CHRYSLER VOYAGER 2002 Service Manual

(4) Remove A-pillar trim panels.
(5) Disconnect wire connectors to windshield
defroster grid.
(6) Place protective covers over instrument panel
and hood.
(7) Remove windshield molding. Using pliers, pull
outward on molding at the bottom of A-pillars.
(8) Using a sharp cold knife, cut urethane adhe-
sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 1). A power
cutting device can be used if available.
(9) Remove windshield from vehicle.
WINDSHIELD REMOVAL ± INTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Remove instrument panel top cover. Refer to
Group 8E, Instrument Panel and Systems.
(3) Remove A-pillar trim covers.
(4) Disconnect wire connectors to windshield
defroster grid.
(5) Place protective covers over instrument panel
and hood.
(6) Using a reciprocating or oscillating power
knife, cut urethane adhesive holding the windshield
to the A-pillars, roof header and cowl pinch weld
fences. Refer to instructions provided with the equip-
ment being used.
(7) Remove windshield from vehicle.
INSTALLATION
The urethane adhesive holding the windshield to
the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-senger compartment. If a door is slammed before
urethane bonding is cured, water leaks can result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.
To avoid stressing the replacement windshield, the
urethane bonding material on the windshield fence
should be smooth and consistent to the shape of
the replacement windshield . The support spacers
should be cleaned and properly installed on weld
studs or repair screws at bottom of windshield
opening.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the compression spacers.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement windshield. If not, the pinch weld fence
must be formed to the shape of the new glass.
(3) Remove replacement windshield from wind-
shield opening.
(4) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 2).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(5) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.
(6) Install molding to perimeter of windshield.
(7) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of windshield and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.
(8) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying time.
(9) Using a razor knife, remove as much original
urethane as possible. Do not damage paint on wind-
shield fence.
(10) Apply pinch weld primer 19 mm (0.75 in.)
wide around the windshield fence. Allow at least
three minutes drying time.
(11) If a low viscosity urethane adhesive is used,
install compression spacers on the fence around the
windshield opening (Fig. 3).
(12) Apply a 10 mm (0.4 in.) bead of urethane on
center line of windshield fence.
(13) With the aid of a helper, position the wind-
shield over the windshield opening.
(14) Slowly lower windshield glass to windshield
opening fence. Guide the molding into proper position
as necessary. Push windshield inward until molding
is flush to roof line and A-pillars (Fig. 3).
Fig. 1 CUT URETHANE AROUND WINDSHIELD
1 - COLD KNIFE
2 - WINDSHIELD
23 - 108 STATIONARY GLASSRS
WINDSHIELD (Continued)
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(15) Clean access urethane from exterior with
MopartSuper Kleen or equivalent.
(16) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place until urethane cures.
(17) Engage wire connectors to windshield
defroster grid.
(18) Install A-pillar trim panels.
(19) Install cowl cover and wipers.
(20) Install inside rear view mirror.
(21) After urethane has cured, remove tape strips
and water test windshield to verify repair.SLIDING DOOR GLASS
REMOVAL
The temperature of the vehicle should be at least
21É C (70É F) before removing the stationary quarter/
sliding door glass. Butyl sealer becomes more pliable
at high temperatures.
(1) Remove interior trim as necessary to gain
access attaching locations on back of glass.
(2) Remove nuts holding stationary glass to fence.
(3)
Using razor knife, cut butyl sealer holding glass
to fence from between the mounting studs (Fig. 4).
(4) Push glass from opening.
INSTALLATION
The temperature of the vehicle should be at least
21É C (70É F) before removing the stationary quarter/
sliding door glass. Butyl sealer becomes more pliable
at high temperatures.
The stationary glass fence should be cleaned of all
old butyl sealer.
(1) Applya6mm(0.25 in.) butyl tape around
perimeter of glass assembly encapsulation track.
Ensure that the butyl tape is wrapped around the
mounting studs.
(2) Place the glass into the opening and insert
mounting studs through holes in fence.
(3) Install nuts to hold stationary glass to fence.
CAUTION: Tighten nuts to 3.4 N´m (30 in. lbs.)
torque in the sequence indicated. Do not over
torque, or glass breakage may result (Fig. 4).
(4) Install interior trim. (Refer to 23 - BODY/
DOORS - SLIDING/TRIM PANEL - INSTALLATION)
(5) Verify alignment and flushness.
Fig. 2 WORK SURFACE SET UP AND MOLDING
INSTALLATION
1 - WINDSHIELD AND MOLDINGS
2 - BLOCKS
Fig. 3 LOWER WINDSHIELD INTO POSITION
1 - WINDSHIELD
2 - COMPRESSION SPACERS
Fig. 4 SLIDING DOOR STATIONARY GLASS
1 - NUMBERS INDICATE THE TIGHTENING SEQUENCE
2-6mmBEAD OF BUTYL TAPE
3 - BODY SIDE/SLIDING DOOR GLASS
RSSTATIONARY GLASS23 - 109
WINDSHIELD (Continued)
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QUARTER WINDOW
REMOVAL
(1) Remove C-pillar trim.
(2) Open quarter glass to vent position.
(3) Disengage quarter window retainer from vent
motor arm.
(4) Remove nuts attaching quarter glass to C-pillar
(Fig. 5).
(5) Use magnetic socket to prevent dropping into
the pillar.
(6) Remove quarter glass from vehicle.
INSTALLATION
(1) Place quarter glass in position on vehicle.
(2) Install nuts attaching quarter glass to C-pillar.
(3) Engage quarter window retainer to vent motor
arm.
(4) Install screw attaching quarter window
retainer to vent motor arm.
(5) Close quarter glass.
(6) Install C-pillar trim.
REAR DOOR GLASS
REMOVAL
Refer to the Safety Precautions in this section for
description of tools and adhesive systems that are
recommended for use in this procedure.
REAR WINDOW REMOVAL ± EXTERIOR METHOD
(1) Remove rear window wiper arm, if equipped.
(2) Remove screws attaching moldings to liftgate
at the sides of the rear window (Fig. 6).(3) Using pliers, pull outward on molding at the
top and bottom of liftgate.
(4) Using a sharp cold knife, cut urethane adhe-
sive attaching the rear window to the liftgate. A
power cutting device can be used if available (Fig. 1).
(5) Remove rear window from vehicle.
REAR WINDOW REMOVAL ± INTERIOR METHOD
(1) Remove rear window wiper arm, if equipped.
(2) Remove screws attaching moldings to liftgate
at the sides of the rear window (Fig. 6).
(3) Remove liftgate inside lamps and trim covers.
(4) Remove center high mounted stop lamp.
(5) Using a reciprocating or oscillating power
knife, cut urethane adhesive holding the rear window
to the liftgate. Refer to instructions provided with
the equipment being used.
(6) Remove rear window from vehicle.
INSTALLATION
Refer to the Safety Precautions in this section for
description of tools and adhesive systems that are
recommended for use in this procedure.
CAUTION: Open the left front door glass before
installing rear window to avoid pressurizing the
passenger compartment. If a door is slammed
before urethane bonding is cured, water leaks can
result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.
To avoid stressing the replacement rear window,
the urethane bonding material on the rear window
fence should be smooth and consistent to the
shape of the replacement glass.
Fig. 5 QUARTER GLASS
1 - VENT CONTROL
2 - QUARTER GLASS
3 - CLIP
Fig. 6 REAR WINDOW SIDE MOLDINGS
1 - COMPRESSION SPACERS
2 - REAR WINDOW WITH MOLDING
3 - LIFT GATE
23 - 110 STATIONARY GLASSRS
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(1) Place replacement glass into rear window open-
ing.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement rear window. If not, the fence must be
formed to the shape of the new glass.
(3) Using a grease pencil, mark the glass and lift-
gate in several locations to aid installation.
(4) Remove replacement glass from liftgate open-
ing.
(5) Position the rear window inside up on a suit-
able work surface with two padded, wood 10 cm by
10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks,
placed parallel 75 cm (2.5 ft.) apart (Fig. 2).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN REAR WINDOW BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(6) Clean inside of rear window with ammonia
based glass cleaner and lint-free cloth.
(7) Apply molding to top and bottom of rear win-
dow.
(8) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of rear window and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.
(9) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of rear window. Allow at least three min-
utes drying time.
(10) Apply Pinch weld Primer 19 mm (0.75 in.)
wide around the rear window fence. Allow at least
three minutes drying time.
(11) If a low viscosity urethane adhesive is used,
install compression spacers on the fence around the
rear window opening (Fig. 7).(12) Apply a 10 mm (0.4 in.) bead of urethane
along center line of rear window fence.
(13) With the aid of a helper, position the rear
window over the rear window opening and align the
reference marks.
(14) Slowly lower the glass to rear window opening
fence. Guide the molding into proper position as nec-
essary. Push glass inward until molding is flush to
liftgate surface (Fig. 7).
(15) Clean excess urethane from exterior with
MopartSuper Kleen, or equivalent.
(16) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place until urethane cures.
(17) Install rear window side moldings and wiper
arm (Fig. 6).
(18) Install interior trim.
(19) After urethane has cured, remove tape strips
and water test rear window to verify repair.
Fig. 7 LOWER REAR WINDOW INTO POSITION
1 - REAR WINDOW WITH MOLDING
2 - LIFTGATE
RSSTATIONARY GLASS23 - 111
REAR DOOR GLASS (Continued)
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WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL............................112
INSTALLATION........................112
FRONT DOOR OUTER BELT MOLDING
REMOVAL............................113
INSTALLATION........................113
FRONT DOOR WEATHERSTRIP
REMOVAL............................113INSTALLATION........................113
SLIDING DOOR WEATHERSTRIP
REMOVAL............................114
INSTALLATION........................114
FRONT DOOR INNER BELT MOLDING
REMOVAL............................114
INSTALLATION........................114
FRONT DOOR GLASS RUN
WEATHERSTRIP
REMOVAL
(1) Remove door frame closeout moldings.
(2) Pull weatherstrip from glass run channel at
rear of door frame, working from the bottom to the
top.
(3) Disengage clip attaching weatherstrip to door
frame.
(4) Pull weatherstrip from lip along top of door
frame (Fig. 1).
(5) Remove door trim panel.
(6) Remove door speaker, if equipped.
(7) Remove watershed as necessary to gain access
to screw attaching front lower corner of glass run
weatherstrip to inner door panel.
(8) Remove screw attaching glass run weatherstrip
to inner door panel.
(9) Remove inner belt weatherstrip.
(10) Pull weatherstrip from front glass run chan-
nel.
(11) Remove glass run weatherstrip from vehicle.
INSTALLATION
(1) Position glass run weatherstrip on vehicle (Fig.
1).
(2) Push weatherstrip into front glass run channel.
(3) Install screw attaching glass run weatherstrip
to inner door panel.
(4) Install inner belt weatherstrip.
(5) Install watershed.
(6) Push weatherstrip groove onto lip along top of
door frame.
(7) Engage clip into slot in door frame.
(8) Push weatherstrip into channel at rear of door
frame, working from the top to bottom.
(9) Install door frame closeout moldings.
(10) Install door speaker, if equipped.
(11) Install door trim panel.
23 - 112 WEATHERSTRIP/SEALSRS
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FRONT DOOR OUTER BELT
MOLDING
REMOVAL
(1) Remove the side view mirror. (Refer to 23 -
BODY/EXTERIOR/SIDE VIEW MIRROR -
REMOVAL)
(2) Remove door trim panel.
(3) Roll door glass down.
(4) Using a hook tool, disengage interlocking lip at
the base of the inward edge of the belt molding (Fig.
1).
(5) Remove belt molding from door.
INSTALLATION
(1) Place belt molding in position on door (Fig. 1).
(2) Engage interlocking lip at the base of the
inward edge of the belt molding on door panel.
(3) Install door trim panel.
FRONT DOOR WEATHERSTRIP
REMOVAL
(1) Open front door.
(2) Using fork tool (C-4829), remove push pin fas-
teners attaching front door weatherstrip to end
frames and bottom of door (Fig. 2).
(3) Pull weatherstrip from retaining channel
around window frame.
(4) Remove weatherstrip from vehicle.
INSTALLATION
(1) Position weatherstrip on door.
(2) Install push pin fasteners attaching front door
weatherstrip to end frames and bottom of door (Fig.
2).
(3) Install weatherstrip into retaining channel
around window frame.
(4) Close front door.
Fig. 1 FRONT DOOR WEATHERSTRIP
1 - DOOR GLASS RUN WEATHERSTRIP
2 - FRONT INNER DOOR
3 - DOOR BELT OUTER WEATHERSTRIP4 - DOOR MOUNTED WEATHERSTRIP
5 - DOOR OUTER BELT WEATHERSTRIP
RSWEATHERSTRIP/SEALS23 - 113
FRONT DOOR GLASS RUN WEATHERSTRIP (Continued)
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SLIDING DOOR
WEATHERSTRIP
REMOVAL
(1) Open sliding door.
(2) Remove door opening sill plate.
(3) Loosen B-pillar trim covers.
(4) Loosen quarter panel trim panels.
(5) From splice at the bottom center of door open-
ing, pull weatherstrip from pinch flange around door
opening.
INSTALLATION
(1) Place splice at the bottom center of door open-
ing, pushing weatherstrip onto pinch flange around
door opening.
(2) Tighten quarter panel trim panels.
(3) Tighten B-pillar trim covers.
(4) Install door opening sill plate.
(5) Close sliding and check alignment.
FRONT DOOR INNER BELT
MOLDING
REMOVAL
(1) Remove door trim panel.
(2) Peel upper corner seals away form inner belt
molding to clear removal path.
(3) Pull inner belt molding upward to disengage
retaining channel in bottom of molding from door
panel flange (Fig. 1).
(4) Remove inner belt molding from vehicle.
INSTALLATION
(1) Place inner belt molding in position on door
(Fig. 1).
(2) Push inner belt molding downward to engage
retaining channel onto door panel flange.
(3) Install upper corner seals in proper location.
(4) Install door trim panel.
Fig. 2 Front Door Weatherstrip
1 - RETAINING CHANNEL
2 - PUSH-IN FASTENER
3 - WEATHERSTRIP
4 - FRONT DOOR
23 - 114 WEATHERSTRIP/SEALSRS
FRONT DOOR WEATHERSTRIP (Continued)
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BODY STRUCTURE
TABLE OF CONTENTS
page page
GAP AND FLUSH
SPECIFICATIONS
GAP AND FLUSH MEASUREMENTS......115
OPENING DIMENSIONS
SPECIFICATIONS
BODY OPENING DIMENSIONS..........118
SEALER LOCATIONS
SPECIFICATIONS
BODY SEALING LOCATIONS...........121STUCTURAL ADHESIVE LOCATIONS
SPECIFICATIONS
STRUCTURAL ADHESIVE LOCATIONS....147
WELD LOCATIONS
SPECIFICATIONS
WELD LOCATIONS...................156
GAP AND FLUSH
SPECIFICATIONS
GAP AND FLUSH MEASUREMENTS
INDEX
DESCRIPTION FIGURE
GAP & FLUSH MEASUREMENTS 1
RSBODY STRUCTURE23 - 115
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Fig. 1 GAP & FLUSH MEASUREMENTS
23 - 116 BODY STRUCTURERS
GAP AND FLUSH (Continued)
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SPECIFICATIONS
ITEM LOCATION GAP FLUSH
A HOOD TO FASCIA (VOYAGER ONLY)
8.0   2.0
PARALLEL WITHIN 2.0 RIGHT TO
LEFT2.5 OVER FLUSH TO HOOD  
1.5 CONSISTENT WITHIN 2.0
B HEADLAMP MODULE TO
HOOD8.0   2.0
PARALLEL WITHIN 2.0 RIGHT TO
LEFT
C HOOD TO FENDER (FOR &
AFT)0.0   1.5
LEFT TO RIGHT WITHIN 1.5
D HOOD TO FENDER 4.0   1.5
PARALLEL WITHIN 2.5   1.5 LEFT
TO RIGHTUNDER FLUSH
  2.0
E FENDER TO DOOR 5.0   1.5
PARALLEL WITHIN 2.0UNDER FLUSH 0.5   1.5
CONSISTENT WITHIN 2.0
F FRONT DOOR TO9A9PILLAR
COVERUNDER FLUSH 0.5   2.0
G9A9PILLAR COVER TO
SLIDING DOOR5.0   PARALLEL WITHIN 1.0 1.0 UNDER FLUSH  
CONSISTENT WITHIN 3.0
H FRONT DOOR APPLIQUE TO
SLIDING DOOR GLASS5.0   2.0
PARALLEL WITHIN 2.01.0 UNDER FLUSH   2.0
CONSISTENT WITHIN 3.0
I FRONT DOOR TO SLIDING
DOOR5.0   2.0
PARALLEL WITHIN 2.0  2.0 CONSISTENT WITHIN
2.0
J SLIDING DOOR TO REAR
APERTURE GLASS5.0   2.0
PARALLEL WITHIN 1.5  3.0 CONSISTENT WITHIN
3.0
K SLIDING DOOR TO REAR
APERTURE5.0   1.5
PARALLEL WITHIN 2.0  1.5 CONSISTENT WITHIN
1.5
L TAIL LAMP TO BODY SIDE
APERTURE1.0   1.0
PARALLEL WITHIN 1.5OVER FLUSH
M TAIL LAMP TO LIFTGATE 4.0   2.0 OVER FLUSH
N LIFTGATE TO BODY SIDE
APERTURE4.0   1.5 UNDER FLUSH 1.0   2.5
CONSISTENT WITHIN 2.0
O LIFTGATE TO ROOF 8.0   2.0   1.5
P LIFTGATE TO FASCIA 8.0   2.5
PARALLEL WITHIN 3.0
Q LIFTGATE TO REAR FASCIA UNDER FLUSH TO 1.0
MAXIMUM OVER FLUSH
R FUEL FILLER DOOR TO BODY
SIDE APERTUREUNDER FLUSH 0.5   1.0
NOTE: All measurements are in mm.
RSBODY STRUCTURE23 - 117
GAP AND FLUSH (Continued)
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