CHRYSLER VOYAGER 2001 Service Manual

EXTERIOR NAME PLATES -
TAPE ATTACHED
REMOVAL
(1) Mark reference points before removing.
(2) Using a heat gun gently apply heat in a circu-
lar motion to loosen the adhesive bond.
(3) Using a nonmetallic prying device, such as a
plastic or wood trim stick gently pry up at corners
and remove.
(4) Clean off all traces of adhesive or double sided
tape from the panel with a general purpose adhesive
remover.
INSTALLATION
(1) Clean panel surface with isopropy alcohol.
(2) Align badgeing to reference points.
(3) Install and press securely to full adhesive con-
tact
(4) Clean away any reference points.
EXTERIOR NAME PLATES -
ADHESIVE ATTACHED
REMOVAL
(1) Mark reference points before removing.
(2) Using a heat gun gently apply heat in a circu-
lar motion to loosen the adhesive bond.
(3) With your fingernail lift up and peel away
badgeing/tape from panel, using a heat gun as you
go.
(4) Clean off all traces of adhesive from the pan-
el(s) with a general purpose adhesive remover.
INSTALLATION
(1) Clean panel surface with isopropy alcohol.
(2) Remove paper carrier and align badgeing/tape
to reference points or adjacent panel.
(3) Install and press securely, using a plastic
spreader to eliminate all air bubbles.
(4) Remove top protective carrier.
(5) Clean away any reference points.
FRONT FENDER
REMOVAL
(1) Remove headlamp housing. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - REMOVAL)
(2) Remove mud guard.
(3) Remove inner splash shield.
(4) Remove fender to fascia nuts.(5) Remove outboard cowl grille/fender bracket
screw.
(6) Remove fender bolt to lower rocker panel.
(7) Remove fender bolt to lower cowl.
(8) Pull fascia away from fender.
(9) Remove bolts attaching fender to upper rail.
(10) Remove fender from vehicle (Fig. 8).
INSTALLATION
(1) Place fender in position on vehicle.
(2) From inside engine compartment, start the
center upper rail bolt. install all the bolts attaching
fender to upper rail and tighten.
(3) Install fender to lower cowl panel bolt.
(4) Install fender to rocker panel bolt.
(5) Place fascia into position.
(6) Install outboard cowl grille/fender bracket
screw.
(7) Install fender to fascia nuts.
(8) Install inner splash shield.
(9) Install mud guard.
(10) Install headlamp assembly. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - INSTALLATION)
(11) Check fender for flush and gap.
FUEL FILL DOOR
REMOVAL
(1) Remove left quarter trim panel.
Fig. 8 Fender
1 - FASTENERS
2 - FENDER
3 - FASTENERS
RSEXTERIOR23 - 191

(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. 12) .
(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. 9) .
(8) Remove fuel fill door from vehicle.
(9) Disengage clip holding link to fuel fill door
(Fig. 13) .
(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.
FUEL FILL DOOR 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. 12) .
(4) Remove screws holding fuel fill blocker latch to
C-pillar (Fig. 10) .
(5) Remove fuel fill blocker latch from vehicle.
INSTALLATION
(1) Position fuel fill blocker latch on vehicle.
(2) Install screws to hold fuel fill blocker latch to
C-pillar.
(3) Engage latch release link into clip on fuel fill
blocker latch arm with fuel door in the closed posi-
tion.
(4) Install water shield patch to cover access hole
in C-pillar.
(5) Verify fuel fill blocker latch operation.
(6) Install left quarter trim panel.
Fig. 9 Fuel Filler Housing and Door
1 - FUEL FILLER HOUSING W/LATCH
2 - CLIP
3 - FUEL FILLER HOUSING DOOR
4 - CLIPS
5 - FIX CLIP
Fig. 10 FUEL FILL
1 - FUEL FILLER BLOCKER LATCH ARM
2 - C-PILLAR
23 - 192 EXTERIORRS
FUEL FILL DOOR (Continued)

FUEL FILL DOOR BLOCKER
LATCH STRIKER
REMOVAL
(1) Remove sliding door trim panel.
(2) Remove sound shield as necessary to access
striker
(3) Remove screws attaching fuel fill door blocker
latch striker to sliding door rear end frame (Fig. 11) .
(4) Remove fuel fill door blocker latch striker from
vehicle.
INSTALLATION
(1) Position fuel fill door blocker latch striker on
vehicle.
(2) Install screws attaching fuel fill door blocker
latch striker to sliding door rear end frame.
(3) Install sliding door sound shield.
(4) Install sliding door trim panel.
FUEL FILL DOOR BLOCKER
LOCKOUT LINK
REMOVAL
(1) Remove left quarter trim panel.
(2) Remove water shield patch covering access hole
in C-pillar.
(3) Disengage fuel filler lockout link from clip on
fuel fill blocker latch arm (Fig. 12).
(4) Open fuel fill door.
(5) Remove screws holding fuel filler housing to
fuel filler tube neck.
(6) Reaching inside fuel filler housing, release clips
holding housing to outer quarter panel.(7) Remove fuel filler housing and lockout link
from vehicle.
(8) Disengage clip holding link to fuel fill door
(Fig. 13).
(9) Remove link from fuel fill door.
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.
Fig. 11 Fuel Fill Door Blocker Latch Striker
1 - LEFT SLIDING DOOR
2 - FUEL FILLER STOP STRIKER
Fig. 12 Fuel Filler Lockout Link at Latch Arm
1 - FUEL FILLER LOCKOUT LINK
2 - C-PILLAR
3 - FUEL FILLER BLOCKER LATCH ARM
4 - PLASTIC LINK CLIP
5 - INNER QUARTER PANEL
Fig. 13 Fuel Filler Lockout Link
1 - FUEL FILLER LOCKOUT LINK
2 - FUEL FILLER OPENING
3 - QUARTER PANEL
RSEXTERIOR23 - 193

(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
(1) Place splash shield in position on vehicle (Fig.
15) .
(2) Install screws to hold wheelhouse splash shield
to front fender.
(3) Install push-in fasteners to hold splash shield
to frame rail rearward of suspension.
(4) Install push-in fasteners to hold splash shield
to frame rail forward of suspension.
(5) Install front wheel. Refer to Group 22, Wheels
and Tires, for proper procedures.
(6) Lower vehicle.
LUGGAGE RACK RISER
REMOVAL
(1) Remove two fasteners from the front riser.
Gently pull up on the luggage rack side rail and
detach the riser snap to remove riser from the rail.
(2) Repeat for the opposite side, if necessary.
(3) Remove front riser(s) from vehicle (Fig. 16) .
INSTALLATION
(1) Place front riser into position on luggage rack
side rail.
(2) Install two fasteners into the riser.
(3) Repeat for the opposite side, if necessary.
LUGGAGE RACK CROSSBAR
REMOVAL
(1) Remove luggage rack front risers.
(2) Depress stanchion levers down until they click
into the unlock position. (Fig. 17) . Work from side to
side sliding the crossbar assembly forward moving a
little at a time to ensure it remains perpendicular to
the side rails.
(3) Remove crossbar from vehicle.
Fig. 15 Front Wheelhouse Splash Shield
1 - BUMPER FASCIA
2 - FRONT WHEELHOUSE SPLASH SHIELD
3 - FRONT FENDER
Fig. 16 Luggage Rack Riser Cover
1 - FRONT RISER COVER
2 - LOCK TABS
3 - LUGGAGE RACK SIDE RAIL
4 - FRONT RISER
Fig. 17 Luggage Rack Crossbar
1 - CROSSBAR
2 - SLIDE LOCK
3 - LOCK BUTTON
4 - LUGGAGE RACK SIDE RAIL
RSEXTERIOR23 - 195
FRONT WHEELHOUSE SPLASH SHIELD (Continued)

INSTALLATION
NOTE: The crossbar assemblies are designed to be
installed in only one way. Check top and bottom
surfaces of the crossbar for the word FRONT and
directional arrows. The directional arrows must
point toward the front of the vehicle.
(1) Place crossbar in position on vehicle.
(2) Work from side to side sliding the crossbar
assembly back a little at a time to ensure it remains
perpendicular to the side rails.
(3) Position first crossbar assembly crossbar at the
second most rearward locator holes. Press the top of
the stanchion lever to lock it into position.
(4) Position the second crossbar assembly in the
second hole from the front. Lock into place.
(5) Place luggage rack riser into position.
(6) Install two fasteners into riser. Tighten fasten-
ers to 4 mm (35 in. lbs.) torque.
REAR QUARTER PANEL/
FENDER AIR EXHAUSTER
DESCRIPTION
Air exhausters, designed to conform to the body
structure, allow air entering at the front of the vehi-
cle to flow out the back. By reducing air pressure
within the vehicle, the exhausters also reduce blower
noise at any given air flow level compared to operat-
ing without them and help reduce door closing effort.
They are located in the lower rear comers of the
body.
REMOVAL
SHORT WHEELBASE
(1) Remove the rear fascia from the body. (Refer to
13 - FRAMES & BUMPERS/BUMPERS/REAR FAS-
CIA - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 18).
(3) Remove the air exhauster from the hole in the
lower aperture panel.
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 removed using the same procedure used toremove the air exhauster from the short wheelbase
model. Refer to SHORT WHEELBASE .
(1) Remove the quarter trim panel from the inside
of the left or right quarter inner panel (Refer to 23 -
BODY/INTERIOR/RIGHT QUARTER TRIM PANEL
- REMOVAL) or (Refer to 23 - BODY/INTERIOR/
LEFT QUARTER TRIM PANEL - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 19).
(1) Remove the air exhauster from the hole in the
lower aperture panel.
Fig. 18 Air Exhauster - Short Wheelbase
1 - LOWER APERTURE PANEL
2 - AIR EXHAUSTER
Fig. 19 Air Exhauster - Long Wheelbase
1 - AIR EXHAUSTER
2 - PLUG
3 - LOWER APERTURE PANEL
23 - 196 EXTERIORRS
LUGGAGE RACK CROSSBAR (Continued)

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)

SIDE VIEW MIRROR
REMOVAL
(1) Using a trim stick or equivalent, remove the
trim cover (Fig. 20).
(2) Remove the bolts.
(3) Seperate the mirror from the pillar.
(4) Disconnect the electrical connector, if equipped.
INSTALLATION
(1) Connect the electrical connector, if equipped.
(2) Place side view mirror in position on vehicle
(Fig. 20).
(3) Install the bolts.
(4) Install the trim cover.
Fig. 20 SIDE VIEW MIRROR
1 - MIRROR
2 - MIRROR TRIM COVER
3 - A-PILLAR
4 - BOLTS
23 - 198 EXTERIORRS

HOOD
TABLE OF CONTENTS
page page
HINGE
REMOVAL.............................199
INSTALLATION..........................199
HOOD
REMOVAL.............................200
INSTALLATION..........................200
LATCH
REMOVAL.............................200INSTALLATION..........................200
LATCH RELEASE CABLE
REMOVAL.............................201
INSTALLATION..........................201
LATCH STRIKER
REMOVAL.............................201
INSTALLATION..........................201
HINGE
REMOVAL
(1) Remove hood.
(2) Remove wiper unit. Refer to Group 8K, Wind-
shield Wipers and Washers, for procedure.
(3) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation.
(4) Remove pivot bolt from the body half of hood
hinge.
(5) Remove bolts attaching body half of hood hinge
to front fender flange and remove hinge from vehicle
(Fig. 1).
INSTALLATION
(1) If necessary, paint new hinge before installa-
tion.
(2) Place body half of hood hinge in position on
vehicle.
(3) Install bolts attaching hood hinge to front
fender flange. Tighten bolts to 8 N´m (70 in. lbs.)
torque.
(4) Install pivot bolt to the body half of hood hinge.
Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(5) Install wiper unit. Refer to Group 8K, Wind-
shield Wipers and Washers, for proper procedures.
(6) Install hood.
(7) Align all marks and secure bolts. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers. Shims can be added or removed under hood
hinge to achieve proper hood height. Tighten bolts to
13.5 N´m (10 ft. lbs.) torque.
Fig. 1 Hood Hinge
1 - HOOD
2 - HOOD HALF OF HOOD HINGE
3 - HOOD HINGE PIVOT BUSHING
4 - BODY HALF OF HOOD HINGE
5 - FENDER
RSHOOD23 - 199

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 attaching hood to hinge
and loosen the bottom bolts until they can be
removed by hand (Fig. 2).
(4) With assistance from a helper at the opposite
side of the vehicle to support the hood, remove bot-
tom bolts attaching 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
to support the hood, install bottom bolts attaching
hood to hinge finger tight.
(2) Install top bolts attaching hood to hinge finger
tight.
(3) Position bolts at marks and tighten. Tighten
bolts to 13.5 N´m (120 in. lbs.) torque. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers.
(4) Verify hood operation and alignment.
LATCH
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching hood latch to radiator
closure panel crossmember (Fig. 3).
(3) Remove hood latch from crossmember.
(4) Disconnect hood release cable from hood latch
(Fig. 4).
(5) Remove hood latch from vehicle.
INSTALLATION
(1) Position hood latch on vehicle.
(2) Connect hood release cable from hood latch.
(3) Position hood latch on crossmember.
Fig. 2 Hood
1 - HOOD
2 - HOOD LATCH STRIKER
3 - HOOD HALF OF HOOD HINGE
Fig. 3 Hood Latch
1 - HOOD RELEASE CABLE
2 - HOOD LATCH
3 - RADIATOR CLOSURE PANEL CROSSMEMBER
Fig. 4 Hood
1 - RELEASE CABLE CASE
2 - HOOD LATCH
3 - RELEASE CABLE END
23 - 200 HOODRS