roof rack CHRYSLER VOYAGER 2004 User Guide

SUN VISOR SUPPORT
REMOVAL
(1) Disengage sun visor from support.
(2) Remove screw holding support to roof header
(Fig. 17).
(3) Remove sun visor support from vehicle.
INSTALLATION
(1) Place sun visor support in position on vehicle.
(2) Install screw holding support to roof header
(Fig. 17).
(3) Engage sun visor into support.
FLOOR CONSOLE TRAY
REMOVAL
(1) Remove the floor console. Refer to the Owner's
Manual for proper procedures.
(2) Remove the four screws and remove the tray.
INSTALLATION
(1) Install the floor console tray and install the
screws.
(2) Install the floor console. Refer to the Owner's
Manual for proper procedures.
FLOOR CONSOLE TRAY -
BRACKET ASSEMBLY
REMOVAL
(1) Remove the floor carpet. (Refer to 23 - BODY/
INTERIOR/CARPETS AND FLOOR MATS -
REMOVAL)
(2) Disconnect the electrical connector.
(3) Remove the four screws and remove the
bracket assembly.
INSTALLATION
(1) Install the bracket assembly and install the
four screws.
(2) Connect the electrical connector.
(3) Install the floor carpet. (Refer to 23 - BODY/
INTERIOR/CARPETS AND FLOOR MATS -
INSTALLATION)
Fig. 17 SUN VISOR SUPPORT
1 - OVERHEAD CONSOLE
2 - SUN VISOR SUPPORT
3 - HEADLINING
RSINTERIOR23-83

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)

(6) Depress the spring feet clips on one side of the
sun shade.
(7) Remove sunshade.
INSTALLATION
(1) Place one side of the sunshade spring feet clips
into the top track U-frame.
(2) Depress the both releasing clips on the other
side to allow them to go into the top track U-frame.
(3) Move sunshade to the open position.
(4) Install water channel (Fig. 1).
(5) Verify that the sunshade move back and forth
properly.
(6) Cycle sunroof towards the closed position.
(7) Install glass panel (Refer to 23 - BODY/SUN-
ROOF/GLASS PANEL - INSTALLATION).
WIND DEFLECTOR
REMOVAL
(1) Fully open sunroof glass panel.
(2) Disconnect negative battery cable.
(3) Remove sunroof assembly (Refer to 23 - BODY/
SUNROOF/MODULE ASSEMBLY - REMOVAL).
(4) Depress the front deflector retaining tabs. (Fig.
2)
(5) Remove wind deflector.
INSTALLATION
(1) Place wind deflector arms in upward position
engage the wind deflector blade into the U-frame.
(2) Engage the retaining clips (Fig. 1).
(3) Verify wind deflector operation.
(4) Install the sun roof assembly (Refer to 23 -
BODY/SUNROOF/MODULE ASSEMBLY - INSTAL-
LATION).
WATER CHANNEL
REMOVAL
(1) Remove glass panel (Refer to 23 - BODY/SUN-
ROOF/GLASS PANEL - REMOVAL).
(2) Remove the retaining screws (Fig. 1).
(3) Carefully slide water channel forward to
release tabs from U-frame and remove from vehicle.
INSTALLATION
(1) Carefully place water channel onto U-frame
and slide it rearward to lock tabs (Fig. 1).
(2) Install the water channel attaching screws
(Fig. 1).
(3) Position glass panel on to mechanism lift arms.
(4) Start the glass attaching screws, and hand
tighten.
(5) Adjust sunroof glass (Refer to 23 - BODY/SUN-
ROOF/GLASS PANEL - ADJUSTMENTS).
(6) Verify sunroof operation and alignment.
SUNROOF MOTOR
REMOVAL
(1) Remove the sunroof (Refer to 23 - BODY/SUN-
ROOF/MODULE ASSEMBLY - REMOVAL).
(2) Remove the sunroof motor retaining bolts and
remove motor (Fig. 1).
INSTALLATION
CAUTION: THE SUNROOF MOTOR MUST BE TIMED
WITH THE SUNROOF ASSEMBLY. FAILURE TO DO
SO WILL RESULT IN IMPROPER SUNROOF OPERA-
TION AND POSSIBLE LEAKAGE OR DAMAGE TO
THE ASSEMBLY.
(1) Assure proper sunroof motor timing before
installation (Refer to 23 - BODY/SUNROOF/DRIVE
MOTOR - ADJUSTMENTS).
(2) Position the sunroof motor to the sunroof
assembly and install the retaining bolts (Fig. 1).
Tighten sunroof motor retaining bolts to 4.2Nm (40
lbs.in.).
Fig. 2 WIND DEFLECTOR
1 - Sun Roof
2 - Retaing Clip
3 - Sun Roof Assembly Trim
RSSUNROOF23 - 121
SUNSHADE (Continued)

SEALER LOCATIONS
SPECIFICATIONS - BODY SEALING LOCATIONS
INDEX
DESCRIPTION FIGURE
METHODS OF APPLYING AUTO BODY SEALANT 5
LOWER WINDSHIELD OPENING - RIGHT AND LEFT SIDES 6
COWL SIDE - LEFT AND RIGHT SIDES 7
SIDE QUARTER WINDSHIELD OPENING - LEFT AND RIGHT SIDES 8
UPPER WINDSHIELD A-PILLAR - LEFT AND RIGHT SIDES 9
ROOF TRACK C-PILLAR - LEFT AND RIGHT SIDES 10
SLIDING DOOR UPPER FLANGE SEAMS - LEFT AND RIGHT SIDES 11
QUARTER PANEL EXTERIOR AREA - LEFT AND RIGHT SIDES 12
LOWER REAR EXTERIOR CORNER PANELS - LEFT AND RIGHT SIDES 13
LOWER SILL LIFT GATE OPENING - LEFT AND RIGHT SIDES 14
C-PILLAR CAN - LEFT AND RIGHT SIDES 15
SHOCK TOWER AREA - LEFT AND RIGHT SIDES 16
OUTER SHOCK TOWER AREA - LEFT AND RIGHT SIDES 17
CROSS MEMBER SUPPORT - LEFT AND RIGHT SIDES 18
A & B-PILLAR FLOOR PAN RISERS - LEFT AND RIGHT SIDES 19
REAR WHEEL HOUSE FLOOR PAN - LEFT AND RIGHT SIDES 20
REAR WHEELHOUSE TO FLOOR PAN - LEFT AND RIGHT SIDES 21
UPPER SLIDING DOOR FLANGE - LEFT AND RIGHT SIDES 22
UPPER LIFTGATE HINGE AREA - LEFT AND RIGHT SIDES 23
REAR BRACKET SUPPORT REAR HANGER - LEFT AND RIGHT SIDES 24
LIFTGATE PANEL OPENING - UNDERSIDE 25
D-PILLAR INSIDE SEAM - LEFT AND RIGHT SIDES 26
REAR TAIL LAMP AREA SEAMS - LEFT AND RIGHT SIDES 27
UPPER LIFTGATE PANEL SILL - LEFT AND RIGHT SIDES 28
FRONT WHEELHOUSE & SHOCK TOWER - LEFT AND RIGHT SIDES 29
REAR QUARTER WHEELHOUSE LIP & SEAT ANCHOR BOLT - LEFT AND RIGHT
SIDES30
TAIL LAMP CAN - LEFT AND RIGHT SIDES 31
B-PILLAR AND SILL AREAS - LEFT AND RIGHT SIDES 32
FRONT FLOOR PAN & RISER 33
FLOOR PAN SEAMS - LEFT AND RIGHT SIDES 34
FLOOR PAN & REAR WHEELHOUSE AREA - LEFT AND RIGHT SIDES 35
FLOOR PAN SILL & D-PILLAR SEAMS - LEFT AND RIGHT SIDES 36
LEFT SIDE SEAT ANCHOR REINFORCEMENT - SHORT WHEEL BASE ONLY 37
UNDERBODY - LEFT AND RIGHT SIDES 38
ROOF TOP JOINT & UPPER FRONT SLIDING DOOR - LEFT AND RIGHT SIDES 39
ROOF TOP JOINT & UPPER REAR SLIDING DOOR - LEFT AND RIGHT SIDES 40
23 - 130 BODY STRUCTURERS

Fig. 10 ROOF TRACK C-PILLAR - LEFT AND RIGHT SIDES
Fig. 11 SLIDING DOOR UPPER FLANGE SEAMS - LEFT AND RIGHT SIDES
RSBODY STRUCTURE23 - 135
SEALER LOCATIONS (Continued)

STRUCTURAL ADHESIVE
LOCATIONS
SPECIFICATIONS - STRUCTURAL ADHESIVE
LOCATIONS
INDEX
DESCRIPTION FIGURE
UPPER COWL PLENUM, UPPER AND
LOWER DASH PANEL52
ROOF AND REAR QUARTER PANELS -
LONG WHEEL BASE ONLY53
FLOOR PAN - LONG WHEEL BASE
ONLY54
SUSPENSION HANGER
REINFORCEMENTS - LONG WHEEL
BASE ONLY55
FRONT HINGE PILLAR
REINFORCEMENTS - LONG WHEEL
BASE ONLY56
ROOF AND REAR QUARTER PANELS -
SHORT WHEEL BASE ONLY57
FLOOR PAN - SHORT WHEEL BASE
ONLY58
FRONT SIDE RAILS/OUTER CROSS
MEMBER BRACKETS59
OUTER ROOF PANEL/UPPER
WINDSHIELD FRAME60
COWL SIDE PANEL / BODY SIDE
APERTURE, B-PILLAR / SLIDING DOOR
TRACK SUPPORT61
FRONT HINGE PILLAR
REINFORCEMENT / COWL SIDE
TAPPING PLATE62
UPPER COWL PLENUM / UPPER AND
LOWER DASH PANEL - RIGHT HAND
DRIVE ONLY63
23 - 156 BODY STRUCTURERS

Fig. 59 FRONT SIDE RAILS/OUTER CROSS MEMBER BRACKETS
Fig. 60 OUTER ROOF PANEL/UPPER WINDSHIELD FRAME
RSBODY STRUCTURE23 - 163
STRUCTURAL ADHESIVE 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
OUTER WHEELHOUSE - SHORT WHEEL BASE ONLY 141
LEFT REAR INNER QUARTER PANEL - SHORT WHEEL BASE ONLY 142
LATCH REINFORCEMENT - SHORT WHEEL BASE ONLY 143
D-PILLAR REINFORCEMENT - SHORT WHEEL BASE ONLY 144
OUTER WHEELHOUSE - SHORT WHEEL BASE ONLY 145
BODY SIDE APERTURE RIGHT SIDE- LONG WHEEL BASE ONLY 146
BODY SIDE APERTURE LEFT SIDE - LONG WHEEL BASE ONLY 147
BODY SIDE APERTURE RIGHT SIDE - SHORT WHEEL BASE ONLY 148
BODY SIDE APERTURE LEFT SIDE - SHORT WHEEL BASE ONLY 149
LOWER SLIDING DOOR TRACK 150
LIFTGATE UPPER FRAME 151
UPPER WINDSHIELD FRAME 152
FRONT FENDER SHIELD BEAM 153
FRONT FENDER SHIELD BEAM/COWL SIDE PANEL 154
HINGE PILLAR REINFORCEMENT 155
INNER SIDE SILL - LONG WHEEL BASE ONLY 156
INNER SIDE SILL/OUTER SIDE SILL - LONG WHEEL BASE ONLY 157
LOWER SLIDING DOOR TRACK REINFORCEMENT - LONG WHEEL BASE ONLY 158
UPPER WINDSHIELD FRAME/ROOF PANEL - LONG WHEEL BASE ONLY 159
ROOF BOWS/INNER ROOF SIDE RAILS 160
OUTER ROOF PANEL - LONG WHEEL BASE ONLY 161
INNER SIDE SILL - SHORT WHEEL BASE ONLY 162
INNER/OUTER SIDE SILLS - SHORT WHEEL BASE ONLY 163
LOWER SLIDING DOOR TRACK - SHORT WHEEL BASE ONLY 164
UPPER WINDSHIELD FRAME/OUTER ROOF PANEL - SHORT WHEEL BASE ONLY 165
REAR SUSPENSION HANGERS - LONG WHEEL BASE SHOWN, SHORT WHEEL BASE
TYPICAL166
FRONT LOWER LIFTGATE OPENING 167
REAR JACKING REINFORCEMENT - LONG WHEEL BASE ONLY 168
INNER WHEELHOUSE - LONG WHEEL BASE ONLY 169
SUSPENSION HANGER REINFORCEMENT - LONG WHEEL BASE ONLY 170
LOWER LIFTGATE OPENING PANEL - LONG WHEEL BASE ONLY 171
ROOF BOWS/UPPER LIFTGATE FRAME - LONG WHEEL BASE ONLY 172
BODY SIDE APERTURE/INNER QUARTER PANEL - LONG WHEEL BASE ONLY 173
REAR JACKING REINFORCEMENT - SHORT WHEEL BASE ONLY 174
INNER WHEELHOUSE/INNER QUARTER PANEL - SHORT WHEEL BASE ONLY 175
SUSPENSION HANGER REINFORCEMENT - SHORT WHEEL BASE ONLY 176
LOWER LIFTGATE OPENING - SHORT WHEEL BASE ONLY 177
ROOF PANEL/ROOF RAIL - SHORT WHEEL BASE ONLY 178
RIGHT SIDE OUTER REAR WHEELHOUSE, EXTENSION AND BODY SIDE APERTURE
- SHORT WHEEL BASE ONLY179
UPPER COWL PLENUM AND REINFORCEMENT - RIGHT HAND DRIVE 180
COWL SIDE PANEL AND DASH PANEL - RIGHT HAND DRIVE 181
23 - 168 BODY STRUCTURERS
WELD LOCATIONS (Continued)

(9) Lower the vehicle.
(10) Remove the right quarter trim panel and
right D-pillar trim panel from the quarter inner
panel (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - REMOVAL).
(11) Remove the rear distribution duct from the
rear HVAC housing and the rear roof duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/AIR OUTLETS - REMOVAL).
(12) Disconnect the body wire harness connector
for the rear HVAC housing from the rear HVAC wire
harness connector located near the expansion valve
at the back of the housing.
(13) Remove the two screws that secure the top of
the quarter trim panel attaching bracket to the quar-
ter inner panel.
(14) Remove the two screws that secure the bottom
of the quarter trim panel attaching bracket to the
rear HVAC housing.
(15) Remove the rear floor heat duct from the
right quarter inner panel (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION/REAR
FLOOR HEAT DUCT - REMOVAL).
(16) Take the proper precautions to protect the
carpeting below the rear heater core from spilled
engine coolant and have absorbent toweling readily
available to clean up any spills.
(17) Disconnect the heater hoses at the rear heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE -
REMOVAL).
(18) Install plugs in, or tape over the opened
heater core fittings and both heater hoses.
(19) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
(20) Remove the screw that secures the back of the
rear HVAC housing to the right D-pillar (Fig. 7).
(21) Remove the screw that secures the front of
the rear HVAC housing to the right quarter inner
panel.
(22) Lift the rear HVAC housing up far enough for
the lower mounting studs and the evaporator exten-
sion lines to clear the mounting holes in the rear
floor panel.
(23) Remove the rear HVAC housing from the
vehicle.
(24) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
INSTALLATION
NOTE: If the rear heater core or the rear HVAC
housing have been removed from the vehicle for
service, the rear heater core may be pre-filled with
the proper engine coolant mixture prior to recon-
necting the heater hoses to the heater core hose fit-tings (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - REAR/HEATER CORE - STANDARD
PROCEDURE - HEATER CORE FILLING).
(1) Position the rear HVAC housing into the vehi-
cle with the evaporator extension line sealing plate
inserted into the rectangular hole in the rear floor
panel behind the right rear wheel house.
(2) Align the rear HVAC housing lower mounting
studs with the mounting holes in the rear floor panel
and lower the unit to the floor.
(3) Install the screw that secures the front of the
rear HVAC housing to the right quarter inner panel.
Tighten the screw to 11 N´m (97 in. lbs.).
(4) Install the screw that secures the back of the
rear HVAC housing to the right D-pillar. Tighten the
screw to 11 N´m (97 in. lbs.).
(5) Remove the plugs or tape from both heater core
fittings and both heater hoses.
(6) Reconnect the heater hoses to the rear heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
(7) Reinstall the rear floor heat duct onto the right
quarter inner panel (Refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION/REAR FLOOR
HEAT DUCT - INSTALLATION).
(8) Install the two screws that secure the bottom
of the quarter trim panel attaching bracket to the
rear HVAC housing. Tighten the screws to 2 N´m (17
in. lbs.).
(9) Install and tighten the two screws that secure
the top of the quarter trim panel attaching bracket to
the quarter inner panel.
(10) Reconnect the body wire harness connector for
the rear HVAC housing to the rear HVAC wire har-
ness connector located near the expansion valve at
the back of the housing.
(11) Reinstall the rear distribution duct onto the
rear HVAC housing and the rear roof duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/AIR OUTLETS - INSTALLATION).
(12) Reinstall the right quarter trim panel and
right D-pillar trim panel onto the quarter inner
panel (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - INSTALLATION).
(13) Raise and support the vehicle.
(14) Install the three nuts that secure the rear
HVAC housing mounting studs to the rear floor panel
behind the right rear wheel housing. Tighten the
nuts to 9 N´m (80 in. lbs.).
(15) Remove the tape or plugs from the underbody
liquid line and suction line fittings and both ports in
the rear evaporator extension line sealing plate that
extends through the rear floor panel behind the right
rear wheel housing.
RSDISTRIBUTION - REAR24-61
HVAC HOUSING (Continued)