remove seats CHRYSLER VOYAGER 2004 Workshop Manual

REMOVAL
REMOVAL - CYLINDER HEAD OFF
(1) With the cylinder head on a bench, position
Special Tool C-3422-D with 8464 Adapter on the
valve and spring retainer (Fig. 20).
(2) Compress the spring only enough to remove the
valve retainer locks.
(3) Slowly release the spring tension and remove
the valve spring and retainer.
(4) For removal of the valve stem seal (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE STEM SEALS -
REMOVAL).
REMOVAL - CYLINDER HEAD ON
(1) Disconnect negative cable from battery.
(2) Remove spark plug wires and all spark plugs.
(3) Remove cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(4) Remove rocker arms and shaft. (Refer to 9 -
ENGINE/CYLINDER HEAD/ROCKER ARMS -
REMOVAL)
(5) Rotate engine until the piston in the cylinder
bore requiring spring removal is at TDC.
(6) Install Special Tool 8453 to the cylinder head
(Fig. 21). Tighten the attaching bolts to 23 N´m (200
in. lbs.).
Fig. 19 VALVE COMPONENTS
1 - VALVE LOCKS 5 - SPRING SEATS
2 - RETAINERS 6 - CYLINDER HEAD
3 - VALVE SPRINGS 7 - VALVE - EXHAUST
4 - VALVE STEM SEALS 8 - VALVE - INTAKE
9s - 24 ENGINE 3.3/3.8L SUPPLEMENTRS
VALVE SPRINGS (Continued)

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 . 1
DIAGNOSIS AND TESTING - WIND NOISE . . . 2
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.......40
EXTERIOR.............................45
HOOD.................................60
INSTRUMENT PANEL.....................63
INTERIOR..............................73
PAINT.................................84
SEATS................................86
STATIONARY GLASS....................108
WEATHERSTRIP/SEALS..................113
SUNROOF.............................116
BODY STRUCTURE.....................124
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 THAT
IS 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.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
RSBODY23-1

(6) Remove lower B-pillar trim cover from vehicle.
INSTALLATION
(1) Place lower B-pillar trim cover in position on
vehicle (Fig. 3).
(2) Insert seat belt through hole in lower B-pillar
trim.
(3) Engage hidden clips attaching lower trim cover
to B-pillar.
(4) Install access cover.
(5) Install upper B-pillar trim cover.
(6) Place seat belt anchor in position on floor so
webbing is pointed rearward and slightly outboard.
(7) Install bolt attaching lower seat belt anchor to
floor. Tighten all seat belt bolts to 39 N´m (29 ft. lbs.)
torque.
(8) Verify that seat belt anchor does not interfere
with seat track travel.
B-PILLAR UPPER TRIM
REMOVAL
(1) Remove bolt attaching lower seat belt anchor to
floor.
(2) Lower shoulder belt height adjuster to the bot-
tom of travel.
(3) Remove shoulder belt turning loop from height
adjuster.(4) Use a Snap-ontTrim Pad Remover tool
(A179A), or equivalent, and remove shoulder belt
height adjuster knob.
(5) Remove shoulder belt bezel from trim cover
(Fig. 3).
(6) Remove screw attaching trim cover to B-pillar
from inside bezel cavity.
(7) Disengage hidden clips attaching trim cover to
B-pillar.
(8) Remove B-pillar trim cover from vehicle.
INSTALLATION
(1) Insert seat belt through B-pillar trim and web
guide (Fig. 3).
(2) Place B-pillar trim cover in position on vehicle.
(3) Engage hidden clips attaching trim cover to
B-pillar.
(4) Install shoulder belt bezel into trim cover.
(5) Install height adjuster knob.
(6) Install shoulder belt turning loop onto height
adjuster. Tighten bolt to 39 N´m (29 ft. lbs.) torque.
(7) Place seat anchor in position on floor so web-
bing is pointed rearward and slightly outboard.
(8) Install bolt attaching lower seat belt anchor to
floor. Tighten seat belt bolt to 39 N´m (29 ft. lbs.)
torque.
CARPETS AND FLOOR MATS
REMOVAL
(1) Remove front seats. (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL)
(2) Remove front center console.
(3) Remove the remaining seats. Refer to the Own-
er's Manual for the proper procedures.
(4) Remove front cowl panels and sill plates.
(5) Remove sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(6) Remove the cargo organizer, if equipped.
(7) Remove liftgate scuff plate. (Refer to 23 -
BODY/INTERIOR/LIFTGATE SCUFF PLATE -
REMOVAL)
(8) Remove lower B-pillar trim covers.
(9) Remove D-pillar trim covers.
(10) Remove Quarter trim panels.
(11) Remove floor escutcheons (Fig. 4).
(12) Remove the floor console trays. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE TRAY -
REMOVAL)
(13) Remove push pin fasteners attaching carpet to
floor in front seat and rear area.
(14) Roll carpet from under instrument panel to
center of sliding door.
Fig. 3 LOWER B-PILLAR TRIM COVER
1 - B-PILLAR UPPER TRIM
2 - B-PILLAR UPPER PLUG
3 - POWER SLIDING DOOR SWITCH AND BEZEL
4 - BELT ASSEMBLY
5 - B-PILLAR LOWER TRIM
RSINTERIOR23-75
B-PILLAR LOWER TRIM (Continued)

(15) Roll and fold carpet forward away from rear
door opening.
(16) Extract carpet through sliding door opening
(Fig. 5).INSTALLATION
(1) Insert carpet through sliding door opening.
(2) Roll carpet rearward toward rear door opening.
(3) Roll carpet under instrument panel.
(4) Install push pins fasteners through carpet and
grommet into floor to attach carpet to floor in front
seat area (Fig. 5).
(5) Install push pins fasteners in the rear area.
CAUTION: Ensure that the correct fasteners are
installed in the proper locations. Damage to the fuel
tank may result.
(6) Install floor escutcheons (Fig. 4).
(7) Install the floor console trays. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE TRAY -
INSTALLATION)
(8) Install Quarter trim panels.
(9) Install D-pillar trim covers.
(10) Install lower B-pillar trim covers.
(11) Install rear door sill plate.
(12) Install sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(13) Install front cowl panels and sill plates.
(14) Install the passenger seats. Refer to the Own-
er's Manual for proper procedures.
(15) Install front center console.
(16) Install front seats. (Refer to 23 - BODY/
SEATS/SEAT - INSTALLATION)
COWL TRIM
REMOVAL
(1) Remove door sill plate.
(2) Disengage hidden clips holding cowl trim to
cowl panel (Fig. 6).
(3) Remove cowl trim from vehicle.
INSTALLATION
(1) Place cowl trim panel in position on vehicle
(Fig. 1).
(2) Engage hidden clips attaching cowl trim to
cowl panel.
(3) Install door sill plate.
Fig. 4 SEAT ESCUTCHEONS
1 - SEAT ESCUTCHEON
2 - FLOOR CARPET
Fig. 5 FLOOR CARPET
1 - CARPET LOCATOR GROMMET
2 - PUSH PIN
3 - CARPET
4 - CARPET GROMMET
5 - HEEL PROTECTOR PAD
6 - BODY ASSEMBLY
23 - 76 INTERIORRS
CARPETS AND FLOOR MATS (Continued)

BENCH SEAT TRACK
REMOVAL............................104
INSTALLATION........................104
PLASTIC GROCERY BAG RETAINER
REMOVAL............................104
INSTALLATION........................105
UNDER SEAT STORAGE BIN
REMOVAL............................105
INSTALLATION........................105
UNDER SEAT STORAGE BIN GUIDE
REMOVAL............................105
INSTALLATION........................105
UNDER SEAT STORAGE BIN LOCK/LATCH
REMOVAL............................105INSTALLATION........................105
LUMBAR SUPPORT
REMOVAL............................106
INSTALLATION........................106
SEAT RISER LATCH LOCKING LINK
REMOVAL............................106
INSTALLATION........................106
QUAD BUCKET SEAT SIDE SHIELD/
CUPHOLDER - FLAP AND SPRING
ASSEMBLY
REMOVAL............................107
INSTALLATION........................107
CHILD SEAT MODULE, BENCH
SEAT
REMOVAL
(1) Close child restraint seat.
(2) Remove seat back cover.
(3) Remove screws attaching child restraint seat
module hinges to seat back frame lower rail (Fig. 1).
(4) Return seat back to upright position.
(5) Disengage push in fasteners attaching upper
bolster to child restraint seat module (Fig. 2).
(6) Remove screws attaching top of module to seat
back frame upper rail (Fig. 3).
(7) Remove child restraint seat module from seat
back (Fig. 4).
Fig. 1 CHILD RESTRAINT SEAT LOWER HINGE
1 - CHILD RESTRAINT SEAT MODULE
2 - LOWER HINGE
Fig. 2 CHILD RESTRAINT SEAT UPPER BOLSTER
1 - UPPER BOLSTER
2 - CHILD RESTRAINT SEAT MODULE
3 - PUSH-IN FASTENER
Fig. 3 CHILD RESTRAINT SEAT UPPER SCREWS
1 - UPPER BOLSTER
2 - CHILD RESTRAINT SEAT MODULE
RSSEATS23-87

INSTALLATION
INSTALLATION
(1) Place child restraint seat module in position on
seat back (Fig. 4).
(2) Position seat back hinge interlock lever over
the top of the outboard child restraint seat hinge
(Fig. 5).
(3) Install screws attaching child restraint seat
module hinges to seat back frame lower rail (Fig. 1).
(4) Install screws attaching top of module to seat
back frame upper rail (Fig. 3). Tighten nuts to 7 N´m
(62 in. lbs.) torque.
(5) Install push in fasteners attaching upper bol-
ster to child restraint seat module (Fig. 2).
(6) Return seat back to folded position.
(7) Install seat back cover.
(8) Check belt for smooth operation and verify
interlock operation. Recliner should not operate with
child seat deployed.
SYNCHRONIZING CABLE ADJUSTMENT
NOTE: Bench seats equipped with child restraint
seats have an interlock feature that will not allow
the seat back to fold forward with the child seat
open.
If the seat back hinges do not release at the same
time the synchronizing cable must be adjusted.
(1) Remove seat from vehicle. Refer to Owner's
Manual for proper procedures.
(2) Disengage cable from the recline mechanism by
pulling the cable end toward the front of the seat
(Fig. 6).
(3) Pull U-shaped locking tab on self-adjusting
mehcanism to disengage auto-adjust feature.
(4) Reattach self-adjusting mechanism, pulling
against spring load to tighten cable.
(5) Press locking tab onto the adjusting mecha-
nism to lock into place.
Fig. 4 CHILD RESTRAINT SEAT MODULE
1 - 1ST REAR SEAT BACK
2 - CHILD RESTRAINT SEAT MODULE
3 - SEAT BACK HINGE INTERLOCK LEVER
Fig. 5 INTERLOCK LEVER
1 - CHILD RESTRAINT SEAT HINGE
2 - SEAT BACK HINGE INTERLOCK LEVER
3 - 1ST REAR SEAT BACK
4 - SEAT BACK FRAME RAIL
23 - 88 SEATSRS
CHILD SEAT MODULE, BENCH SEAT (Continued)

QUAD CHILD SEAT
REMOVAL
(1) Remove the seat. Refer to Owner's Manual for
proper procedures.
(2) Remove seat back cover (Fig. 7).
(3) Remove fasteners attaching quad child seat to
the seat (Fig. 8).
(4) Remove quad child seat from the seat.
INSTALLATION
(1) Place quad child seat in position.
(2) Install fasteners and tighten to 13.5 N´m (10 ft.
lbs.)
(3) Install seat back cover.
(4) Install seat in vehicle.
HEADREST
REMOVAL
(1) Lift head restraint to top of travel.
(2) Depress lock button on side of sleeve at top of
seat back (Fig. 9).
(3) Pull head restraint from top of seat back.
INSTALLATION
(1) Place head restraint in position.
(2) Depress lock button on side of sleeve at top of
seat back.
(3) Push heat restraint down into position.
Fig. 6 SYNCHRONIZING CABLE
1 - CABLE END
2 - LOCKING TAB
3 - SETBACK HINGE
Fig. 7 SEAT BACK COVER
1 - SEAT BACK COVER
Fig. 8 CHILD RESTRAINT SEAT BACK
1 - FASTENERS
2 - J-STRAPS
3 - FASTENERS
RSSEATS23-89
CHILD SEAT MODULE, BENCH SEAT (Continued)

HEADREST SLEEVE
REMOVAL
(1) Remove head rest.
(2) Disengage closure attaching bottom of trim
cover together.
(3) Reach under trim cover through opening at
bottom of seat back.
(4) Pinch retainer barbs on end of head restraint
sleeve together (Fig. 10).
(5) Pull head restraint sleeve upward and out the
top of the seat back frame guide tube (Fig. 11).
INSTALLATION
(1) Insert head restraint sleeve into guide tube at
top of seat back.
(2) Push head restraint sleeve downward until
retainer clicks into lock position.
(3) Engage closure to hold bottom of trim cover
together.
(4) Install head restraint.
RECLINER HANDLE
REMOVAL
(1) Remove screw holding recliner handle to
recliner spline shaft (Fig. 12).
(2) Remove recliner handle from spline shaft.
INSTALLATION
(1) Place recliner handle in position on spline
shaft.
(2) Install screw to hold recliner handle to recliner
spline shaft (Fig. 12).
Fig. 9 HEAD RESTRAINT
1 - HEAD RESTRAINT
2 - SLEEVES
3 - LOCK BUTTON
Fig. 10 HEAD RESTRAINT SLEEVE RETAINER
1 - GUIDE TUBE
2 - PINCH RETAINER TO RELEASE
3 - SEAT BACK FRAME
Fig. 11 HEAD RESTRAINT SLEEVE
1 - SEAT BACK FRAME
2 - HEAD RESTRAINT SLEEVE
3 - RETAINER
4 - GUIDE TUBE
23 - 90 SEATSRS
HEADREST (Continued)

ARMREST
REMOVAL
(1) Using a small flat blade, pry cap from side of
armrest (Fig. 13).
(2) Remove bolt attaching armrest to seat back.
(3) Remove armrest from seat back.
INSTALLATION
(1) Place armrest in position on seat back.
(2) Install bolt attaching armrest to seat back.
Tighten bolt to 29N´m (21 ft. lbs.) torque.
(3) Install side cap into the side of the armrest.
FRONT SEAT
REMOVAL
(1) From under vehicle, remove nuts attaching
front seat risers to the floor.
(2) Remove seat and riser from floor (Fig. 14).
(3) Tip seat rearward and disconnect wire connec-
tors from body harness, if equipped.
(4) Remove seat from vehicle.
INSTALLATION
(1) Place seat into position
(2) Tip seat rearward and connect wire connectors
to body harness, if equipped.
(3) Place seat and riser into floor.
(4) From under vehicle, install nuts attaching
front seat risers to the floor. Tighten nuts to 60 N´m
(44 ft. lbs.) torque.
Fig. 12 RECLINER HANDLE - MANUAL
1 - CUSHION SIDE COVER
2 - RECLINER SPLINE
3 - SCREW
4 - RECLINER HANDLE
Fig. 13 ARMREST
1 - SEAT BACK
2 - ARMREST
3 - SHOULDER BOLT
4 - CAP
5 - WASHER
6 - STOP SCREW
Fig. 14 FRONT SEAT
1 - FRONT SEAT
2 - CONNECTORS
3 - B-PILLAR
RSSEATS23-91
RECLINER HANDLE (Continued)

FRONT SEAT BACK
REMOVAL
NOTE: On front seats equipped with side air bags,
the seatback is serviced as an assembly.
(1) Remove head rest sleeves. (Refer to 23 - BODY/
SEATS/HEADREST SLEEVE - REMOVAL)
(2) Remove the armrest. (Refer to 23 - BODY/
SEATS/ARMREST - REMOVAL)
(3) Remove the seatback recliner lever.
(4) Remove the lumbar adjustment lever.
(5) Remove both seat cushion side covers. (Refer to
23 - BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - REMOVAL)
(6) Remove nut attaching the recliner to the seat-
back frame (Fig. 15).
(7) Remove both pivot bolts and remove seatback
from recliner.
INSTALLATION
(1) Place seat back into position.
(2) Install both pivot bolts attaching seat back
frame to seat track. Tighten bolts to 54 N´m (40 ft.
lbs.) torque.(3) Install nut attaching the recliner to the seat
back frame. Tighten nut to 12 N´m (105 in. lbs.)
torque.
(4) Install both seat cushion side covers. (Refer to
23 - BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - INSTALLATION)
(5) Install the lumbar adjustment lever.
(6) Install the seat back recliner lever.
(7) Install the armrest. (Refer to 23 - BODY/
SEATS/ARMREST - INSTALLATION)
(8) Install headrest sleeves. (Refer to 23 - BODY/
SEATS/HEADREST SLEEVE - INSTALLATION)
FRONT SEATBACK ASSIST
STRAP
REMOVAL
(1) Using a small screw driver, pry screw plugs
from ends of assist strap (Fig. 16).
(2) Remove screws attaching assist strap to seat-
back.
(3) Remove assist strap from vehicle.
INSTALLATION
(1) Place assist strap in position on vehicle.
(2) Install screws attaching assist strap to seat
back. Tighten screws to 2.5 N´m (22 in. lbs.).
(3) Insert screw plugs into ends of assist strap
(Fig. 16).
FRONT SEATBACK PANEL
REMOVAL
(1) Remove the screws (Fig. 17).
(2) Tip the top of the panel away from the seat
back and lift off the hooks at the bottom to remove.
Fig. 15 FRONT SEATBACK
Fig. 16 FRONT SEATBACK ASSIST STRAP
1 - ASSIST STRAP
2 - SCREW PLUG
3 - SEAT BACK
23 - 92 SEATSRS