CHRYSLER VOYAGER 2003 Service Manual
Manufacturer: CHRYSLER, Model Year: 2003, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2003Pages: 2177, PDF Size: 59.81 MB
Page 1781 of 2177
Fig. 4 BODY SIDE MOLDINGS - PREMIUM 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 - 48 EXTERIORRS
BODY SIDE MOLDINGS (Continued)
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COWL GRILLE
REMOVAL
(1) Remove wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL)
(2) Remove four (4) screws securing cowl cover to
wiper module (Fig. 6).
(3) Disengage quarter turn fasteners at outboard
ends of cowl grill from body.
(4) Release hood latch and open hood.
CAUTION: To prevent hood scratching of cowl grille
before removal, cover outboard exterior ends of
cowl grille with masking tape or equivalent method.NOTE: Do not over bend cowl grille during removal.
Bend cowl grille just enough to clear top of wiper
pivot shaft and bottom rear corner of hood.
(5) Remove cowl grill by raising above driver side
wiper pivot shaft and swinging away towards engine
compartment. The cowl grille will need to be bent on
outboard end to clear simultaneously top of wiper
pivot shaft and bottom corner of hood.
(6) Close hood. Do not latch. Remove outboard
screws. (Fig. 7).
(7) Disconnect washer hose in line connector.
(8) Disconnect washer hose and grommet from
hole in wiper module and pull out.
(9) Remove cowl grille by raising over opposite
wiper pivot shaft and removing away from vehicle.
(10) Remove cowl cover from vehicle.
Fig. 5 BODY SIDE MOLDINGS WITH APPLIQUE - TYPICAL
1 - FRONT ROCKER PANEL APPLIQUE
2 - FRONT DOOR MOLDING
3 - SLIDING DOOR MOLDING4 - REAR ROCKER PANEL APPLIQUE
5 - LIFTGATE MOLDING
6 - POP-RIVET
RSEXTERIOR23-49
BODY SIDE MOLDINGS (Continued)
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INSTALLATION
(1) Reverse removal procedure.
(2) When installing cowl cover over wiper module,
make sure fore aft locator on the underside of cowl
grill seat into the locator grooves on top of wiper
module.
(3) Star all cowl grille mounting screws by hand
before torquing to specifications.
(4) Assure washer hose is properly routed and not
pinched.
(5) Center cowl grille to body and windshield.(6) Assure ªarrowº indicator head of quarter turn
fasteners is pointing toward windshield.
(7) Tighten screw to 1.2 N´m (11 in. lbs.) torque.
(8) Install the wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS - INSTAL-
LATION)
(9) Check for proper spray pattern from washer
nozzles.
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.
Fig. 6 COWL COVER
1 - COWL COVER
2 - WIPER PIVOT
3 - WASHER HOSES
4 - HOOD
Fig. 7 COWL COVER RETAINERS
1 - SCREW
2 - WINDSHIELD
3 - COWL COVER
4 - FRONT FENDER
23 - 50 EXTERIORRS
COWL GRILLE (Continued)
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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.
(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.
Fig. 8 FENDER
1 - FASTENERS
2 - FENDER
3 - FASTENERS
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
RSEXTERIOR23-51
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(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.
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.
Fig. 10 FUEL FILL
1 - FUEL FILLER BLOCKER LATCH ARM
2 - C-PILLAR
Fig. 11 FUEL FILL DOOR BLOCKER LATCH
STRIKER
1 - LEFT SLIDING DOOR
2 - FUEL FILLER STOP STRIKER
23 - 52 EXTERIORRS
FUEL FILL DOOR (Continued)
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Page 1786 of 2177
(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.
(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.
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 PANELFig. 14 RADIATOR CLOSURE PANEL
CROSSMEMBER
1 - RADIATOR CLOSURE PANEL CROSSMEMBER
2 - FRONT FASCIA
RSEXTERIOR23-53
FUEL FILL DOOR BLOCKER LOCKOUT LINK (Continued)
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Page 1787 of 2177
(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.
(3) Remove push pin fasteners attaching splash
shield to frame rail forward of suspension.
(4) Remove push pin fasteners attaching splash
shield to frame rail rearward of suspension.
(5) Remove screws attaching wheelhouse splash
shield to front fender and front bumper fascia.
(6) Remove splash shield from vehicle (Fig. 15).
INSTALLATION
(1) Place splash shield in position on vehicle (Fig.
15).
(2) Install push pin fasteners attaching splash
shield to frame rail forward of suspension.
(3) Install push pin fasteners attaching splash
shield to frame rail rearward of suspension.
(4) Install screws attaching wheelhouse splash
shield to front fender.
(5) Install front wheel.
(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
(Fig. 16).
(2) Repeat for the opposite side, if necessary.
(3) Remove front riser(s) from vehicle (Fig. 17).
Fig. 15 FRONT WHEELHOUSE SPLASH SHIELD
1 - FRONT FENDER WHEELHOUSE SPLASH SHIELD
2 - PUSH PIN FASTENERS
3 - ACCESSORY DRIVE SPLASH SHIELD
4 - SCREWS
Fig. 16 LUGGAGE RACK RISER COVER
1 - FRONT RISER COVER
2 - LOCK TABS
3 - LUGGAGE RACK SIDE RAIL
4 - FRONT RISER
23 - 54 EXTERIORRS
GRILLE OPENING REINFORCEMENT (Continued)
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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. 18). 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. 17 LUGGAGE RACK, CROSSBARS AND RISER COVER
1 - LUGGAGE RACK SIDE RAILS
2 - SCREWS
3 - CROSSBARS4 - FRONT RISER COVER
5 - RIV-NUTS
Fig. 18 LUGGAGE RACK CROSSBAR
1 - LUGGAGE RACK
2 - CROSSBAR
3 - SLIDE LOCK
4 - FRONT RISER COVER
5 - FRONT RISER
RSEXTERIOR23-55
LUGGAGE RACK RISER (Continued)
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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. 19).
(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. 20).
(1) Remove the air exhauster from the hole in the
lower aperture panel.
Fig. 19 AIR EXHAUSTER - SWB
1 - LOWER APERTURE PANEL
2 - AIR EXHAUSTER
Fig. 20 AIR EXHAUSTER - LWB
1 - AIR EXHAUSTER
2 - PLUG
3 - LOWER APERTURE PANEL
23 - 56 EXTERIORRS
LUGGAGE RACK CROSSBAR (Continued)
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Page 1790 of 2177
INSTALLATION
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 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. 20).
(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 MopartSuper
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 MopartSuper 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.
SIDE VIEW MIRROR
REMOVAL
(1) Using a trim stick C-4755 or equivalent, lift up
the end of the instrument panel top pad enough to
gain access to the mirror electrical connector, if
equipped. (Refer to 23 - BODY/INSTRUMENT PAN-
EL/INSTRUMENT PANEL TOP COVER -
REMOVAL)
(2) Disconnect the electrical connector, if equipped.
(3) Using a trim stick or equivalent, remove the
trim cover (Fig. 21).
(4) Remove the bolts.
(5) Remove the mirror from the pillar.
INSTALLATION
(1) Route the mirror wire harness, if equipped,
through the a-pillar and place side view mirror in
position on vehicle (Fig. 21).
(2) Install the bolts and tighten to 10 N´m (85 in.
lbs.).
(3) Install the mirror trim cover.
(4) Connect the electrical connector, if equipped.
(5) Install the instrument panel top cover, if
equipped with the electric mirror. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION)
RSEXTERIOR23-57
REAR QUARTER PANEL/FENDER AIR EXHAUSTER (Continued)
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