belt CHRYSLER VOYAGER 2004 Service Manual

WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL............................113
INSTALLATION........................113
FRONT DOOR OUTER BELT MOLDING
REMOVAL............................113
INSTALLATION........................113
FRONT DOOR WEATHERSTRIP
REMOVAL............................114INSTALLATION........................114
SLIDING DOOR WEATHERSTRIP
REMOVAL............................115
INSTALLATION........................115
FRONT DOOR INNER BELT MOLDING
REMOVAL............................115
INSTALLATION........................115
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.
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).
NOTE: Make sure end of applique is against outer
belt.
(2) Engage interlocking lip at the base of the
inward edge of the belt molding on door panel.
(3) Install door trim panel.
RSWEATHERSTRIP/SEALS23 - 113

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
Fig. 2 Front Door Weatherstrip
1 - RETAINING CHANNEL
2 - PUSH-IN FASTENER
3 - WEATHERSTRIP
4 - FRONT DOOR
23 - 114 WEATHERSTRIP/SEALSRS
FRONT DOOR OUTER BELT MOLDING (Continued)

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.
RSWEATHERSTRIP/SEALS23 - 115

SYMPTOM POSSIBLE CAUSE
Buzz, Squeak,Rattles from sunroof Loose or broken attaching hardware.
No lubracation in track.
Worn or broken mechanism.
Cables bunched or kinked
Sunshade will not function or does not
operate smoothlySunshade feet are missing, broken or loose.
No lubracation in track.
Track obstructions or interference.
Glass movement not consistant or glass does
not operate smoothlyGlass and Track timing.
Glass and Track alignment
Cables and Guide alignment
WATER DRAINAGE AND WIND NOISE DIAGNOSIS
The sliding glass panel is designed to seal water
entry with a snug fit between the roof and the seal.
The fit can be checked by inserting a piece of paper
between the roof and the seal. The piece of paper
should have some resistance when pulled out when
the glass panel is in the closed position. The sunroof
housing will drain off a minimum amount of water.
Excessive wind noise could result if the gap clear-
ances are exceeded. The sunroof glass panel may
need to be adjusted. Refer to Sunroof Glass Panel
Adjustment for proper procedures.
Adequate drainage is provided by a drain trough in
the sunroof housing which encircles the sliding glass
panel and leads to drain hoses. If a wet headliner or
other water leak complaints are encountered, before
performing any adjustments, first ensure that the
drainage system is not plugged or disconnected. Use
a pint container to pour water into the sunroof hous-
ing drain trough. If water flow is restricted, use com-
pressed air to blow out any material plugging the
drain system. Retest system again.
To further check for a disconnected drain hose:
(1) Remove A-pillar trim, sun visors, and map
lamps/mini console.
(2) Remove sunroof opening trim lace. Refer to
Sunroof Opening Trim Lace.
NOTE: Care must be taken not to fold or kink the
headliner upon removal.
(3) Lower headliner as necessary to gain access to
sunroof housing drain tubes. Refer to Headlining
Removal and Installation for proper procedures.
(4) Repair as necessary.
DRAIN TUBE
REMOVAL
FRONT HOSES
NOTE: Front A-pillars are filled with sound deaden-
ing foam and the front drain tubes are sealed into
the pillars.
(1) Move glass panel to the fully closed position.
(2) Disconnect negative battery cable.
(3) Remove headliner (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL).
(4) Disconnect the drain hose from the sunroof
housing (Fig. 1).
(5) Drain any liquid from hose connection, repair
as necessary.
REAR HOUSING HOSE
(1) Move glass panel to the fully closed position.
(2) Disconnect negative battery cable.
(3) Remove headliner (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL).
(4) Remove third seat or seats from vehicle.
(5) Remove second seat belt lower anchor.
(6) Remove third seat lower anchor.
(7) Remove quarter trim bolster.
(8) Remove trim panel screws.
(9) Remove quarter trim panel
(10) Disconnect the drain hose from the sunroof
housing. (Fig. 1).
(11) Drain any liquid from hose connection, if nec-
essary, and remove tube.
RSSUNROOF23 - 119
SUNROOF (Continued)

DESCRIPTION FIGURE
ROOF TOP JOINT & WINDSHIELD OPENING - LEFT AND RIGHT SIDES 41
LIFT GATE ROOF COACH JOINT - LEFT AND RIGHT SIDES 42
ROOF RAP JOINT - LEFT AND RIGHT SIDES 43
DRAIN HOLE PATCHES 44
WHEELHOUSE VENT HOLE - LEFT SIDE SHOWN - RIGHT SIDE TYPICAL 45
FLOOR PAN HOLES - LEFT AND RIDE SIDES 46
HOOD FRONT HEM FLANGE & SIDES 47
FRONT DOOR LOWER FLANGE 48
LIFTGATE HEM FLANGE AND LATCH COVER SEAMS 49
FRONT DOOR BELT DOOR BELT SEAMS (FRONT) 50
FRONT DOOR BELT DOOR BELT SEAMS (REAR) 51
RSBODY STRUCTURE23 - 131
SEALER LOCATIONS (Continued)

Fig. 50 FRONT DOOR BELT DOOR BELT SEAMS (FRONT)
Fig. 51 FRONT DOOR BELT DOOR BELT SEAMS (REAR)
RSBODY STRUCTURE23 - 155
SEALER LOCATIONS (Continued)

DESCRIPTION FIGURE
REAR SEAT REINFORCEMENTS - SHORT WHEEL BASE ONLY 100
CENTER CONSOLE REINFORCEMENT - SHORT WHEEL BASE ONLY 101
WHEELHOUSES - SHORT WHEEL BASE ONLY 102
FRONT SEAT CROSS MEMBER - SHORT WHEELBASE, ALL WHEEL DRIVE ONLY 103
FLOOR PAN SIDE RAIL - LONG WHEEL BASE ONLY 104
INNER BODY SIDE SILL REINFORCEMENTS 105
TOE BOARD CROSS MEMBER 106
FRONT SIDE RAIL - SHORT WHEEL BASE ONLY 107
DASH PANEL REINFORCEMENT 108
LOWER COWL PLENUM 109
UPPER COWL PLENUM SUPPORT 110
UPPER DASH PANEL 111
COWL SIDE PANELS 112
INSTRUMENT PANEL ATTACHMENT TAPPING PLATES 113
INSTRUMENT PANEL, DASH PANEL, ACM MODULE AND ACCELERATOR PEDAL 114
STRUT TOWER BRACKET AND COWL PLENUM 115
FRONT SIDE RAILS TO LOWER DASH PANEL 116
INNER BODY SIDE SILL TO LOWER DASH PANEL 117
FRONT HINGE TAPPING PLATE 118
FRONT HINGE PILLAR 119
INNER WINDSHIELD FRAME 120
WINDSHIELD FRAME 121
FENDER BRACKET 122
INNER B-PILLAR 123
STRIKER LATCH AND TAPPING PLATES 124
RIGHT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY 125
RIGHT REAR INNER QUARTER PANEL/OUTER WHEELHOUSE - LONG WHEEL BASE
ONLY126
RIGHT REAR BODY SIDE APERTURE - LONG WHEEL BASE ONLY 127
STRIKER LATCH REINFORCEMENT - LONG WHEEL BASE ONLY 128
BELT TAPPING PLATE - LONG WHEEL BASE ONLY 129
C-PILLAR REINFORCEMENT - LONG WHEEL BASE ONLY 130
OUTER WHEELHOUSE - LONG WHEEL BASE ONLY 131
C AND D-PILLAR INNER REINFORCEMENTS - LONG WHEEL BASE ONLY 132
LEFT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY 133
OUTER WHEELHOUSE EXTENSION - LONG WHEEL BASE ONLY 134
TAIL LAMP - LONG WHEEL BASE ONLY 135
SLIDING DOOR LATCH - LONG WHEEL BASE ONLY 136
ROOF BOW EXTENSION - LONG WHEEL BASE ONLY 137
RIGHT REAR INNER QUARTER PANEL - SHORT WHEEL BASE ONLY 138
LATCH REINFORCEMENT AND OUTER WHEELHOUSE - SHORT WHEEL BASE ONLY 139
D-PILLAR REINFORCEMENT - SHORT WHEEL BASE ONLY 140
RSBODY STRUCTURE23 - 167
WELD LOCATIONS (Continued)

DESCRIPTION FIGURE
LOWER COWL PLENUM, SUPPORT AND DASH PANEL - RIGHT HAND DRIVE 182
STEERING COLUMN REINFORCEMENT, BELT REINFORCEMENT AND DASH PANEL -
RIGHT HAND DRIVE183
INSTRUMENT PANEL TAPPING PLATE AND COWL SIDE PANEL - RIGHT HAND DRIVE 184
DASH PANEL AND BELT REINFORCEMENT - RIGHT HAND DRIVE 185
UPPER SUPPORT, UPPER REINFORCEMENT AND UPPER COWL PLENUM - RIGHT
HAND DRIVE186
UPPER SUPPORT, BRAKE PEDAL BRACKET REINFORCEMENT AND DASH PANEL -
RIGHT HAND DRIVE187
REINFORCEMENT, MOUNTING BRACKETS AND DASH PANEL - RIGHT HAND DRIVE 188
STRUT TOWER, COWL SIDE PANEL - RIGHT HAND DRIVE 189
REINFORCEMENTS, SIDE RAILS, COWL SIDE PANELS AND DASH PANEL - RIGHT
HAND DRIVE190
UPPER COWL PLENUM, GUSSETS, SIDE SHIELDS AND BODY SIDE APERTURE -
RIGHT HAND DRIVE191
SIDE GLASS ANTENNA TAPPING PLATE AND INNER BODY SIDE APERTURE - RIGHT
HAND DRIVE192
RSBODY STRUCTURE23 - 169
WELD LOCATIONS (Continued)

Fig. 129 BELT TAPPING PLATE - LONG WHEEL BASE ONLY
RSBODY STRUCTURE23 - 227
WELD LOCATIONS (Continued)

Fig. 183 STEERING COLUMN REINFORCEMENT, BELT REINFORCEMENT AND DASH PANEL - RIGHT HAND
DRIVE
RSBODY STRUCTURE23 - 275
WELD LOCATIONS (Continued)