torque CHRYSLER VOYAGER 2005 Service Manual

INSTALLATION
(1) Using the motor housing tab, hook the liftgate
motor assembly on the D-pillar.
(2) Install the three motor assembly retaining
bolts. Torque the two rear most bolts first to 9.5 N´m
(85 in. lbs.). Torque the remaining bolt next to the
window actuator to 9.5 N´m (85 in. lbs.).
(3) Connect the liftgate motor assembly electrical
connector.
(4) Install the D-pillar trim panel on the vehicle,
(Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR
TRIM PANEL - INSTALLATION).
(5) Connect the battery negative cable.
(6) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes related to the door motor assembly.
(7) Verify power liftgate system operation. Cycle
the power liftgate through one complete open and
close cycle, this will allow the power liftgate control
module to relearn its cycle with the new components.
LIFT GEAR & LINK ROD
DESCRIPTION
The lift gear and rod assembly are located in the
left rear of the vehicle and are visible without remov-ing the D-pillar trim (Fig. 16). The lift gear provides
the leverage to move the liftgate from the closed to
the open position. The lift gear attaches to a bearing
on the gear motor assembly with four bolts. On the
outboard side of the lift gear are riveted on teeth,
which mesh with the gear motor assembly drive
gears during a open or close operation. The rod
assembly is a steel shaft, equipped with two spheri-
cal rod ends which attaches the lift gear to the lift-
gate. The lift gear and rod assembly are serviceable
components.
OPERATION
One end of the rod assembly is attached to the lift-
gate, the other attached to the lift gear. When the lift
gear is driven by the gear motor assembly the lift-
gate is moved to the open or closed position.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the left rear D-pillar trim panel from
the vehicle, (Refer to 23 - BODY/INTERIOR/LEFT
D-PILLAR TRIM PANEL - REMOVAL).
(3) Remove the lift gear retaining bolts (Fig. 17).
(4) Remove the lift gear and rod from the vehicle.
Fig. 16 LIFTGATE GEAR/MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Fig. 17 LIFTGATE GEAR MOTOR ASSEMBLY
1 - ENGAGE ACTUATOR RETAINING SCREWS
2 - LIFT GEAR RETAINING BOLTS
8N - 16 POWER LIFTGATE SYSTEMRS
LIFTGATE MOTOR (Continued)

INSTALLATION
(1) Position the lift gear and rod assembly and
install the retaining bolts (Fig. 18). Torque the bolts
to 8 N´m (71 in. lbs.).
(2) Install the D-pillar trim panel on the vehicle,
(Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR
TRIM PANEL - INSTALLATION).
(3) Connect the battery negative cable.
(4) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes related to the door motor assembly.
(5) Verify power liftgate system operation. Cycle
the power liftgate through one complete open and
close cycle, this will allow the power liftgate control
module to relearn its cycle with the new components.
CAUTION: Torque link rod to liftgate attachment
bolt to 250 in. lbs. Care must be taken not to over-
torque link rod bolt.
PINCH SENSOR
DESCRIPTION
Pinch sensors are located on each side of the lift-
gate (Fig. 19). These sensors look like weather-strips,
however they consist of pieces of electrically conduc-
tive rubber (tapeswitch), wires, resistor, double sided
tape, and a plastic carrier. They are used to indicate
an obstruction during a power liftgate close cycle.
OPERATION
During a power liftgate close cycle, if either of the
two conductive rubber strips (tapeswitch) of the
pinch sensor come in contact with an obstacle, the
pinch sensor circuit is completed. This tells the
power liftgate control module that a obstruction is
felt. The control module will stop the liftgate imme-
diately and return it to the full open position.
Fig. 18 LIFTGATE GEAR MOTOR ASSEMBLY
1 - ENGAGE ACTUATOR RETAINING SCREWS
2 - LIFT GEAR RETAINING BOLTS
Fig. 19 PINCH SENSOR LOCATION
1 - LIFTGATE
2 - PINCH SENSOR ASSEMBLY
3 - LIFTGATE PROP ROD
4 - PINCH SENSOR WIRE HARNESS CONNECTOR
5 - PINCH SENSOR WIRE HARNESS
RSPOWER LIFTGATE SYSTEM8N-17
LIFT GEAR & LINK ROD (Continued)

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove trim panel from liftgate, (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL).
(3) Disconnect the pinch sensor wire harness con-
nector (Fig. 20).
(4) Remove screws holding the pinch sensor to lift-
gate.
(5) Feed the pinch sensor wire harness out of the
liftgate and remove the sensor from the vehicle.
INSTALLATION
WARNING: USE EXTREME CAUTION WHEN TEST-
ING PINCH SENSOR OPERATION.
CAUTION: Ensure liftgate surface is clean and dry
prior to pinch sensor installation. Failure to do so
will inhibit the adhesive backings ability to adhere
to the liftgate and cause improper system operation
or premature component failure.
(1) Position the pinch sensor to the liftgate.
(2) Install the third screw from the top of the sen-
sor first.Do not torque screw at this time.(3) Install the remaining three screws holding the
sensor to the liftgate. Torque all screws to 25 in. lbs.
(4) Install wire harness grommet in liftgate flange
and route, connect the pinch sensor wire harness
connector (Fig. 21).
(5) Remove protective tap from the top of the
pinch sensor. Firmly apply pressure to the sensor
adhesive to secure it to the liftgate.
(6) Install the trim panel on the liftgate, (Refer to
23 - BODY/DECKLID/HATCH/LIFTGATE/TAIL-
GATE/TRIM PANEL - INSTALLATION).
(7) Connect the battery negative cable.
(8) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes related to the pinch sensor.
(9) Verify power liftgate system and pinch sensor
operation. Cycle the power liftgate through one com-
plete open and close cycle, during the final close cycle
press the pinch sensor to verify the power liftgate
detects an obstruction and returns to the full open
position.
Fig. 20 PINCH SENSOR LOCATION
1 - LIFTGATE
2 - PINCH SENSOR ASSEMBLY
3 - LIFTGATE PROP ROD
4 - PINCH SENSOR WIRE HARNESS CONNECTOR
5 - PINCH SENSOR WIRE HARNESS
Fig. 21 PINCH SENSOR LOCATION
1 - LIFTGATE
2 - PINCH SENSOR ASSEMBLY
3 - LIFTGATE PROP ROD
4 - PINCH SENSOR WIRE HARNESS CONNECTOR
5 - PINCH SENSOR WIRE HARNESS
8N - 18 POWER LIFTGATE SYSTEMRS
PINCH SENSOR (Continued)

TRANSVERSE BRACKET
DESCRIPTION
The transverse bracket (Fig. 22) is used to support
and secure the power liftgate gear/motor assembly to
the left rear body D-pillar. The transverse bracket is
a serviceable power liftgate component.
OPERATION
The power liftgate transverse bracket supports the
gear motor assembly by supplying an additional
attachment point. Located on the leading edge of the
gear motor assembly, one end of the transverse
bracket attaches to the motor assembly the other to
the leading edge of the vehicles D-pillar.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the left D-pillar trim from the vehicle,
(Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR
TRIM PANEL - REMOVAL).
(3) Disconnect the gear motor assembly electrical
connector and disengage retaining pushpin.
(4) Loosen the gear motor assembly retaining bolts
to allow room for transverse bracket to be removed.
(5) Remove the transverse bracket retaining bolts
(Fig. 23).
(6)
Remove the transverse bracket from the vehicle.
INSTALLATION
(1) Position the transverse bracket in the vehicle.
Be certain the transverse bracket is properly posi-
tioned. The bracket should just touch the engage
actuator arm and be positioned between the actuator
arm and the motor housing.
(2) Torque the transverse bracket retaining bolts
to the gear motor assembly to 9.5 N´m (85 in. lbs.).
Do not tighten the transverse bracket retaining bolt,
located under the window actuator at this time.
(3) Torque the gear motor assembly retaining bolts
to 9.5 N´m (85 in. lbs.).
(4) Torque the final transverse bracket retaining
bolt to 9.5 N´m (85 in. lbs.).
(5) Connect the gear motor assembly electrical con-
nector and engage retaining pushpin.
(6) Install the left D-pillar trim, (Refer to 23 -
BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL -
INSTALLATION).
(7) Connect the battery negative cable.
(8) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes related to the door motor assembly.
(9) Verify power liftgate system operation. Cycle
the power liftgate through one complete open and
close cycle, this will allow the power liftgate control
module to relearn its cycle with the new components.
Fig. 22 LIFTGATE GEAR/MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Fig. 23 LIFTGATE GEAR MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
RSPOWER LIFTGATE SYSTEM8N-19

(2) Remove the appropriate seat from the vehicle
and place it on a clean work surface, (Refer to 23 -
BODY/SEATS/SEAT - REMOVAL).
(3) Remove the Memory Seat/Mirror Module
(MSMM) mounting fasteners (if equipped).
(4) Disconnect the MSMM electrical harness con-
nectors and remove the MSMM from the power seat
track (if equipped).
(5) Remove the front seat track rear cover, (Refer
to 23 - BODY/SEATS/SEAT TRACK REAR COVER -
REMOVAL).
(6) Remove the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION SIDE COVERS - REMOVAL).
(7) Disconnect all electrical connectors connecting
the power seat track to the seat assembly.
(8) Pull the seat back trim cover up slightly to
access and remove the two seat back frame mounting
bolts and also remove two seat back recliner bolts.
(9) Remove four seat track mounting bolts from
the seat cushion pan.
(10) Remove the power seat track from the seat.INSTALLATION
(1) Position the seat cushion on the seat track.
(2) Install the four seat track retaining bolts in the
seat cushion pan. Torque the bolts to 28.5 N´m (21 ft-
lbs.).
(3) Position the seat back and install the two seat
back frame mounting bolts and the two seat back
recliner bolts. Torque the bolts to 55 N´m (40.5
ft-lbs.).
(4) Route and connect the electrical connectors
between the power seat track and the seat assembly.
(5) Install the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION SIDE COVERS - INSTALLATION).
(6) Install the front seat track rear cover, (Refer to
23 - BODY/SEATS/SEAT TRACK REAR COVER -
INSTALLATION).
(7) Position the Memory Seat/Mirror Module
(MSMM) and connect the MSMM electrical connec-
tors (if equipped).
(8) Install the MSMM mounting fasteners (if
equipped).
(9) Install the seat assembly in the vehicle (Refer
to 23 - BODY/SEATS/SEAT - INSTALLATION).
(10) Connect the battery negative cable.
RSPOWER SEAT SYSTEM8N-39
POWER SEAT TRACK (Continued)

(5) Partially close the door and pull the latch
assembly out of the side door inner panel, (Fig. 5).
(6) Disconnect all electrical connectors leading to
the latch assembly.
(7) Disconnect the inside and outside handle cables
from the latch assembly.
(8) Disconnect the hold open latch cable from the
latch assembly.
(9) Disconnect lock actuator link rod from the
latch assembly.
(10) Remove the latch assembly from the vehicle.
INSTALLATION
(1) Position the latch assembly in the vehicle. Be
certain all latch mounted components are installed
on the replacement latch assembly. If not, transfer
components from the old latch to the new latch
assembly, (Fig. 6).
(2) Connect the lock actuator link rod on the latch
assembly.
(3) Connect the hold open latch cable on the latch
assembly.
(4) Connect the inside and outside handle cables
on the latch assembly.
(5) Connect all electrical connectors leading to the
latch assembly.
(6) With assistance from another person, position
the side door and install the door latch retaining
bolts, (Fig. 7). Torque to 10 - 12 N´m (100 in. lbs.).
(7) Install the weathershield if necessary.(8) Install the appropriate side door trim panel,
(Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - INSTALLATION) for detailed instructions.
(9) Connect the negative battery cable.
Fig. 5 POWER LATCH POSITION & ORIENTATION
1 - POWER LATCH ASSEMBLY
Fig. 6 POWER LATCH POSITION & ORIENTATION
1 - POWER LATCH ASSEMBLY
Fig. 7 REMOVING LATCH RETAINING BOLTS
1 - LATCH RETAINING BOLTS
2 - SIDE DOOR
8N - 50 POWER SLIDING DOOR SYSTEMRS
LATCH (Continued)

SLIDING DOOR MOTOR
DESCRIPTION
The door motor is located in the center of the
power sliding door (Fig. 8) and is comprised of three
parts. The three parts of the door motor assembly are
the motor, gear reduction and clutch assembly. The
door motor assembly provides the power and torque
to move the sliding door from the open/closed posi-
tion to full closed/open position, after the power
latching mechanism has released.
The door motor is replaced as a complete assembly,
which includes the DC motor, gear reduction and
clutch assemblies.
OPERATION
With the push of a power sliding door command
switch, the power sliding door control module will
signal the latch assembly to release the door from its
primary locked position. The door motor will then
take over to provide the power to open the door to its
full open or closed position. The gear reduction por-
tion of the motor assembly reduces the speed of the
motor from 5800 to 260 rpm and also increases the
torque to the lower drive unit. The clutch portion of
the motor assembly engages the motor to drive thedoor under power and disengages it so the door can
be moved easily under manual operation.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the door trim panel from the appropri-
ate door, (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - REMOVAL).
(3) Remove the water shield as necessary to gain
access to motor assembly.
(4) Remove retaining clip holding flex drive assem-
bly to the motor (Fig. 9). Pull flex drive cable straight
out of the motor assembly.
(5) Disconnect door motor electrical connector.
(6) Using a trim stick (special tool #C-4755) or
equivalent, gently pry out push-pin fasteners retain-
ing the door motor.
(7) Remove the door motor assembly from the
vehicle.
INSTALLATION
(1) Position the door motor assembly on the door
inner panel.
(2) Install the push-pin fasteners retaining the
motor assembly to the power sliding door.
Fig. 8 POWER SLIDING DOOR COMPONENTS
1 - POWER SLIDING DOOR CONTROL MODULE
2 - MODULE RETAINING SCREW
3 - MODULE ELECTRICAL CONNECTORS
4 - DOOR MOTOR ASSEMBLY
5 - FLEX DRIVE ASSEMBLY
6 - DOOR MOTOR RETAINING FASTENERS
7 - DOOR MOTOR ELECTRICAL CONNECTOR
Fig. 9 FLEX DRIVE RETAINING CLIP
1 - FLEX DRIVE CABLE RETAINING CLIP
2 - FLEX DRIVE CABLE
3 - DOOR MOTOR ASSEMBLY
RSPOWER SLIDING DOOR SYSTEM8N-51

INSTALLATION
(1) Position the lower drive unit near the lower
hinge.
(2) Connect the flex drive assembly on the lower
drive unit. Push the flex drive collar straight on until
the it snaps in place (Fig. 14).It may be necessary
to rotate the drive unit slightly until the flex
drive seats in place.
(3) Install the lower drive unit retaining fasteners
(Fig. 15). Torque the larger allen headed center stud
to 9 N´m (80 in. lbs.). Torque the smaller screw to 3
N´m (28 in. lbs.).
(4) Install the lower drive unit cover and retaining
screws (Fig. 16).
(5) Connect the battery negative cable.
Fig. 14 LOWER DRIVE UNIT
1 - LOWER DRIVE UNIT
2 - FLEX DRIVE ASSEMBLY
Fig. 15 LOWER DRIVE UNIT RETAINING
FASTENERS
1 - LOWER DRIVE UNIT RETAINING SCREW
2 - DO NOT REMOVE
3 - LOWER DRIVE UNIT RETAINING BOLT
Fig. 16 SLIDING DOOR LOWER HINGE ASSEMBLY
1 - LOWER DRIVE UNIT COVER
2 - LOWER DRIVE UNIT COVER RETAINING SCREWS
3 - SLIDING DOOR
4 - LOWER HINGE ARM BRACKET
8N - 54 POWER SLIDING DOOR SYSTEMRS
LOWER DRIVE UNIT (Continued)

FLEX DRIVE
DESCRIPTION
The flex drive assembly is located in the lower por-
tion of the power sliding door (Fig. 17) and is used to
connect the door motor to the lower drive unit. An
E-clip is used to secure the flex drive to the motor
assembly, while the flex drive collar is used to secure
the drive to the lower drive unit. The flex drive
assembly is basically a flexible drive shaft for the
power sliding door system. The flex drive assembly is
a replaceable component.
OPERATION
With one end of the flex drive attached to the door
motor and the other attached to the lower drive unit,the flex drive transfers the power and torque from
the motor to the drive unit. A square shaped drive
cable, inside the flex drive assembly engages the
motor drive and rotates to move the door accordingly.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the appropriate sliding door trim
panel, (Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - REMOVAL).
(3) Position the weathershield aside to gain access
to the flex drive assembly.
(4) Remove the E-clip from the flex drive assembly
(Fig. 18).
(5) Pull the flex drive straight out of the motor
assembly.
Fig. 17 POWER SLIDING DOOR COMPONENTS
1 - POWER SLIDING DOOR CONTROL MODULE
2 - MODULE RETAINING SCREW
3 - MODULE ELECTRICAL CONNECTORS
4 - DOOR MOTOR ASSEMBLY
5 - FLEX DRIVE ASSEMBLY
6 - DOOR MOTOR RETAINING FASTENERS
7 - DOOR MOTOR ELECTRICAL CONNECTOR
Fig. 18 FLEX DRIVE E-CLIP
1 - FLEX DRIVE CABLE RETAINING CLIP
2 - FLEX DRIVE CABLE
3 - DOOR MOTOR ASSEMBLY
RSPOWER SLIDING DOOR SYSTEM8N-55

(7) Pull back the sealing patches and remove the
lower track retaining nuts (Fig. 24).
(8) Carefully remove the lower sliding door track
from the vehicle.
INSTALLATION
(1) Carefully position the lower sliding door track
in the vehicle.
(2) Install the lower track retaining nuts and
install the sealing patches, (Fig. 25). Torque the nuts
to 8 N´m (70 in. lbs).
(3) Install the lower hinge assembly on the door,
(Refer to 23 - BODY/DOORS - SLIDING/LOWER
ROLLER ARM - INSTALLATION).NOTE: Take care to locate the lower hinge assem-
bly on the door in its original position (ie. match
screw washer with rings left on hinge). Adjust door
fit if required, (Refer to 23 - BODY/DOORS - SLID-
ING/SLIDING DOOR - ADJUSTMENTS).
(4) Remove the floor jack.
(5) Install the hold-open striker, (Refer to 23 -
BODY/DOORS - SLIDING/HOLD OPEN LATCH
STRIKER - INSTALLATION).
(6) Install the side door sill plate, (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION).
(7) Connect the battery negative cable.
Fig. 24 Lower Track Retaining Nuts
1 - Lower Track Retaining Nuts
2 - Lower Door Track
Fig. 25 Lower Track Retaining Nuts
1 - Lower Track Retaining Nuts
2 - Lower Door Track
8N - 58 POWER SLIDING DOOR SYSTEMRS
LOWER DRIVE UNIT TRACK & RACK (Continued)