CHRYSLER VOYAGER 2001 Service Manual

PAINT CODE
DESCRIPTION
Exterior vehicle body colors are identified on the
Body Code plate. The plate is located in the engine
compartment on the radiator closure panel cross-
member. Refer to the Introduction section at the
front of this manual for body code plate description.
The paint code is also identified on the Vehicle Safety
Certification Label which is located on the drivers
door shut face. The first digit of the paint code listed
on the vehicle indicates the sequence of application,
ie: P= primary coat, Q= secondary coat. The codes
listed in the color code charts are used for manufac-
turing purposes. The first digit may vary from the
Body Code Plate.
BASE COAT/CLEAR COAT
FINISH
DESCRIPTION
On most vehicles a two-part paint application (base
coat/clear coat) is used. Color paint that is applied to
primer is called base coat. The clear coat protects the
base coat from ultraviolet light and provides a dura-
ble high-gloss finish.
CAUTION:
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning solvents
on painted surfaces. Damage to finish or color can
result.
PAINT TOUCH-UP
DESCRIPTION
When a painted metal surface has been scratched
or chipped, it should be touched-up as soon as possi-
ble to avoid corrosion. For best results, use Moparž
Scratch Filler/Primer, Touch-Up Paints and Clear Top
Coat. Refer to Introduction group of this manual for
Body Code Plate information.
WARNING:
USE A OSHA APPROVED BREATHING FILTER
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT.
OPERATION
(1) Scrape loose paint and corrosion from inside
scratch or chip.(2) Clean affected area with Moparž Tar/Road Oil
Remover, and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur-
face finish. The applicator brush should be wet
enough to puddle-fill the defect without running. Do
not stroke brush applicator on body surface. Allow
the filler/primer to dry hard.
(4) Cover the filler/primer with color touch-up
paint. Do not overlap touch-up color onto the original
color coat around the scratch or chip. Butt the new
color to the original color, if possible. Do not stroke
applicator brush on body surface. Allow touch-up
paint to dry hard.
(5) On vehicles without clear coat, the touch-up
color can be lightly finesse sanded (1500 grit) and
polished with rubbing compound.
(6) On vehicles with clear coat, apply clear top coat
to touch-up paint with the same technique as
described in Step 4. Allow clear top coat to dry hard.
If desired, Step 5 can be performed on clear top coat.
WARNING:
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL ± BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL ± BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT.
WET SANDING/BUFFING &
POLISHING
DESCRIPTION
Minor acid etching, orange peel, or smudging in
clear coat or single-stage finishes can be reduced
with light finesse sanding, hand buffing, and polish-
ing.If the finish has been finesse sanded in the
past, it cannot be repeated. Finesse sanding
operation should be performed by a trained
automotive paint technician.
CAUTION: Do not remove clear coat finish, if
equipped. Base coat paint must retain clear coat for
durability.
RSPAINT23 - 221

SEATS
TABLE OF CONTENTS
page page
CHILD SEAT MODULE
REMOVAL.............................223
INSTALLATION..........................223
QUAD CHILD SEAT
REMOVAL.............................225
INSTALLATION..........................225
HEADREST
REMOVAL.............................225
INSTALLATION..........................225
HEADREST SLEEVE
REMOVAL.............................226
INSTALLATION..........................226
RECLINER HANDLE
REMOVAL.............................226
INSTALLATION..........................226
ARMREST
REMOVAL.............................226
INSTALLATION..........................226
CENTER ARMREST 3 PASSENGER BENCH
REMOVAL.............................227
INSTALLATION..........................227
FRONT SEAT
REMOVAL.............................227
INSTALLATION..........................227
FRONT SEATBACK
REMOVAL.............................227
INSTALLATION..........................228
FRONT SEATBACK ASSIST STRAP
REMOVAL.............................228
INSTALLATION..........................228
FRONT SEATBACK PANEL
REMOVAL.............................228
INSTALLATION..........................228
FRONT SEATBACK COVER
REMOVAL.............................229
INSTALLATION..........................229
FRONT/QUAD SEAT CUSHION
REMOVAL.............................229
INSTALLATION..........................229
FRONT SEAT CUSHION SIDE COVER
REMOVAL.............................230
INSTALLATION..........................230
FRONT SEAT RISER - MANUAL TRACK
REMOVAL.............................230
INSTALLATION..........................230
FRONT SEAT TRACK POWER ADJUSTER
REMOVAL.............................231
INSTALLATION..........................231FRONT SEAT TRACK MANUAL ADJUSTER
REMOVAL.............................231
INSTALLATION..........................231
FRONT SEAT TRACK - FRONT COVER
REMOVAL.............................232
INSTALLATION..........................232
FRONT SEAT TRACK - REAR COVER
REMOVAL.............................232
INSTALLATION..........................232
QUAD BUCKET SEAT SIDE SHIELD/CUP
HOLDER
REMOVAL.............................233
INSTALLATION..........................233
QUAD BUCKET SEAT SIDE SHIELD - NO CUP
HOLDER
REMOVAL.............................234
INSTALLATION..........................234
QUAD BUCKET SEAT RISER
REMOVAL.............................234
INSTALLATION..........................234
BUCKET SEAT BACK - QUAD BUCKET
REMOVAL.............................234
INSTALLATION..........................235
BENCH SEATBACK PANEL
REMOVAL.............................235
INSTALLATION..........................236
SEAT CUSHION COVER - QUAD BUCKET,
50/50 SPLIT, BENCH
REMOVAL.............................236
INSTALLATION..........................236
BENCH SEAT RISER - 50/50 SPLIT
REMOVAL.............................237
INSTALLATION..........................237
BENCH SEAT RISER - SECOND ROW
REMOVAL.............................237
INSTALLATION..........................237
BENCH SEAT RISER - THIRD ROW
REMOVAL.............................237
INSTALLATION..........................237
SEAT BACK HINGE COVERS - QUAD BUCKET,
50/50 SPLIT, BENCH
REMOVAL.............................238
INSTALLATION..........................238
BENCH SEAT BACK HINGE
REMOVAL.............................238
INSTALLATION..........................238
BENCH SEAT BACK
REMOVAL.............................239
INSTALLATION..........................240
23 - 222 SEATSRS

BENCH SEAT BACK COVER
REMOVAL.............................240
INSTALLATION..........................240
BENCH SEAT TRACK
REMOVAL.............................240
INSTALLATION..........................240
PLASTIC GROCERY BAG RETAINER
REMOVAL.............................241
INSTALLATION..........................241
UNDER SEAT STORAGE BIN
REMOVAL.............................241INSTALLATION..........................241
UNDER SEAT STORAGE BIN GUIDE
REMOVAL.............................242
INSTALLATION..........................242
UNDER SEAT STORAGE BIN LOCK/LATCH
REMOVAL.............................242
INSTALLATION..........................242
LUMBAR SUPPORT
REMOVAL.............................242
INSTALLATION..........................242
CHILD SEAT MODULE
REMOVAL
(1) Close child restraint seat.
(2) Remove seat back cover.
(3) Remove screws attaching child restraint seat
module hinges to seat back frame lower rail (Fig. 1).
(4) Return seat back to upright position.
(5) Disengage push in fasteners attaching upper
bolster to child restraint seat module (Fig. 2).
(6) Remove screws attaching top of module to seat
back frame upper rail (Fig. 3).
(7) Remove child restraint seat module from seat
back (Fig. 4).
INSTALLATION
(1) Place child restraint seat module in position on
seat back (Fig. 4).
(2) Position seat back hinge interlock lever over
the top of the outboard child restraint seat hinge
(Fig. 5).
(3) Install screws attaching child restraint seat
module hinges to seat back frame lower rail (Fig. 1).(4) Install screws attaching top of module to seat
back frame upper rail (Fig. 3). Tighten nuts to 7 N´m
(62 in. lbs.) torque.
Fig. 1 Child Restraint Seat Lower Hinge
1 - CHILD RESTRAINT SEAT MODULE
2 - LOWER HINGE
Fig. 2 Child Restraint Seat Upper Bolster
1 - UPPER BOLSTER
2 - CHILD RESTRAINT SEAT MODULE
3 - PUSH-IN FASTENER
Fig. 3 Child Restraint Seat Upper Screws
1 - UPPER BOLSTER
2 - CHILD RESTRAINT SEAT MODULE
RSSEATS23 - 223

(5) Install push in fasteners attaching upper bol-
ster to child restraint seat module (Fig. 2).
(6) Return seat back to folded position.
(7) Install seat back cover.
(8) Verify child restraint seat operation.
SYNCHRONIZING CABLE ADJUSTMENT
NOTE:
Bench seats equipped with child restraint seats
have an interlock feature that will not allow the seat
back to fold forward with the child seat open.
If the seat back hinges do not release at the same
time the synchronizing cable must be adjusted.
(1) Remove seat from vehicle. Refer to Owner's
Manual for proper procedures.
(2) Disengage cable from the recline mechanism by
pulling the cable end toward the front of the seat
(Fig. 6).
(3) Pull U-shaped locking tab on self-adjusting
mehcanism to disengage auto-adjust feature.(4) Reattach self-adjusting mechanism, pulling
against spring load to tighten cable.
(5) Press locking tab onto the adjusting mecha-
nism to lock into place.
Fig. 4 Child Restraint Seat Module
1 - 1ST REAR SEAT BACK
2 - CHILD RESTRAINT SEAT MODULE
3 - SEAT BACK HINGE INTERLOCK LEVER
Fig. 5 Interlock Lever
1 - CHILD RESTRAINT SEAT HINGE
2 - SEAT BACK HINGE INTERLOCK LEVER
3 - 1ST REAR SEAT BACK
4 - SEAT BACK FRAME RAIL
Fig. 6 SYNCHRONIZING CABLE
1 - CABLE END
2 - LOCKING TAB
3 - SETBACK HINGE
23 - 224 SEATSRS
CHILD SEAT MODULE (Continued)

QUAD CHILD SEAT
REMOVAL
(1) Remove the seat. Refer to Owner's Manual for
proper procedures.
(2) Remove seat back cover (Fig. 7).
(3) Remove fasteners attaching quad child seat to
the seat (Fig. 8).
(4) Remove quad child seat from the seat.
INSTALLATION
(1) Place quad child seat in position.
(2) Install fasteners and tighten to 13.5 N´m (10 ft.
lbs.)
(3) Install seat back cover.
(4) Install seat in vehicle.
HEADREST
REMOVAL
(1) Lift head restraint to top of travel.
(2) Depress lock button on side of sleeve at top of
seat back (Fig. 9).
(3) Pull head restraint from top of seat back.
INSTALLATION
(1) Place head restraint in position.
(2) Depress lock button on side of sleeve at top of
seat back.
(3) Push heat restraint down into position.
Fig. 7 Seat Back Cover
1 - SEAT BACK COVER
Fig. 8 CHILD RESTRAINT SEAT BACK
1 - FASTENERS
2 - J-STRAPS
3 - FASTENERS
Fig. 9 Head Restraint
1 - HEAD RESTRAINT
2 - SLEEVES
3 - LOCK BUTTON
RSSEATS23 - 225

HEADREST SLEEVE
REMOVAL
(1) Remove head rest.
(2) Disengage closure attaching bottom of trim
cover together.
(3) Reach under trim cover through opening at
bottom of seat back.
(4) Pinch retainer barbs on end of head restraint
sleeve together (Fig. 10).
(5) Pull head restraint sleeve upward and out the
top of the seat back frame guide tube (Fig. 11).
INSTALLATION
(1) Insert head restraint sleeve into guide tube at
top of seat back.
(2) Push head restraint sleeve downward until
retainer clicks into lock position.
(3) Engage closure to hold bottom of trim cover
together.
(4) Install head restraint.
RECLINER HANDLE
REMOVAL
(1) Remove screw holding recliner handle to
recliner spline shaft (Fig. 12).
(2) Remove recliner handle from spline shaft.
INSTALLATION
(1) Place recliner handle in position on spline
shaft.
(2) Install screw to hold recliner handle to recliner
spline shaft (Fig. 12).
ARMREST
REMOVAL
(1) Using a small flat blade, pry cap from side of
armrest (Fig. 13).
(2) Remove bolt attaching armrest to seat back.
(3) Remove armrest from seat back.
INSTALLATION
(1) Place armrest in position on seat back.
Fig. 10 Head Restraint Sleeve Retainer
1 - GUIDE TUBE
2 - PINCH RETAINER TO RELEASE
3 - SEAT BACK FRAME
Fig. 11 Head Restraint Sleeve
1 - SEAT BACK FRAME
2 - HEAD RESTRAINT SLEEVE
3 - RETAINER
4 - GUIDE TUBE
Fig. 12 Recliner Handle ± Manual
1 - CUSHION SIDE COVER
2 - RECLINER SPLINE
3 - SCREW
4 - RECLINER HANDLE
23 - 226 SEATSRS

(2) Install bolt attaching armrest to seat back.
Tighten bolt to 29N´m (21 ft. lbs.) torque.
(3) Install side cap into the side of the armrest.
CENTER ARMREST 3
PASSENGER BENCH
REMOVAL
(1) Remove screws attaching the plastic grocery
bag retainer. (Refer to 23 - BODY/SEATS/PLASTIC
GROCERY BAG RETAINER - REMOVAL).
(2) Remove seat back rear cover.
(3) Remove E-clip from pivot post.
(4) Remove pivot post.
(5) Remove armrest.
(6) Remove pivot bushings.
INSTALLATION
(1) Install pivot bushings.
(2) Place armrest in position.
(3) Install pivot post.
(4) Install E-clip to pivot post.
(5) Install seat back rear cover.(6) Install screws attaching the plastic grocery bag
retainer. (Refer to 23 - BODY/SEATS/PLASTIC GRO-
CERY BAG RETAINER - INSTALLATION).
FRONT SEAT
REMOVAL
(1) From under vehicle, remove nuts attaching
front seat risers to the floor.
(2) Remove seat and riser from floor (Fig. 14).
(3) Tip seat rearward and disconnect wire connec-
tors from body harness, if equipped.
(4) Remove seat from vehicle.
INSTALLATION
(1) Place seat into position
(2) Tip seat rearward and connect wire connectors
to body harness, if equipped.
(3) Place seat and riser into floor.
(4) From under vehicle, install nuts attaching
front seat risers to the floor. Tighten nuts to 60 N´m
(44 ft. lbs.) torque.
FRONT SEATBACK
REMOVAL
NOTE: On front seats equipped with side air bags,
the seatback is serviced as an assembly.
(1) Remove head rest sleeves. (Refer to 23 - BODY/
SEATS/HEADREST SLEEVE - REMOVAL).
Fig. 13 Armrest
1 - SEAT BACK
2 - ARMREST
3 - SHOULDER BOLT
4 - CAP
5 - WASHER
6 - STOP SCREW
Fig. 14 Front Seat
1 - FRONT SEAT
2 - CONNECTORS
3 - B-PILLAR
RSSEATS23 - 227
ARMREST (Continued)

(2) Remove the armrest. (Refer to 23 - BODY/
SEATS/ARMREST - REMOVAL).
(3) Remove the seatback recliner lever.
(4) Remove the lumbar adjustment lever.
(5) Remove both seat cushion side covers. (Refer to
23 - BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - REMOVAL).
(6) Remove nut attaching the recliner to the seat-
back frame (Fig. 15).
(7) Remove both pivot bolts and remove seatback
from recliner.
INSTALLATION
(1) Place seat back into position.
(2) Install both pivot bolts attaching seat back
frame to seat track. Tighten bolts to 54 N´m (40 ft.
lbs.) torque.
(3) Install nut attaching the recliner to the seat
back frame. Tighten nut to 12 N´m (105 in. lbs.)
torque.
(4) Install both seat cushion side covers. (Refer to
23 - BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - INSTALLATION).
(5) Install the lumbar adjustment lever.
(6) Install the seat back recliner lever.
(7) Install the armrest. (Refer to 23 - BODY/
SEATS/ARMREST - INSTALLATION).(8) Install headrest sleeves. (Refer to 23 - BODY/
SEATS/HEADREST SLEEVE - INSTALLATION).
FRONT SEATBACK ASSIST
STRAP
REMOVAL
(1) Using a small screw driver, pry screw plugs
from ends of assist strap (Fig. 16).
(2) Remove screws attaching assist strap to seat-
back.
(3) Remove assist strap from vehicle.
INSTALLATION
(1) Place assist strap in position on vehicle.
(2) Install screws attaching assist strap to seat
back. Tighten screws to 2.5 N´m (22 in. lbs.).
(3) Insert screw plugs into ends of assist strap
(Fig. 16).
FRONT SEATBACK PANEL
REMOVAL
(1) Remove the screws (Fig. 17).
(2) Tip the top of the panel away from the seat
back and lift off the hooks at the bottom to remove.
INSTALLATION
(1) Place seat back cover onto the seat and engage
the bottom hooks.
Fig. 15 FRONT SEATBACK
Fig. 16 FRONT SEATBACK ASSIST STRAP
1 - ASSIST STRAP
2 - SCREW PLUG
3 - SEAT BACK
23 - 228 SEATSRS
FRONT SEATBACK (Continued)

(2) Install the top screws.
FRONT SEATBACK COVER
REMOVAL
NOTE: On vehicles equipped with seat side air bags
the seat cover is NOT serviceable. The seat back is
serviced as an assembly. (Refer to 23 - BODY/
SEATS/SEAT BACK - REMOVAL).
(1) Remove the seat back. (Refer to 23 - BODY/
SEATS/FRONT SEATBACK - REMOVAL).
(2) Unclip J-straps as necessary.
(3) Remove seat back cover from seat back cushion
and frame assembly.
INSTALLATION
NOTE: On vehicles equipped with seat side air bags
the seat cover is NOT serviceable. The seat back is
serviced as an assembly only. (Refer to 23 - BODY/
SEATS/SEAT BACK - INSTALLATION).
(1) Fit seat cover onto seat back cushion and
frame assembly.
(2) Connect the J-straps.
(3) Install the seat back. (Refer to 23 - BODY/
SEATS/FRONT SEATBACK - INSTALLATION).
FRONT/QUAD SEAT CUSHION
REMOVAL
(1) Remove seat cushion side covers, and leave
connector connected, if equipped. (Refer to 23 -
BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - REMOVAL).
(2) On quad buckets, remove the seat side shield
and cup holder. (Refer to 23 - BODY/SEATS/SEAT
SIDE SHIELD/QUAD BUCKET SEAT SIDE
SHIELD/CUP HOLDER - REMOVAL) and (Refer to
23 - BODY/SEATS/QUAD BUCKET SEAT SIDE
SHIELD - NO CUP HOLDER - REMOVAL).
(3) Remove seat track front and rear covers if
equipped. (Refer to 23 - BODY/SEATS/SEAT TRACK
REAR COVER - REMOVAL) and (Refer to 23 -
BODY/SEATS/SEAT TRACK FRONT COVER -
REMOVAL).
(4) If equipped, open stowage bin to access front
pan bolts.
(5) Remove bolts attaching seat cushion pan to
seat track.
(6) Disconnect wire connectors, if equipment.
(7) Remove seat cushion from seat.
(8) Disengage J-strap retainers holding seat cover
to cushion.
(9) Remove seat cushion pan from cover and pad.
INSTALLATION
(1) Place seat cushion cover in position on seat
cushion.
(2) Engage J-strap retainers to hold seat cover to
cushion.
(3) Place seat cushion in position on seat.
(4) Connect wire connectors, if equipment.
(5) Install bolts attaching seat cushion to seat
track. Tighten bolts to 28.5 N´m (21 ft. lbs.) torque.
(6) If equipped, close stowage bin.
(7) Install seat track front and rear covers, if
equipped. (Refer to 23 - BODY/SEATS/SEAT TRACK
REAR COVER - INSTALLATION) and (Refer to 23 -
BODY/SEATS/SEAT TRACK FRONT COVER -
INSTALLATION).
(8) Install the quad seat side shield and cup holder
if equipped. (Refer to 23 - BODY/SEATS/QUAD
BUCKET SEAT SIDE SHIELD/CUP HOLDER -
INSTALLATION) and (Refer to 23 - BODY/SEATS/
QUAD BUCKET SEAT SIDE SHIELD - NO CUP
HOLDER - INSTALLATION).
(9) Install seat cushion side covers. (Refer to 23 -
BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - INSTALLATION).
Fig. 17 FRONT SEATBACK PANEL - TYPICAL
1 - SCREWS
2 - SEAT BACK PANEL
3 - SEAT BACK
RSSEATS23 - 229
FRONT SEATBACK PANEL (Continued)

FRONT SEAT CUSHION SIDE
COVER
REMOVAL
(1) Remove screws and plastic push pin attaching
seat cushion side cover to bucket seat (Fig. 18).
(2) Disengage J-strap along rear of seat cushion to
access screw.
(3) Remove screw attaching rear of side cover to
seat cushion frame.
(4) Remove side cover from seat cushion.
(5) If equipped, disconnect wire connector from
power seat switch (Fig. 19).
INSTALLATION
(1) Place side cover in position on seat cushion.
(2) If equipped, connect wire connector into power
seat switch.
(3) Install screw attaching rear of side cover to
seat cushion frame. Tighten screw to 1 N´m (9 in.
lbs.) torque.
(4) Engage J-strap along rear of seat cushion to
access screw.
(5) Install screws attaching seat cushion side cover
to bucket seat (Fig. 18).
FRONT SEAT RISER - MANUAL
TRACK
REMOVAL
(1) Remove seat from vehicle. (Refer to 23 - BODY/
SEATS/FRONT SEAT - REMOVAL).
(2) Remove storage bin from riser. (Refer to 23 -
BODY/SEATS/UNDER SEAT STORAGE BIN -
REMOVAL).
(3) Remove nuts attaching riser to manual seat
track (Fig. 20).
(4) Remove riser from seat.
INSTALLATION
(1) Place riser in position on seat.
(2) Install nuts attaching riser to manual seat
track (Fig. 20). Tighten fasteners to 81 N´m (60 ft.
lbs.) torque.
(3) If equipped, install storage bin into riser. (Refer
to 23 - BODY/SEATS/UNDER SEAT STORAGE BIN
- INSTALLATION).
Fig. 18 FRONT SEAT SIDE SHIELD
1 - SCREWS
2 - SIDE SHIELD
3 - SEAT CUSHION
Fig. 19 Power Seat Switch Wire Connector
1 - SEAT CUSHION SIDE COVER
2 - POWER SEAT SWITCH
3 - WIRE CONNECTOR
Fig. 20 FRONT SEAT RISER - MANUAL TRACK
1 - RISER
2 - SEAT TRACK
23 - 230 SEATSRS