Front door CHRYSLER VOYAGER 2005 Service Manual

NOTE: Center hinge has an adjustable bolt for
up/down alignment. (Refer to 23 - BODY/DOORS -
SLIDING/SLIDING DOOR - ADJUSTMENTS)
(1) Place center hinge in position on vehicle.
(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)

(4) Check door for height using character lines as
a reference. Also check roof contour as a controlling
factor.
Using the procedures noted below, adjust the side
door in the order the individual steps are called out.
DOOR FLUSHNESS ADJUSTMENT
(1) Check sliding door flushness at the C-pillar
striker.
(2) If the sliding door is under or over flush,
remove striker assembly and move thread plate over
keeping one bolt in plate so it will not fall between
inner and outer panels.
(3) Adjust the C-pillar striker in or out until the
door is flush. Then, the on size hole can be elongated
in the direction required. This can be done by grind-
ing or filing the sheet metal and then painting raw
edge to prevent rusting.
(4) Check upper B-pillar flushness to A-pillar
cover.
(5) The sliding door upper hinge can only be
moved outboard by addinga1mmshim behind the
hinge mounting area once the two attachment bolts
are removed and reinstalled.
(6) Check flushness at upper C-pillar.
(7) If upper C-pillar flushness is out of specifica-
tion use a heavy rubber mallet on the door assembly
until door is in specifications.
DOOR GAP ADJUSTMENT - UP/DOWN
(1) Check height of sliding door at the B-pillar and
C-pillar to determine which area is contributing the
greatest to the incorrect gaps.
(2) Visually inspect the sliding door for fitting low
at the top of the door by checking the alignment of
the top contour of the door to the quarter panel.
(3) If the sliding door is high at the C-pillar.
(a) Open the door to mid-point of travel.
(b) Mark outline of center hinge on sliding door
to assist in making adjustments.
(c) Loosen center hinge bolts (Fig. 14).
(d) Move hinge fore or aft to position the sliding
door into the correct location.
(e) Tighten center hinge bolts to 13 N´m (115 in.
lbs.) torque.
(f) Verify alignment, adjust as necessary.
(4) If the sliding door is low at the B-pillar ;
(a) Remove access plug in the sliding door trim
panel.
(b) Open the door to mid-point of travel.
(c) Mark outline of lower roller arm bracket on
sliding door to assist in making adjustments.
(d) Loosen lower roller arm bracket bolts (Fig.
15).
(e) Move hinge upward to raise the door.(f) Tighten lower roller arm bracket bolts to 13
N´m (115 in. lbs.) torque.
(g) Verify alignment, adjust as necessary.
(5) If the sliding door is low at the C-pillar;
(a) Open the door to mid-point of travel.
(b) Mark outline of center hinge on sliding door
to assist in making adjustments.
(c) Adjust the adjustment bolt up or down to
move the door position. (Fig. 14).
(d) Move hinge downward to raise the door.
(e) Tighten center hinge bolts to 13 N´m (115 in.
lbs.) torque.
(f) Verify alignment adjust as necessary.
(6) If the sliding door is high at the B-pillar;
(a) Remove access plug in the sliding door trim
panel.
(b) Open the door to mid-point of travel.
(c) Mark outline of lower roller arm bracket on
sliding door to assist in making adjustments.
(d) Loosen lower roller arm bracket bolts (Fig.
15).
(e) Move hinge upward to raise the door.
(f) Tighten lower roller arm bracket bolts to 13
N´m (115 in. lbs.) torque.
(g) Verify alignment, adjust as necessary.
(7) Fully open the sliding door.
(8) Verify that all center hinge bolts are tight.
(9) Adjust the rear of the sliding door up by turn-
ing the center hinge bolt clockwise (Fig. 14).
(10) Close the door and check the sliding door
alignment.
(11) Adjust the front of the sliding door up by
adjusting lower hinge bolts.
Fig. 14 SLIDING DOOR CENTER HINGE
1 - ADJUSTING BOLT
2 - WELD NUT
RSDOORS - SLIDING23-31
SLIDING DOOR (Continued)

(12) Open door half way and remove lower hinge
bolt access plug.
(13) Loosen bolts as necessary to move the front of
door up or down.
(14) Check the upper hinge for possible bind,
adjust as necessary.
(15) Close the door and check the sliding door
alignment.
(16) Fully open door and apply thread lock nut
onto the center hinge bolt. Tighten nut until till it
butts up against the welded nut on the center hinge.
Tighten nut to 13 N´m (115 in. lbs.) torque. It may be
necessary to hold the center hinge bolt to prevent it
from turning while tightening nut.
(17) Verify alignment, adjust as necessary.
DOOR GAP ADJUSTMENT - FORE/AFT
(1) Check C-pillar and B-pillar for door to aperture
gaps (5 mm + 1 mm), and door to door gap (5 mm +
1 mm).
(2) If adjust gaps require adjustment, loosen cen-
ter hinge screws as necessary to move center hinge
forward or rearward.
(3) Moving center hinge rearward increases the
gap at C-pillar and decreases gap at B-pillar. Moving
center hinge forward decreases gap at the C-pillar
and increases gap at the B-pillar
(4) Move center hinge as necessary, and tighten
screws.
(5) Close the door and check the sliding door align-
ment.
(6) Verify door alignment, adjust as necessary.
(7) Tighten center hinge screws to 13 N´m (115 in.
lbs.) torque.
DOOR SEAL COMPRESSION
(1) First check Gap & Flush (Refer to 23 - BODY/
BODY STRUCTURE/GAP AND FLUSH - SPECIFI-
CATIONS). Check seal compression near the middle
of the door even with the latch assembly. Using a
piece of paper, place it across door seal and close
door. Pull paper out of door opening. If paper tears
setting is to tight, if paper slides thought to easily
the compression is insufficient and needs to be
adjusted.
(2) Adjust seal compression at the top of the B-pil-
lar seal;
(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. 16).
(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 to 13 N´m
(115 in. lbs.) torque.
(g) Verify door alignment, adjust as necessary.
(3) Adjust seal compression at the bottom of B-pil-
lar 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. 17).
(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.
Fig. 15 SLIDING DOOR LOWER ROLLER ARM
1 - LOWER ROLLER ARM BRACKET
2 - BOLTS
3 - SLIDING DOOR
Fig. 16 Sliding Door Upper Roller Arm
1 - UPPER STOP PLATE
2 - SLIDING DOOR
3 - UPPER SLIDING DOOR HINGE
23 - 32 DOORS - SLIDINGRS
SLIDING DOOR (Continued)

EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL.............................45
INSTALLATION.........................46
COWL GRILLE
REMOVAL.............................50
INSTALLATION.........................50
EXTERIOR NAME PLATES - TAPE ATTACHED
REMOVAL.............................51
INSTALLATION.........................51
EXTERIOR NAME PLATES - ADHESIVE
ATTACHED
REMOVAL.............................51
INSTALLATION.........................51
FRONT FENDER
REMOVAL.............................51
INSTALLATION.........................52
FUEL FILL DOOR
REMOVAL.............................52
INSTALLATION.........................52
FUEL FILL DOOR BLOCKER LATCH
REMOVAL.............................53
INSTALLATION.........................53
FUEL FILL DOOR BLOCKER LATCH STRIKER
REMOVAL.............................53
INSTALLATION.........................53
FUEL FILL DOOR BLOCKER LOCKOUT LINK
REMOVAL.............................54
INSTALLATION.........................54
GRILLE
DESCRIPTION.........................55REMOVAL.............................55
INSTALLATION.........................55
UPPER RADIATOR CROSSMEMBER
REMOVAL.............................56
INSTALLATION.........................56
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL.............................57
INSTALLATION.........................57
LUGGAGE RACK RISER
REMOVAL.............................57
INSTALLATION.........................58
LUGGAGE RACK CROSSBAR
REMOVAL.............................58
INSTALLATION.........................59
REAR QUARTER PANEL/FENDER AIR
EXHAUSTER
DESCRIPTION.........................59
REMOVAL.............................59
INSTALLATION.........................60
ROOF JOINT MOLDING
REMOVAL.............................60
INSTALLATION.........................60
SIDE VIEW MIRROR
REMOVAL.............................60
INSTALLATION.........................60
GLASS-OUTSIDE REARVIEW MIRROR
REMOVAL.............................61
INSTALLATION.........................61
BODY SIDE MOLDINGS
REMOVAL
Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig.
5)for proper location of fasteners holding the molding
to the wheelhouse lip and rocker panels.
(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) If equipped, remove pop rivets holding molding
edge to wheelhouse lip.
(3) Pull stick on molding from painted surface.
(4) Remove adhesive tape residue from painted
surface of vehicle. Use a 3M Scotch-BriteŸ Molding
Adhesive and Stripe Removal Disc, or equivalent, to
clean adhesive residue from painted surfaces. These
products are available from automotive paint suppli-
ers. Refer to instructions supplied with the specific
product for proper usage.
RSEXTERIOR23-45

INSTALLATION
Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig.
5)for proper location of fasteners to hold the molding
to the wheelhouse lip and rocker panels.
(1) If molding is to be reused;
(a) Remove tape residue from molding.
(b) Clean back of molding with MopartSuper
Kleen, or equivalent.
(c) Wipe molding dry with lint free cloth.
(d) Apply a single coat of MopartTPO Molding
Prep to tape side of molding and allow to dry thor-
oughly.
(e) Apply new body side molding (two sided
adhesive) tape to back of molding.(2) Clean body surface with MopartSuper Kleen,
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 to rear,
inserting locator pins into hole in body panel.
(5) Using a roller tool, roll molding onto body
panel with enough force to assure adhesion. Do not
apply excessive force, or damage to body panels may
result.
(6) Install pop rivets to hold molding edge to
wheelhouse lip, if necessary.
Fig. 1 BODY SIDE MOLDINGS - BASE TYPICAL
1 - GUIDE PINS
2 - FRONT DOOR MOLDING3 - SLIDING DOOR MOLDING
4 - QUARTER PANEL MOLDING
23 - 46 EXTERIORRS
BODY SIDE MOLDINGS (Continued)

Fig. 2 BODY SIDE MOLDINGS - HIGHLINE TYPICAL
1 - QUARTER PANEL
2 - FRONT FENDER
3 - POP-RIVET
4 - FENDER MOLDING
5 - FRONT DOOR MOLDING6 - SLIDING DOOR MOLDING
7 - GUIDE PINS
8 - QUARTER PANEL MOLDING
9 - LIFTGATE MOLDING
10 - POP-RIVET
RSEXTERIOR23-47
BODY SIDE MOLDINGS (Continued)

Fig. 3 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)

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
RSEXTERIOR23-49
BODY SIDE MOLDINGS (Continued)

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 onoutboard 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.
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) Start 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.
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
23 - 50 EXTERIORRS
BODY SIDE MOLDINGS (Continued)

(6) Remove outboard cowl grille/fender bracket
screw and antenna right side only.
(7) Remove fender bolt to lower rocker panel.
(8) Remove fender bolt to lower cowl.
(9) Support/remove hood.
(10) Pull fascia away from fender.
(11) Remove bolts attaching fender to upper rail.
(12) 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 hood/remove support.
(7) Install outboard cowl grille/fender bracket
screw and install antenna right side only.
(8) Install fender to fascia nuts.
(9) Install inner splash shield.
(10) Install mud guard.
(11) Install headlamp assembly. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - INSTALLATION)
(12) Check fender for flush and gap. (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS).
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.
(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.
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
23 - 52 EXTERIORRS
FRONT FENDER (Continued)