CHRYSLER VOYAGER 2002 Service Manual

HINGE
REMOVAL
(1) Release front door latch and open door.
(2) Mark hinge foot print on both door and pillar
to aid when installing door.
(3) Support door on suitable lifting device.
(4) Remove bolts attaching front door to door
hinge.
(5) Remove bolts attaching hinge to pillar.
(6) Remove door hinge from vehicle.
INSTALLATION
CAUTION: When installing a new hinge, make sure
that the head of each hinge pin is fully seated into
the door hinge. Also, remove the plastic shipping
clip and replace it with the correct metal retaining
clip once the hinge pin is seated.
(1) Paint hinge prior to installation, if necessary.
(2) Position door hinge on vehicle.
(3) Install bolts attaching hinge to pillar. Tighten
bolts to 34 N´m (25 ft. lbs.).
(4) Install bolts attaching front door to door hinge.
Tighten bolts to 34 N´m (25 ft. lbs.).
(5) Align door to achieve equal spacing to sur-
rounding body panels. Panels should be flush across
all gaps.
(6) Verify door alignment and operation. Adjust as
necessary.
LATCH
REMOVAL
(1) Roll door glass up.
(2) Remove front door trim panel. (Refer to 23 -
BODY/DOOR - FRONT/TRIM PANEL - REMOVAL)
(3) Remove watershield as necessary to gain access
to the outside door handle.
(4) Through access hole at rear of inner door
panel, disconnect wire connector from power door
lock motor, if equipped.
(5) Disengage clips holding linkage to door latch
(Fig. 9).
(6) Remove linkages from door latch.
(7) Remove screws attaching door latch to door end
frame (Fig. 10).
(8) Remove door latch from door.
INSTALLATION
NOTE: The screws attaching the door latch to the
door end frame have nylon patches on the threads.
All screws must be replaced when the latch has
been removed.
(1) Insert inside handle latch link to door latch
and engage clip (Fig. 9).
Fig. 8 FRONT DOOR FRAME CLOSEOUT
MOLDINGS
1 - FRONT DOOR FRAME HEADER CLOSEOUT MOLDING
2 - FRONT DOOR FRAME B-PILLAR CLOSEOUT MOLDING
3 - FRONT DOOR FRAME A-PILLAR CLOSEOUT MOLDING
4 - FRONT DOOR
5 - FRONT DOOR FRAME
Fig. 9 LATCH ASSEMBLY
1 - OUTSIDE HANDLE TO LATCH LINK
2 - KEY CYLINDER TO LATCH LINK
3 - LATCH ASSEMBLY
4 - INSIDE HANDLE LINK AND SLEEVE
5 - LOCK KNOB LINK
23 - 18 DOOR - FRONTRS
FRAME CLOSEOUT MOLDING (Continued)
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(2) Place door latch in position on door end frame.
(3) Install screws attaching door latch to door end
frame. Tighten screws to 10 N´m (90 in. lbs.) torque
(Fig. 10).
(4) Insert other linkages to door latch and engage
clips.
(5) Connect wire connector into power door lock
motor, if equipped.
(6) Insert a hex wrench through the elongated hole
located in the door shut face above the latch.
(7) Loosen allen head screw.
(8) Pull outward on the outside door handle and
release.
(9) Tighten allen head screw.
(10) Verify door latch and power door lock opera-
tion.
(11) Install watershield and front door trim panel.
LATCH STRIKER
REMOVAL
(1) Mark outline of door striker on B-pillar to aid
in installation.
(2) Remove screws attaching door latch striker to
B-pillar (Fig. 11).
(3) Remove door latch striker from vehicle.
(4) Retrieve any shims found between latch striker
and B-pillar.
INSTALLATION
(1) Position latch striker and any shims retrieved
on vehicle.
(2) Loosely install screws attaching latch striker to
B-pillar.
(3) Align latch striker to outline on B-pillar made
previously.
(4) Tighten fasteners to 28 N´m (21 ft. lbs.) torque.
(5) Verify door fit and operation. Adjust latch
striker as necessary.
LOCK CYLINDER
REMOVAL
(1) Roll door glass up.
(2) Remove front door watershield as necessary to
gain access to the outside door handle. (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.
Fig. 10 FRONT DOOR LATCH
1 - FRONT DOOR
2 - LATCH ASSEMBLY
7 - INSIDE HANDLE LINK
Fig. 11 DOOR LATCH STRIKER
1 - B-PILLAR
2 - SHIM
3 - DOOR LATCH STRIKER
RSDOOR - FRONT23-19
LATCH (Continued)
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(5) Disengage clip holding door latch linkage to
door latch (Fig. 12).
(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 attaching outside door handle to
door outer panel.
(10) Remove outside door handle from vehicle.
(11) Disengage clip holding lock cylinder into out-
side handle.
(12) Pull lock cylinder from door handle.
INSTALLATION
(1) Engage clip into outside handle to hold lock
cylinder (Fig. 12).
(2) With link arm toward rear of vehicle, push lock
cylinder into door handle until clip snaps into place.
(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 attaching 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 watershield and door trim panel.
TRIM PANEL
REMOVAL
(1) Remove the plug and remove screw attaching
door pull cup to inner door panel.
(2) Remove switch bezel and disconnect power win-
dow/memory switch.
(3) Remove screws attaching trim panel to door
from below map pocket.
(4) If equipped, remove window crank. (Refer to 23
- BODY/DOOR - FRONT/WINDOW CRANK -
REMOVAL)
(5) Remove screw holding door trim to door panel
from behind inside latch release handle.
(6) Disengage clips attaching door trim to door
frame around perimeter of panel.
(7) Lift trim panel upward to disengage flange
from inner belt molding at top of door.
(8) Tilt top of trim panel away from door to gain
access to latch linkage.
(9) Disengage clip attaching linkage rod to inside
latch release handle (Fig. 13).
(10) Separate linkage rod from latch handle.
(11) Disconnect the power door switch, courtesy
lamp electrical connectors.
Fig. 12 OUTSIDE DOOR HANDLE
1 - CLIP
2 - LOCK CYLINDER
3 - KEY CYLINDER TO LATCH LINK
4 - OUTSIDE HANDLE TO LATCH LINK
5 - LOCK KNOB LINK6 - FRONT DOOR
7 - KEY POSITION SWITCH
8 - OUTSIDE HANDLE
23 - 20 DOOR - FRONTRS
LOCK CYLINDER (Continued)
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(12) Remove front door trim panel from vehicle.
INSTALLATION
(1) Hold top of trim panel away from door to gain
access to latch linkage.
(2) Place linkage rod in position on latch handle.
(3) Engage clip to hold linkage rod to inside latch
release handle.
(4) Place front door trim panel in position on door.
(5) Install trim panel into inner belt molding at
top of door.
(6) Install clips to attach door trim to door frame
around perimeter of panel.
(7) If equipped, install screw to attach door trim to
door panel behind inside latch release handle.
(8) If equipped, connect power switch into wire
connector.
(9) Place power accessary switch in position on
door trim.
(10) Connect wire connector into memory seat/mir-
ror switch and install switch into trim panel.
(11) Install screws to attach accessary switch
panel to door trim.
(12) Install screw cover into switch panel.
(13) If equipped, install window crank.
(14) If equipped, install screws to attach trim
panel to door inside map pocket.
(15) If equipped, install screw to attach door pull
cup to inner door panel.
(16) If equipped, install screws to attach door
assist handle to inner door panel.
(17) Connect wire connector into courtesy lamp.
(18) Install lamp in door trim.
(19) Install switch bezel.
WATERSHIELD
REMOVAL
(1) Remove door trim panel.
(2) Remove the front door speaker.
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
INSTALLATION
(1) Insure that enough adhesive remains to
securely retain the water dam. Replace as necessary.
(2) Place the sound shield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(3) Install door trim panel.
WINDOW CRANK
REMOVAL
(1) Using a window crank removal tool, disengage
clip attaching window crank to regulator shaft (Fig.
14).
NOTE: Wrap a shop towel around the window crank
to catch the clip when it springs out.
(2) Pull window crank from regulator shaft.
INSTALLATION
(1) Place the clip on to the window crank handle.
(2) Position window crank to regulator shaft.
(3) Push window crank onto regulator shaft to
engage retaining clip.
Fig. 13 INSIDE DOOR HANDLE LINKAGE
1 - DOOR LATCH HANDLE
2 - DOOR TRIM
3 - LATCH LINKAGE
4 - CLIP
5 - MEMORY SEAT SWITCH
Fig. 14 WINDOW CRANK - TYPICAL
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
RSDOOR - FRONT23-21
TRIM PANEL (Continued)
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WINDOW REGULATOR
REMOVAL
(1) Remove the watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(2) Remove door glass retaining clips and secure
the window in the up position using masking tape or
equivalent (Fig. 15).
(3) Disconnect wire connector from power window
motor, if equipped.
(4) Loosen screws attaching front and rear window
guide rails to inner door panel (Fig. 16).
(5) Remove screw heads on guide rails from key
hole slots in inner door panel.
(6) Loosen screws attaching regulator to inner door
panel.
(7) Remove regulator from inner door panel.
(8) Extract rear guide rail through inner door
panel rear access hole (Fig. 17).
(9) Extract front guide rail through front access
hole.
INSTALLATION
(1) Insert front guide rail through front access
hole.
(2) Insert rear guide rail through rear access hole.
(3) Place window regulator in position on inner
door panel.(4) Place screw heads on guide rails in position
through key hole slots in inner door panel.
(5) Tighten screws to attach front and rear guide
rails to inner door panel.
(6) Connect wire connector into power window
motor, if equipped.
(7) Install door glass.
(8) Verify door glass alignment and operation.
(9) Install sound shield and door trim panel.
Fig. 15 FRONT DOOR GLASS CLIPS
1 - DOOR GLASS
2 - GLASS LIFT PLATE
3 - CLIP
4 - GUIDE RAIL
5 - REGULATOR LIFT PLATE
Fig. 16 FRONT DOOR MANUAL WINDOW
REGULATOR - TYPICAL
1 - FRONT DOOR
2 - MANUAL WINDOW REGULATOR
3 - GUIDE RAILS
Fig. 17 FRONT DOOR POWER WINDOW - TYPICAL
1 - POWER WINDOW MOTOR
2 - FRONT DOOR
3 - GUIDE RAILS
23 - 22 DOOR - FRONTRS
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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 (Fig. 12).
(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.(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. 12). Tighten nuts to 6 N´m (50
in. lbs.).
(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.
RSDOOR - FRONT23-23
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DOORS - SLIDING
TABLE OF CONTENTS
page page
CENTER HINGE
REMOVAL.............................24
INSTALLATION.........................24
SLIDING DOOR STOP BUMPER BEZEL
REMOVAL.............................25
INSTALLATION.........................25
STOP BUMPER
REMOVAL.............................25
INSTALLATION.........................25
HOLD OPEN LATCH
REMOVAL.............................25
INSTALLATION.........................25
HOLD OPEN LATCH STRIKER
REMOVAL.............................26
INSTALLATION.........................26
LATCH / LOCK ASSEMBLY
REMOVAL.............................26
INSTALLATION.........................26
CENTER STRIKER
REMOVAL.............................27
INSTALLATION.........................27
LOWER HINGE
REMOVAL.............................28
INSTALLATION.........................28
REAR LATCH STRIKER
REMOVAL.............................28
INSTALLATION.........................28
SLIDING DOOR
REMOVAL.............................29
INSTALLATION.........................29
ADJUSTMENTS
SLIDING DOOR ADJUSTMENTS..........30STABILIZER
REMOVAL.............................32
INSTALLATION.........................32
STABILIZER SOCKET
REMOVAL.............................33
INSTALLATION.........................33
TRIM PANEL
REMOVAL.............................33
INSTALLATION.........................33
INSIDE LATCH HANDLE
REMOVAL.............................33
INSTALLATION.........................34
BELLCRANK
REMOVAL.............................34
INSTALLATION.........................34
OUTSIDE HANDLE
REMOVAL.............................35
INSTALLATION.........................35
UPPER HINGE
REMOVAL.............................36
INSTALLATION.........................36
OUTSIDE HANDLE CABLE
REMOVAL.............................36
INSTALLATION.........................37
INSIDE HANDLE CABLE
REMOVAL.............................37
INSTALLATION.........................37
HOLD OPEN LATCH CABLE
REMOVAL.............................38
INSTALLATION.........................38
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 attaching center hinge to sliding
door.(5) Remove center hinge from sliding door.
(6) Roll center hinge to rear of roller channel.
(7) Remove center hinge from vehicle.INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
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.
23 - 24 DOORS - SLIDINGRS
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(2) Roll center hinge forward in roller channel.
(3) Place center hinge in position on sliding door
and align marks.
(4) Install bolts attaching center hinge to sliding
door.
(5) Verify sliding door alignment and operation.
SLIDING DOOR STOP BUMPER
BEZEL
REMOVAL
(1) Using a trim stick (C-4755), disengage clips
attaching door stop bumper bezel to the door trim
panel.
(2) Remove bezel from vehicle (Fig. 1).
INSTALLATION
(1) Place door stop bumper bezel into position (Fig.
1).
(2) Engage clips attaching door stop bumper bezel
to the door trim panel.
STOP BUMPER
REMOVAL
(1) Remove door stop bumper bezel.
(2) Loosen screws attaching rear of stop bumper to
door inner panel (Fig. 1).
(3) Remove screw attaching front of door stop
bumper to door inner panel.
(4) Remove door stop bumper from vehicle.
INSTALLATION
(1) Place stop bumper in position on vehicle.
(2) Install screw attaching front of stop bumper to
door inner panel (Fig. 1).(3) Tighten screws attaching rear of stop bumper
to door inner panel.
(4) Install door stop bumper bezel.
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 attaching hold open latch to lower
roller arm (Fig. 2).
(4) Remove hold open latch from lower arm.
(5) Disconnect cable from hold open latch.
(6) Remove hold open latch from vehicle.
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 attaching the hold open latch to
lower roller arm. Tighten nuts to 5 N´m (45 in. lbs.)
torque.
(5) Install sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(6) Verify sliding door operation.
Fig. 1 SLIDING DOOR STOP BUMPER
1 - DOOR STOP BUMPER
2 - DOOR STOP BUMPER BEZEL
3 - SLIDING DOOR
Fig. 2 SLIDING DOOR HOLD OPEN LATCH
1 - SLIDING DOOR HOLD OPEN LATCH - MANUAL DOOR
2 - LOWER ROLLER ARM
RSDOORS - SLIDING23-25
CENTER HINGE (Continued)
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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 two bolts attaching sliding door hold
open latch striker to door sill (Fig. 3).
(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 two bolts 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 ASSEMBLY
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.
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.
(4) Disengage external cable from latch/lock
assembly (Fig. 4).
(5) Remove foam block.
(6) Remove inside door handle assembly (Refer to
23 - BODY/DOORS - SLIDING/INSIDE LATCH
HANDLE - REMOVAL).
(7) Disengage inside cable from latch/lock assem-
bly.
(8) Disengage link from bellcrank.
(9) Disengage hold open latch cable from lower
hinge.
(10) Remove bolts attaching latch/lock control to
sliding door (Fig. 5).
(11) If equipped, lower latch and disconnect wire
connector from power door lock motor.
(12) Remove latch/lock from door.
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) Place latch/lock in position on door (Fig. 5).
(3) If equipped, engage wire connector into power
door lock motor (Fig. 4).
(4) Insert bolt into slots in sliding door inner
panel.
(5) Tighten bolts attaching latch/lock assembly to
sliding door.
(6) Engage inside cable into latch/lock assembly.
Fig. 3 SLIDING DOOR HOLD OPEN LATCH STRIKER
1 - POWER DOOR LOWER TRACK
2 - POWER DOOR HOLDING STRIKER
3 - MANUAL DOOR HOLDING STRIKER
4 - MANUAL DOOR LOWER TRACK
23 - 26 DOORS - SLIDINGRS
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(7) Install inside door handle assembly (Refer to
23 - BODY/DOORS - SLIDING/INSIDE LATCH
HANDLE - INSTALLATION).
(8) Install foam block.
(9) Engage external cable to latch/lock assembly.
(10) Engage link rod to bellcrank.
(11) Engage hold open latch cable from lower
hinge.(12) Engage clip to hold bellcrank link to latch/lock
control.
(13) Verify sliding door operation.
(14) Install latch/lock cover.
(15) Insure that enough adhesive remains to
securely retain the watershield. Replace as necessary.
(16) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(17) Install sliding door stop bumper.(Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(18) Install sliding door trim panel.(Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
CENTER STRIKER
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove bolts attaching stop bumper. Remove
stop bumper from door.
(3) Remove screws attaching center striker assem-
bly to door end frame (Fig. 6).
(4) Remove center striker assembly from door
through access hole.
INSTALLATION
(1) Place center striker in position on door through
access hole (Fig. 6).
(2) Install screws to attach center striker to door
end frame.
Fig. 4 SLIDING DOOR LATCH/LOCK ASSEMBLY
1 - SLIDING DOOR
2 - LATCH LOCK ASSEMBLY
Fig. 5 REMOVING SLIDING DOOR LATCH/LOCK
ASSEMBLY
1 - WIRE HARNESS
2 - LATCH/LOCK ASSEMBLY
3 - BELLCRANK LINK ROD
4 - LINK AND SLEEVE ASSEMBLY
Fig. 6 SLIDING DOOR CENTER STRIKER
ASSEMBLY
1 - STRIKER BOLT ASSEMBLY
2 - SLIDING DOOR
RSDOORS - SLIDING23-27
LATCH / LOCK ASSEMBLY (Continued)
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