torque CHRYSLER VOYAGER 2003 Service Manual

Remover, Special Tool C-4150A on hub and bearing
assembly flange and wheel stud (Fig. 35).
(7) Tighten down on special tool, pushing wheel
stud out of the hub flange. When shoulder of wheel
stud is past flange, remove special tool from hub and
bearing. Remove nut from stud and remove stud
from hub flange.
INSTALLATION
(1) Install replacement wheel stud into flange of
hub and bearing assembly. Install washers on wheel
stud, then install a wheel mounting (lug) nut on stud
with flat side of lug nut against washers as shown
(Fig. 36).
(2) Tighten the nut, pulling the wheel stud into
the flange of the hub and bearing. When the head of
the stud is fully seated against the rear of the hub
flange, remove nut and washers from stud.
(3) Install the brake rotor back on the hub and
bearing (Fig. 34).
(4) Install brake caliper and adapter back over
brake rotor aligning adapter with mounting holes on
steering knuckle (Fig. 34).
(5) Install the two adapter mounting bolts securing
the adapter to the steering knuckle. Tighten the
mounting bolts to 169 N´m (125 ft. lbs.) torque.
(6) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting lug nuts in proper
sequence until all nuts are torqued to half specifica-
tion, then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(7) Lower vehicle to the ground.
WHEEL MOUNTING STUDS -
REAR
REMOVAL
CAUTION: If a wheel attaching stud needs to be
replaced in the hub and bearing assembly the studs
MUST NOT be hammered out of the hub flange. If a
stud is removed by hammering it out of the bearing
flange, damage to the hub and bearing assembly
will occur leading to premature hub and bearing
failure.
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the rear wheel and tire assembly.
(3) Remove the brake drum or disc brake caliper
and rotor. Refer to Brakes.
(4) Install a lug nut on the wheel stud to be
removed from the hub and bearing assembly (Fig. 37)
so the threads on stud are even with end of lug nut.
Install Remover, Special Tool C-4150A on hub and
bearing assembly flange and wheel stud (Fig. 37).
(5) Tightening down on special tool will push
wheel stud out of the hub and bearing assembly
flange.
(6) Remove lug nut from stud and remove wheel
stud from flange.
Fig. 35 Wheel Stud Removal (Typical)
1 - WHEEL MOUNTING (LUG) NUT
2 - HUB AND BEARING ASSEMBLY
3 - SPECIAL TOOL C-4150A
4 - STEERING KNUCKLE
5 - WHEEL STUD
Fig. 36 Installing Wheel Stud (Typical)
1 - WASHERS
2 - HUB AND BEARING ASSEMBLY
3 - WHEEL MOUNTING (LUG) NUT
4 - STEERING KNUCKLE
RSTIRES/WHEELS22-21
WHEEL MOUNTING STUDS - FRONT (Continued)
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INSTALLATION
(1) Install replacement wheel stud into flange of
hub and bearing assembly. Install washers on wheel
stud, then install a wheel lug nut on stud with flat
side of lug nut against washers (Fig. 38).
(2) Tighten the wheel lug nut, pulling the wheel
stud into the flange of the hub and bearing assembly.
When the head of the stud is fully seated against the
bearing flange, remove lug nut and washers from
wheel stud.(3) Install the brake drum or disc brake rotor and
caliper on the hub and bearing assembly.
(4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica-
tion. Then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(5) Lower vehicle to the ground.
Fig. 37 Wheel Stud Removal From Hub And Bearing
1 - HUB AND BEARING ASSEMBLY
2 - WHEEL MOUNTING (LUG) NUT
3 - WHEEL STUD
4 - SPECIAL TOOL C-4150A
Fig. 38 Wheel Stud Installation
1 - WHEEL MOUNTING (LUG) NUT
2 - HUB AND BEARING ASSEMBLY
3 - WASHERS
4 - WHEEL STUD
22 - 22 TIRES/WHEELSRS
WHEEL MOUNTING STUDS - REAR (Continued)
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BODY
TABLE OF CONTENTS
page page
BODY
DESCRIPTION - VEHICLE IDENTIFICATION....1
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 2
DIAGNOSIS AND TESTING - WIND NOISE . . . 3
STANDARD PROCEDURE
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR........................3
STANDARD PROCEDURE - HEAT STAKING . 10
SPECIFICATIONS
TORQUE............................11
BODY LUBRICATION...................12
SPECIAL TOOLS
BODY..............................13DOOR - FRONT.........................14
DOORS - SLIDING.......................24
DECKLID/HATCH/LIFTGATE/TAILGATE.......39
EXTERIOR.............................44
HOOD.................................59
INSTRUMENT PANEL.....................62
INTERIOR..............................72
PAINT.................................83
SEATS................................85
STATIONARY GLASS....................105
WEATHERSTRIP/SEALS..................110
SUNROOF.............................113
BODY STRUCTURE.....................121
BODY
DESCRIPTION - VEHICLE IDENTIFICATION
Throughout this group, references to the
DaimlerChrysler Corporation vehicle family identifi-
cation code are used when describing a procedure
that is unique to that vehicle. Refer to Introduction
Group of this manual for detailed information on
vehicle identification. If a procedure is common to all
vehicles covered in this manual, no reference will be
made to a vehicle family code.
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE A OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL ± BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE THATIS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use when
welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.
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 or upholstered surfaces. Damage to fin-
ish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
RSBODY23-1
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SPECIFICATIONS
TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
All seat belt anchor bolts 39 29 Ð
Armrest shoulder bolt 29 21 Ð
Bench seat riser bolts 48 35 Ð
Bench seat track nuts 48 35 Ð
Quad bucket seat track to cushion frame bolts 40 30 Ð
Bucket seat back pivot bolts 33 24 Ð
Center seat to seat track bolts 24 17 Ð
Child seat module screws (bench seats) 7 Ð 62
Child seat module screws (quad seats) 13.5 10 Ð
Crossmember to radiator closure panel bolts 28 21 Ð
Door check strap to door end frame 12 Ð 105
Door latch to door end frame bolts 10 Ð 89
Floor latch to seat cushion frame bolts 27 19 Ð
Front cover to seat track screws 4 Ð 32
Front door hinge to hinge pillar bolts 34 25 Ð
Front door hinge to door nuts and bolts 34 25 Ð
Front door latch striker bolts 28 21 Ð
Front/quad seat cushion bolts 28.5 21 Ð
Front seat belt retractor bolts 38 28 Ð
Front seat riser to floor nuts 60 44 Ð
Front seat track cover screws 4 Ð 35
Front seat riser to seat track nuts 81 60 Ð
Front seatback pivot bolts 54 40 Ð
Front seatback recliner nut 12 Ð 105
Front seatback assist strap screws 2.5 Ð 22
Grocery bag holder screws 2 Ð 17
Hinge to liftgate bolts 33 24 Ð
Hood latch to bolts 13.5 10 Ð
Hood latch striker bolts 13.5 10 Ð
Hood hinge to hood bolts 13.5 10 Ð
Liftgate exterior handle outer screws 20 15 Ð
Liftgate exterior handle inner bolts 40 30 Ð
Lifgate hinge to roof header bolts 33 24 Ð
Liftgate latch bolts 16 12 Ð
Liftgate latch striker bolts 28 21 Ð
Liftgate lift motor link to liftgate 28 21 Ð
Liftgate spoiler bolts 9 Ð 80
Lifgate stabilizer wedge striker to D-pillar bolts 3 Ð 30
RSBODY23-11
BODY (Continued)
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CHECK STRAP
REMOVAL
(1) Remove front door trim panel.
(2) Remove front door watershield (Refer to 23 -
BODY/DOOR - FRONT/WATERSHIELD - REMOV-
AL).
(3) Remove front door speaker, if equipped.
(4) Remove bolts attaching door check strap to
A-pillar.
(5) Remove nuts attaching check strap to door end
frame (Fig. 2).
(6) Remove check strap from door through speaker
hole.
INSTALLATION
(1) Position check strap on door through speaker
hole.
(2) Install nuts to attach check strap to door end
frame. Tighten nuts to 11 N´m (90 in. lbs.) torque.
(3) Install bolts to attach check strap to A-pillar.
Tighten bolts to 12 N´m (105 in. lbs.) torque.
(4) Install door speaker, if equipped.
(5) Install front door trim panel.
DOOR
REMOVAL
(1) Remove front wheelhouse splash shield. (Refer
to 23 - BODY/EXTERIOR/LF WHEELHOUSE
SPLASH SHIELD - REMOVAL)
(2) Disengage clips attaching door harness wire
connector to inner fender brace.
(3) Disconnect positive lock slide on the side of the
wire connectors (Fig. 3).
(4) Depress lock tab attaching wire connector
halves together.
(5) Disconnect door harness from body wiring har-
ness.
(6) Remove bolts attaching door check strap to
A-pillar (Fig. 4).
(7) Support door on suitable lifting device.
(8) Remove bolts attaching lower hinge to door end
frame (Fig. 5).
(9) Steady door on lifting device and remove bolts
attaching upper hinge to door end frame.
(10) Remove door from vehicle.
Fig. 1 FRONT DOOR APPLIQUE
1 - GLASS RUN WEATHERSTRIP
2 - CLIPS
3 - APPLIQUE
4 - FRONT DOOR
Fig. 2 FRONT DOOR CHECK STRAP
1 - FRONT DOOR
2 - DOOR CHECK STRAP
RSDOOR - FRONT23-15
APPLIQUE (Continued)
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INSTALLATION
NOTE: If new hinge pins are to be used, verify that
the knurling on the hinge pin is aligned with the
knurling on in the door hinge prior to driving in the
pin. Also, verify that the hinge pin is fully seated to
the door hinge and a new retaining clip is installed.
(1) Support door on suitable lifting device.
(2) Position door to vehicle. Verify net pierce nub-
bin is engaged if reusing original hinges.
(3) Steady door on lifting device and install bolts
attaching upper hinge to door end frame. Tighten
bolts to 34 N´m (25 ft. lbs.) torque.
(4) Install bolts attaching door check strap to
A-pillar. Tighten bolts to 12 N´m (105 in. lbs.) torque.
(5) Install bolts attaching lower hinge to door end
frame. Tighten bolts to 34 N´m (25 ft. lbs.) torque.
Align door to achieve equal spacing to surrounding
body panels. Panels should be flush across all gaps.
(6) Connect door harness into body wiring harness.
(7) Connect positive lock slide on the side of the
wire connectors.
(8) Connect clips attaching door harness wire con-
nector to inner fender brace.
(9) Install front wheelhouse splash shield.
(10) Verify door operation and alignment. Adjust
as necessary.
Fig. 3 FRONT DOOR WIRE CONNECTORS
1 - LOCK TAB
2 - POSITIVE LOCK
3 - BODY HARNESS CONNECTOR
4 - FRONT FENDER
5 - DOOR HARNESS CONNECTOR
6 - BODY HARNESS
Fig. 4 FRONT DOOR - HINGE PIN REMOVAL
1 - FRONT DOOR
2 - CLIP
3 - A-PILLAR
4 - HINGE PIN
5 - CLIP
6 - DOOR CHECK STRAP
Fig. 5 FRONT DOOR - HINGE BOLT REMOVAL
1 - FRONT DOOR
2 - UPPER HINGE
3 - CHECK STRAP
4 - LOWER HINGE
23 - 16 DOOR - FRONTRS
DOOR (Continued)
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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. 8).
(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. 9).
(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. 10).
(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.
(5) Disengage clip holding door latch linkage to
door latch (Fig. 11).
(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.
Fig. 10 DOOR LATCH STRIKER
1 - B-PILLAR
2 - SHIM
3 - DOOR LATCH STRIKER
RSDOOR - FRONT23-19
LATCH (Continued)
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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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LOWER HINGE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Open sliding door.
(2) Mark outline of roller arm on sliding door to
aid installation (Fig. 7).
(3) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(4) Remove screws attaching open latch to lower
roller arm.
(5) Remove open latch from lower arm.
(6) Support sliding door on a suitable lifting device
with a padded upper surface. The door must be
moveable with lifting device in place.
(7) Remove hold open latch striker.
(8) Remove bolts attaching lower roller arm to
sliding door.
(9) Remove roller arm from sliding door.
(10) Disengage roller arm from lower channel.
(11) Remove roller arm from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.(1) Place roller arm into position (Fig. 7).
(2) Engage roller arm to lower channel.
(3) Install roller arm to sliding door.
(4) Install bolts attaching lower roller arm to slid-
ing door.
(5) Install hold open latch striker.
(6) Install screws attaching open latch to lower
roller arm.
(7) Install sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(8) Check sliding door for proper operation.
REAR LATCH STRIKER
REMOVAL
(1) Open sliding door.
(2) Mark outline of striker on C-pillar door jamb
face to aid installation.
(3) Remove screws attaching striker to C-pillar
(Fig. 8).
(4) Remove striker from vehicle.
INSTALLATION
(1) Place striker in position on vehicle.
(2) Align striker to outline marks on C-pillar.
(3) Install screws attaching striker to C-pillar.
Tighten screws to 28 N´m (21 ft. lbs.) torque.
(4) Verify sliding door alignment and operation.
Fig. 7 SLIDING DOOR LOWER ROLLER ARM
1 - POWER LOWER ROLLER ARM
2 - MANUAL LOWER ROLLER ARM
Fig. 8 SLIDING DOOR LATCH STRIKER
1 - LATCH STRIKER
2 - SLIDING DOOR
23 - 28 DOORS - SLIDINGRS
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(a) Open door to mid-point of travel.
(b) Mark outline of upper roller arm on door to
assist in making adjustments.
(c) Loosen bolts attaching upper roller arm to
door (Fig. 9).
(d) Decrease the length of the upper roller arm
to increase seal compression.
(e) Increase the length of the upper roller arm to
decrease seal compression.
(f) Tighten all upper roller arm bolts.
(g) Verify door alignment, adjust as necessary.
(3) Adjust seal compression at the bottom of B-post
seal.
(a) Open door to mid-point of travel.
(b) Mark outline of lower roller arm on lower
roller arm bracket to assist in making adjustments
(Fig. 15).
(c) Loosen bolts holding lower roller arm to
lower roller arm bracket.
(d) Pivot lower roller arm toward center of vehi-
cle to decrease seal compression.
(e) Pivot lower roller arm outward to increase
seal compression.
(f) Tighten lower roller arm bolts.
(g) Verify alignment, adjust as necessary.
NOTE: Adjusting seal compression at the B-post
can affect door flushness the C-post.
STABILIZER ADJUSTMENT - UPPER/LOWER
(1) Open sliding door.
(2) Loosen the bolts holding the male stabilizers to
the sliding door enough that the stabilizers can move
with some effort.
(3) Close and then reopen sliding door.
(4) Tighten all stabilizers bolts.
STABILIZER
REMOVAL
(1) Open sliding door.
(2) Remove screws attaching stabilizer to door end
frame (Fig. 16).
(3) Remove stabilizer from vehicle.
INSTALLATION
(1) Place stabilizer in position on vehicle.
NOTE: Loose install screws first. Fit should be
snug but free to move when closing door to align to
body half stabilizer.
(2) Install screws attaching stabilizer to door end
frame.
(3) Open door and final tighten screws.
(4) Verify sliding door operation.
STABILIZER SOCKET
REMOVAL
(1) Open sliding door.
(2) Remove screws holding stabilizer socket to
B-pillar (Fig. 17).
(3) Remove stabilizer socket from vehicle.
INSTALLATION
(1) Place stabilizer socket in position on vehicle.
(2) Install screws to hold stabilizer socket to B-pil-
lar. Tighten nuts to 5 N´m (45 in. lbs.) torque.
(3) Close sliding door and verify operation.
Fig. 15 Sliding Door Lower Roller Arm
1 - POWER LOWER ROLLER ARM
2 - MANUAL LOWER ROLLER ARM
Fig. 16 SLIDING DOOR STABILIZER
1 - SLIDING DOOR
2 - STABILIZER
23 - 32 DOORS - SLIDINGRS
SLIDING DOOR (Continued)
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