Support sliding door on a suitable lifting
device.(3) Mark outline of center hinge of inner door
panel to aid installation.
(4) Remove bolts holding center hinge to sliding
door.
(5) Remove center hinge from sliding door.
(6) Roll center hinge to rear of roller channel.
(7) Separate center hinge from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
23 - 162 DOORS - SLIDINGRS

NOTE: Center hinge has an adjustable bolt for
up/down alignment. (Refer to 23 - BODY/DOORS -
SLIDING/SLIDING DOOR - ADJUSTMENTS)
(1) Place center hinge in position on vehicle.
(2) Roll center hinge forward in roller channel.
(3) Place center hinge in position on sliding door
and align marks.
(4) Install bolts to hold center hinge to sliding
door.
(5) Verify sliding door alignment and operation.
CENTER STOP TRIM COVER
REMOVAL
(1) Using a trim stick (C-4755), disengage clips
attaching center stop trim cover to the door trim
panel.
(2) Remove trim cover from vehicle (Fig. 1).
INSTALLATION
(1) Place trim cover into position.
(2) Engage clips attaching center stop trim cover
to the door trim panel.
STOP BUMPER
REMOVAL
(1) Remove center stop bumper trim panel.(Refer
to 23 - BODY/DOORS - SLIDING/CENTER STOP
TRIM COVER - REMOVAL)
(2) Loosen screws holding rear of stop bumper to
door inner panel (Fig. 2).
(3) Remove screw holding front of stop bumper to
door inner panel.
(4) Remove stop bumper from vehicle.
INSTALLATION
(1) Place stop bumper in position on vehicle.
(2) Install screw to hold front of stop bumper to
door inner panel (Fig. 2).
(3) Tighten screws to hold rear of stop bumper to
door inner panel.
(4) Install center stop trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/CENTER STOP TRIM
COVER - INSTALLATION)
HOLD OPEN LATCH
REMOVAL
(1) Open sliding door.
(2) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(3) Remove nuts holding hold open latch to lower
roller arm (Fig. 3).
(4) Separate hold open latch from lower arm.
(5) Disconnect cable from hold open latch.
(6) Remove hold open latch from vehicle.
Fig. 1 Sliding Door Center Stop Trim Cover
1 - SLIDING DOOR TRIM PANEL
2 - CENTER STOP BUMPER
3 - CENTER STOP TRIM COVER
Fig. 2 Sliding Door Stop Bumper
1 - CENTER STOP BUMPER
2 - TRIM COVER
3 - SLIDING DOOR
RSDOORS - SLIDING23 - 163
CENTER HINGE (Continued)

INSTALLATION
(1) Place hold open latch in position on vehicle.
(2) Connect cable to hold open latch.
(3) Place hold open latch in position on lower arm.
(4) Install nuts to hold the hold open latch to
lower roller arm.
(5) Install sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(6) Verify sliding door operation.
HOLD OPEN LATCH STRIKER
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Open sliding door, do not latch open.
(2) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(3) Remove screws attaching sliding door hold
open latch striker to door sill (Fig. 4).
(4) Remove hold open latch striker from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Place hold open latch striker in position on
vehicle.(2) Install screws attaching sliding door hold open
latch striker to door sill.
(3) Install sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(4) Verify sliding door operation.
LATCH / LOCK CONTROL
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
(4) Remove latch/lock control cover (Fig. 5).
(5) With sliding door ajar, disengage clip holding
rear latch link to latch/lock control (Fig. 6) and (Fig.
7).
(6) Place a flat head screw driver between metal
clip ears and bottom of link.
NOTE: Rotate screw driver to remove link.
Fig. 3 Sliding Door Hold Open Latch
1 - SLIDING DOOR HOLD OPEN LATCH
2 - LOWER ROLLER ARM
Fig. 4 Sliding Door Hold Open Latch Striker
1 - SLIDING DOOR SILL
2 - HOLD OPEN STRIKER
23 - 164 DOORS - SLIDINGRS
HOLD OPEN LATCH (Continued)

CAUTION: Replace the latch/lock control if any of
the metal clips on the latch/lock control are bent or
broken. DO NOT attempt to repair the clips to retain
the links.
(7) Remove rear latch link from latch/lock control.
(8) Disengage clip holding outside door handle link
to latch/lock control (Fig. 7).
(9) Remove outside door handle link from latch/
lock control.
(10) Disengage clip holding inside door handle
bellcrank link to latch/lock control (Fig. 7).
(11) Remove inside door handle bellcrank link
from latch/lock control.
(12) Remove lock cylinder link from control.
(13) Disengage clip holding inside lock link to
latch/lock control.
(14) Disengage clip holding inside lock link to
latch/lock control.
(15) Remove inside lock link from control.
(16) Disengage lock tabs holding hold open latch
cable case to latch/lock control.
(17) Remove hold open latch cable ball end from
latch/lock control.
(18) Loosen bolts attaching latch/lock control to
sliding door.
(19) If equipped, disconnect wire connector from
power door lock motor.
(20) Remove latch/lock from vehicle.INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Position latch/lock locking lever in unlocked
position.
(2) Engage rigging cam (Fig. 6).
(3) Place latch/lock in position on vehicle.
(4) If equipped, engage wire connector into power
door lock motor.
(5) Insert bolt heads into slots in sliding door
inner panel.
(6) Tighten bolts attaching latch/lock control to
sliding door.
(7) Engage hold open latch cable ball end into
latch/lock control.
(8) Engage lock tabs to hold the hold open latch
cable case to latch/lock control.
(9) Insert lock cylinder link into control.
(10) Engage clip to hold inside lock link to latch/
lock control.
(11) Insert inside lock link into control.
(12) Engage clip to hold inside lock link to latch/
lock control.
(13) Lift clip for inside door handle bellcrank link
to top of slot in mechanism (Fig. 6).
(14) Engage clip to hold bellcrank link to latch/lock
control.
(15) Pull inside release bell crank link downward
to remove cable slack then engage link to clip.
(16) Lower clip for outside door handle link to bot-
tom of slot in mechanism and engage link to clip
(Fig. 6).
NOTE: Move link rearward until movement stops
before engaging link to clip.
(17) Place rear latch link in position on control by
moving link rearward until movement stops.
(18) Engage clip to hold rear latch release link to
latch/lock control.
(19) Push inside lock link button downward to dis-
engage rigging cam.
(20) Verify sliding door operation.
(21) Install latch/lock cover.
(22) Insure that enough adhesive remains to
securely retain the watershield. Replace as necessary.
(23) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(24) Install sliding door stop bumper.(Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
Fig. 5 Latch/Lock Cover
1 - LOCK BUTTON
2 - LATCH/LOCK CONTROL
3 - LATCH/LOCK CONTROL COVER
RSDOORS - SLIDING23 - 165
LATCH / LOCK CONTROL (Continued)

(25) Install sliding door trim panel.(Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
LOWER ROLLER ARM
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Open sliding door.
(2) Mark outline of roller arm on sliding door
bracket to aid installation.
Fig. 6 Sliding Door Latch/Lock Control Linkage
1 - INSIDE HANDLE CABLE
2 - HOLD OPEN LATCH CABLE
3 - INSIDE LOCK LINK
4 - CAM POSITION DURING LINK INSTALLATION
5 - REAR LATCH RELEASE LINK
6 - PLACE CLIP AT TOP OF SLOT7 - INSIDE RELEASE BELLCRANK LINK
8 - LOCK CYLINDER LINK
9 - PLACE CLIP AT BOTTOM OF SLOT
10 - OUTSIDE RELEASE HANDLE LINK
Fig. 7 Latch/Lock Control Link Removal
1 - METAL LINK CLIP
2 - LINK
3 - FLAT HEAD SCREWDRIVER
23 - 166 DOORS - SLIDINGRS
LATCH / LOCK CONTROL (Continued)

(3) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(4) Remove screws attaching open latch to lower
roller arm.
(5) Remove open latch from lower arm.
(6) Support sliding door on a suitable lifting device
with a padded upper surface. The door must be
moveable with lifting device in place.
(7) Remove bolts attaching lower roller arm to
sliding door (Fig. 8).
(8) Remove roller arm from sliding door.
(9) Disengage roller arm from lower channel (Fig.
9).
(10) Remove roller arm from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Place roller arm into position.
(2) Engage roller arm to lower channel.
(3) Install roller arm to sliding door.
(4) Install bolts attaching lower roller arm to slid-
ing door.
(5) Install screws attaching open latch to lower
roller arm.
(6) Install sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(7) Check sliding door for proper operation.
LOWER ROLLER ARM
BRACKET
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Remove access hole plug.
(2) Open sliding door.
(3) Support sliding door on a suitable lifting
device.
(4) Remove lower roller arm. (Refer to 23 - BODY/
DOORS - SLIDING/LOWER ROLLER ARM -
REMOVAL)
(5) Mark outline of roller arm bracket on inside of
sliding door.
(6) Remove bolts attaching lower roller arm
bracket to sliding door (Fig. 10).
(7) Remove lower roller bracket from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Place lower roller bracket in position on vehi-
cle.
(2) Align outline mark on inside of sliding door to
roller arm bracket.
Fig. 8 Sliding Door Lower Roller Arm
1 - SLIDING DOOR
2 - LOWER ROLLER ARM
3-LATCH
Fig. 9 Sliding Door Roller Arm Channel
1 - SLIDING DOOR SILL
2 - LOWER ROLLER ARM
3 - ROLLER CHANNEL
4 - HOLD OPEN LATCH STRIKER
RSDOORS - SLIDING23 - 167
LOWER ROLLER ARM (Continued)

(3) Install bolts attaching lower roller arm bracket
to sliding door. Tighten bolts to 12 N´m (105 in. lbs.)
torque.
(4) Install lower roller arm. (Refer to 23 - BODY/
DOORS - SLIDING/LOWER ROLLER ARM -
INSTALLATION)
(5) Remove lifting device.
(6) Verify sliding door operation.
(7) Install access hole plug.
REAR LATCH
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Peel watershield away from adhesive around
perimeter of inner door panel.
(3) Open sliding door to the ajar position.
(4) Disengage clip attaching linkage to rear latch.
(5) Remove screws attaching rear latch to sliding
door end frame (Fig. 11).
(6) Remove sliding door rear latch from door
through rear access hole.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.NOTE: The screws attaching the rear latch to slid-
ing door end frame have locking patch on the
threads. Screws must be replaced during installa-
tion.
(1) Position sliding door rear latch on door through
rear access hole.
(2) Install screws attaching rear latch to sliding
door end frame. Tighten screws to 10 N´m (90 in.
lbs.) torque.
(3) Engage clip attaching linkage to rear latch.
(4) Verify sliding door operation. Adjust as neces-
sary.
(5) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(6) Install sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
CENTER LATCH STRIKER
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove screws attaching center striker assem-
bly to door end frame (Fig. 12).
(3) Remove center striker assembly from door
through access hole.
INSTALLATION
(1) Place center striker in position on door through
access hole.
Fig. 10 Sliding Door Lower Roller Arm Bracket
1 - LOWER ROLLER ARM BRACKET
2 - SLIDING DOOR
Fig. 11 Sliding Door
1 - REAR LATCH
2 - SLIDING DOOR
23 - 168 DOORS - SLIDINGRS
LOWER ROLLER ARM BRACKET (Continued)

(2) Install screws to attach center striker to door
end frame.
(3) Install sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
REAR LATCH STRIKER
REMOVAL
(1) Open sliding door.
(2) Mark outline of striker on C-pillar door jamb
face to aid installation.
(3) Remove screws attaching striker to C-pillar
(Fig. 13) .
(4) Remove striker from vehicle.
INSTALLATION
(1) Place striker in position on vehicle.
(2) Align striker to outline marks on C-pillar.
(3) Install screws attaching striker to C-pillar.
Tighten screws to 28 N´m (21 ft. lbs.) torque.
(4) Verify sliding door alignment and operation.
SLIDING DOOR
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Apply masking tape to outside surface of quar-
ter panel below the center roller channel, rearward of
the door opening.
(2) Release sliding door latch and open door.
(3) Apply masking tape to door jamb area, rear-
ward of the upper roller channel.
(4) Remove screw holding upper roller arm stop
bumper to upper roller arm (Fig. 14).
(5) Remove stop bumper from upper roller arm.
(6) Remove center stop from sliding door. (Refer to
23 - BODY/DOORS - SLIDING/STOP BUMPER -
REMOVAL)
(7) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(8) Remove hold open latch striker (Fig. 15).
(9) Open quarter glass.
(10) Remove center roller channel end cover (Fig.
16).
Fig. 14 Sliding Door Upper Stop
1 - SLIDING DOOR
2 - UPPER STOP
3 - UPPER ROLLER ARM
Fig. 12 Sliding Door Center Striker Assembly
1 - CENTER STABILIZER
2 - SLIDING DOOR
Fig. 13 Sliding Door Latch Striker
1 - LATCH STRIKER
2 - SLIDING DOOR
RSDOORS - SLIDING23 - 169
CENTER LATCH STRIKER (Continued)

(11) Support sliding door on a suitable lifting
device with a padded upper surface. The door must
be moveable with lifting device in place.
CAUTION: Do not allow the center hinge roller to
contact the quarter glass. Glass can break.
(12) Roll door rearward until lower rollers disen-
gage from lower channel.
(13) Roll the door rearward until the upper (Fig.
17)and center hinge rollers exit the upper and center
channels (Fig. 18).
(14) Remove sliding door from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Place sliding door in position on lifting device.(2) Position door rearward of the sliding door open-
ing.
CAUTION: Do not allow the center hinge roller to
contact the quarter glass. Glass can break.
(3) Engage the center hinge rollers into the center
channels (Fig. 18).
(4) Roll door forward until lower rollers engage
into rear of lower channel.
(5) Engage the upper hinge into the upper chan-
nels (Fig. 17).
(6) Install hold open latch striker (Fig. 15).
(7) Install sliding door sill plate.
Fig. 15 Sliding Door Hold Open Latch Striker
1 - SLIDING DOOR SILL
2 - HOLD OPEN STRIKER
Fig. 16 Center Channel End Cover
1 - QUARTER GLASS
2 - CENTER CHANNEL END COVER
Fig. 17 Sliding Door Upper Roller
1 - SLIDING DOOR
2 - ROLLER
3 - UPPER CHANNEL
Fig. 18 Sliding Door Center Roller
1 - SLIDING DOOR
2 - QUARTER GLASS
3 - ROLLERS
4 - CENTER ROLLER ARM
23 - 170 DOORS - SLIDINGRS
SLIDING DOOR (Continued)