Door CHRYSLER VOYAGER 2001 Service Manual

Fig. 4 Body Side Moldings ± Luxury Typical
1 - QUARTER PANEL
2 - FRONT FENDER
3 - POP-RIVET
4 - FENDER MOLDING
5 - POP-RIVET
6 - FASCIA7 - FRONT DOOR MOLDING
8 - SLIDING DOOR MOLDING
9 - QUARTER PANEL MOLDING
10 - FASCIA MOLDING
11 - POP-RIVET
23 - 188 EXTERIORRS
BODY SIDE MOLDINGS (Continued)

Fig. 5 Body Side Moldings with Applique -Typical
1 - FRONT ROCKER PANEL APPLIQUE
2 - FRONT DOOR MOLDING
3 - SLIDING DOOR MOLDING
4 - REAR ROCKER PANEL APPLIQUE5 - LIFTGATE MOLDING
6 - POP-RIVET
RSEXTERIOR23 - 189
BODY SIDE MOLDINGS (Continued)

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
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)

(5) Install the cup holder. Align the cup holder
assembly with the track and firmly slide shut to
engage retaining tang.
GLOVE BOX
REMOVAL
(1) Open glove box.
(2) Push in on sides of glove box bin and lower
door.
(3) Pivot glove box downward and disengage hinge
hooks from instrument panel.
(4) Remove glove box.
INSTALLATION
(1) Place glove box in position.
(2) Engage hinge hooks into instrument panel and
pivot glove box upward.
(3) Push in sides of glove box bin and snap glove
box assembly into instrument panel.
(4) Close glove box door.
GLOVE BOX LATCH
REMOVAL
(1) Open glove box.
(2) Push in on sides of glove box bin and lower
door.
(3) Pivot glove box downward and disengage hinge
hooks from instrument panel.
(4) Remove glove box.
(5) Remove the assembly screws.
(6) Disassemble the glove box.
(7) Separate the latch from the glove box assembly.
INSTALLATION
(1) Install the latch onto the glove box assembly.
(2) Assemble the glove box.
(3) Install the assembly screws.
(4) Engage hinge hooks into instrument panel and
pivot glove box upward.
(5) Push in sides of glove box bin and snap glove
box assembly into instrument panel.
(6) Close glove box door.
GLOVE BOX LATCH STRIKER
REMOVAL
(1) Open glove box door.
(2) Remove screws holding lock striker to instru-
ment panel.
(3) Remove glove box latch striker.
INSTALLATION
(1) Install the glove box latch striker.
(2) Install the screws holding latch striker to
instrument panel.
(3) Close glove box door.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the lower console:
(a) Remove six retaining screws.
(b) Pull rearward and disconnect the auxiliary
power outlet.
(c) Remove lower console from vehicle.
(3) Remove the bolts holding the lower supports to
the instrument panel frame.
(4) Remove the bolts holding the lower supports to
the floor pan.
(5) Disconnect the wire connectors from the Pas-
senger Airbag.
(6) Remove the two screws to each right and left
cowl trim covers.
(7) Remove the both left and right side A-pillar
trim covers using a trim stick (special tool #C-4755)
or equivalent gently pry out on the trim covers and
remove.
(8) Remove the glove box:
(a) Push in on sides of glove box bin and lower
door.
(b) Pivot glove box downward and disengage
hinge hooks from instrument panel.
(c) Remove glove box from vehicle.
(9) Disconnect the antenna lead connector from
behind the glove box.
(10) Remove the four screws to the lower steering
column cover.
(11) Remove the eight screws to the plastic knee
blocker reinforcement.
(12) Unclip the Data Link Connector (DLC) from
the instrument panel reinforcement.
(13) Remove one screw to the left side instrument
panel silencer and remove.
(14) Disconnect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.
(c) Five harness connectors.
(d) Driver airbag connector.
(15) Remove the two screws to the hood release
handle.
(16) Remove five screws to the left under column
instrument panel reinforcement brace and remove.
RSINSTRUMENT PANEL23 - 203
CUP HOLDER (Continued)

(17) Remove the two steering column shroud
retaining screws. Separate the shrouds and remove
from vehicle.
(18) Disconnect the steering column wiring. There
are seven connectors and then unclip the harness
from the column.
(19) Disconnect the ORC harness connector.
(20) Remove the four nuts retaining the steering
column and lower to the floor.
(21) Remove the four nuts attaching the instru-
ment panel to the brake pedal support bracket.
(22) Loosen the left side roll down bolt.
(23) Remove the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(24) If equipped with a mechanical transmission
range indicator:
(a) Remove the indicator cable loop.
(b) Remove the clip holding gear shift cable end
to the gear selector adapter.
(c) Pull the cable end from gear selector.
(d) Disconnect the clip for the indicator cable
and guide tube from the shift cable bracket and
move out of the way.
(25) Remove the instrument panel top cover. Using
a trim stick or equivalent, gently pry up on the front
edge of the top cover, pull rearward and remove from
vehicle.
(26) Disconnect the right side wire connectors from
the HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(27) Remove the right end cover by pulling out-
board.
(28) Remove the right side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(29) Loosen the right side roll down bolt.
(30) Disconnect the two front window defroster
grid wire connectors. One on each side of vehicle.
(31) Remove both the left and right power mirrors:
(a) Using a trim stick or equivalent, gently pry
out on mirror trim cover.
(b) Open door and remove the three torx retain-
ing screws.
(c) Disconnect the wire connector and remove
mirror from the vehicle.
(32) Feed power mirror wire harness inboard
through the A-pillar.
(33) Remove the bolts holding the instrument
panel frame to the dash panel below windshield
opening.
(34) With the help of an assistant remove the
instrument panel from vehicle. Lift the instrument
panel up off the HVAC so you won't damage the seal-
ing surface of the distribution duct.
If the instrument panel is being replaced, transfer
all parts to the new instrument panel assembly.INSTALLATION
(1) With the help of an assistant place the instru-
ment panel into vehicle on roll down bolts. As you
roll the instrument panel up, lift the instrument
panel up so the duct work does not bind or bend and
you can set it down on the HVAC housing to get the
proper seal at the distribution duct. Get one bolt
started in the dash panel.
(2) Install the bolts holding the instrument panel
frame to the dash panel below windshield opening.
(3) Feed power mirror wire harness outboard
through the A-pillar.
(4) Install both the left and right power mirrors:
(a) Connect the wire connector and install the
mirror onto the vehicle.
(b) Install the three torx retaining screws.
(c) Using a firm push, snap the mirror trim
cover into place.
(5) Connect the two front window defroster grid
wire connectors. One on each side of vehicle.
(6) Tighten the right side roll down bolt.
(7) Install the right side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(8) Install the right end cover. Position over retain-
ing slots and firmly snap into place.
(9) Connect the right side wire connectors to the
HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(10) Install the instrument panel top cover. Slide
the front edge of the top cover toward dash panel,
and firmly snap down the rear edge of the to cover to
engage clips.
(11) If equipped with a mechanical transmission
range indicator:
(a) Connect the clip for the indicator cable and
guide tube to the shift cable bracket.
(b) Install the cable end to the gear selector.
(c) Install the clip holding the gear shift cable
end to the gear selector adapter.
(d) Install the indicator cable loop.
(12) Install the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(13) Tighten the left side roll down bolt.
(14) Install the four nuts attaching the instrument
panel to the brake pedal support bracket.
(15) Install the four nuts retaining the steering
column and lower to the floor.
(16) Connect the ORC harness connector.
(17) Connect the steering column wiring. There
are seven connectors and then clip the harness to the
column.
(18) Connect the shrouds and install the two steer-
ing column shroud retaining screws.
(19) Install five screws to the left under column
instrument panel reinforcement brace.
23 - 204 INSTRUMENT PANELRS
INSTRUMENT PANEL ASSEMBLY (Continued)

(20) Install the two screws to the hood release
handle.
(21) Connect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.
(c) Five harness connectors.
(d) Driver airbag connector.
(22) Install one screw to the left side instrument
panel silencer.
(23) Clip the Data Link Connector (DLC) to the
instrument panel reinforcement.
(24) Install the eight screws to the plastic knee
blocker reinforcement.
(25) Install the four screws to the lower steering
column cover.
(26) Install the glove box:
(a) Install glove box into the vehicle. Line up the
hinges and firmly snap together.
(b) Push in on sides of glove box bin and raise
door.
(27) Install the both left and right side A-pillar
trim covers. Position trim cover over slots and firmly
snap into place.
(28) Install the two screws to each right and left
cowl trim covers.
(29) Connect the wire connectors to the Passenger
Airbag.
(30) Install the bolts holding the lower supports to
the floor pan.
(31) Install the bolts holding the lower supports to
the instrument panel frame.
(32) Install the lower console:
(a) Install lower console to vehicle.
(b) Connect the auxiliary power outlet.
(c) Install the six retaining screws.
(33) Connect the battery negative cable.
INSTRUMENT PANEL CENTER
BEZEL
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove cup holder. Refer to Body, Instrument
Panel, Cup Holder, Removal.
(3) Insert the trim stick (special tool #C-4755) or
equivalent between access cover and center bezel.
(4) Carefully pry the access cover from the instru-
ment panel.
(5) Remove the cup holder track. Refer to Body,
Instrument Panel, Cup Holder, Removal.
(6) Using a trim stick or equivalent, gently pry out
on the edge of the instrument panel center bezel and
pull outward.(7) Disconnect the wire connectors to the accessory
switches and HVAC control.
(8) Remove the instrument panel center bezel from
the vehicle.
INSTALLATION
(1) Install the instrument panel center bezel from
the vehicle.
(2) Connect the wire connectors to the accessory
switches and HVAC control.
(3) Position the center bezel over the retaining
slots and firmly snap the instrument panel center
bezel into place.
(4) Install the cup holder track. Refer to Body,
Instrument Panel, Cup Holder, Installation.
(5) Position the center bezel over the retaining
slots and firmly snap into place.
(6) Install cup holder. Refer to Body, Instrument
Panel, Cup Holder, Installation.
(7) Connect the battery negative cable.
INSTRUMENT PANEL END
COVER
REMOVAL
(1) Open passenger side front door.
(2) Place fingers in end cover grille, and with a
firm outboard pulling motion, disengage clips holding
end cover to instrument panel.
INSTALLATION
(1) Position end cover over retaining slots and
firmly snap into place.
(2) Close passenger side front door.
INSTRUMENT PANEL TOP
COVER
REMOVAL
(1) Remove A-pillar trim. Using a trim stick (spe-
cial tool #C-4755) or equivalent, gently pry out and
remove.
(2) Using a trim stick, disengage clips holding rear
edge of top cover to instrument panel.
NOTE: The Instrument Panel Top Cover may be
hard to unsnap from the instrument panel. Be sure
not to mar, scuff, or damage the instrument panel
pad.
(3) Pull top cover rearward to disengage hooks
holding front of top cover to instrument panel.
(4) Remove top cover from vehicle.
RSINSTRUMENT PANEL23 - 205
INSTRUMENT PANEL ASSEMBLY (Continued)