CHRYSLER VOYAGER 2005 Service Manual

INSTALLATION
(1) Place center bezel near opening and connect
the wire connectors to the accessory switches and
HVAC control.
(2) Position the center bezel over the retaining
slots and firmly snap the instrument panel center
bezel into place (Fig. 10).
(3) Install the two center bezel attaching screws.
(4) Install the screw access cover to the bottom of
the center bezel.
INSTRUMENT PANEL RIGHT
END CAP
REMOVAL
(1) Open passenger side front door.
(2) Using a trim stick, disengage clips holding end
cover to instrument panel (Fig. 11).
INSTALLATION
(1) Position end cover over retaining slots and
firmly snap into place (Fig. 11).
(2) Close passenger side front door.
INSTRUMENT PANEL TOP
COVER
REMOVAL
(1) Remove A-pillar trim. Using a trim stick (spe-
cial tool #C-4755) or equivalent, gently pry out and
remove.
(2) Using a trim stick, disengage clips attaching
rear edge of top cover to instrument panel (Fig. 12).
NOTE: The Instrument Panel Top Cover may be
hard to unsnap from the instrument panel. Be sure
not to mar, scuff, or damage the instrument panel
pad.
(3) Remove top cover from vehicle and silencer.
INSTALLATION
(1) Place the silencer pad into position.
(2) Place instrument panel top cover in position on
vehicle (Fig. 12).
(3) Engage clips attaching rear edge of top cover to
instrument panel.
(4) Pull top cover rearward.
(5) Install A-pillar trim.
Fig. 10 INSTRUMENT PANEL CENTER BEZEL
1 - LOWER INSTRUMENT PANEL
2 - INSTRUMENT PANEL CENTER BEZEL
3 - CUPHOLDER
Fig. 11 INSTRUMENT PANEL END CAP
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL END CAP
23 - 72 INSTRUMENT PANELRS
INSTRUMENT PANEL CENTER BEZEL (Continued)

LOWER CONSOLE
REMOVAL
(1) Remove screws attaching the lower console to
floor bracket and instrument panel (Fig. 13).
(2) Slide lower console rearward from around
instrument panel supports.
(3) Disconnect the auxiliary power outlet wire con-
nector (if equipped).
(4) Remove lower console from vehicle.
INSTALLATION
(1) Connect the auxiliary power outlet wire con-
nector (if equipped).
(2) Install the lower console into the vehicle (Fig.
13).
(3) Slide console forward around instrument panel
supports.
(4) Install the screws attaching lower console to
floor bracket and instrument panel.
LOWER INSTRUMENT PANEL
REMOVAL
When servicing the lower instrument panel, refer
to Body, Instrument Panel, and then the appropriate
removal procedure.
(1) Remove the right end cover.
(2) Remove the lower steering column cover (Fig.
14).
(3) Remove the center bezel.
(4) Remove the lower console.
(5) Remove the cup holder and track.
(6) Remove the glove box.
(7) Remove the glove box latch striker.
(8) Remove the glove box lamp.
(9) Remove the eighteen screws holding the lower
instrument panel to the reinforcement frame (Fig.
15).
(10) Remove the lower instrument panel from
vehicle.
INSTALLATION
When servicing the lower instrument panel, refer
to Body, Instrument Panel, and then the appropriate
removal procedure.
(1) Install the lower instrument panel into the
vehicle (Fig. 15).
(2) Install the eighteen screws holding the lower
instrument panel to the reinforcement frame.
(3) Install the glove box lamp.
(4) Install the glove box latch striker.
(5) Install the glove box.
(6) Install the cup holder and track.
(7) Install the lower console.
(8) Install the center bezel.
(9) Install the lower steering column cover (Fig.
14).
(10) Install the right end cover.
Fig. 12 INSTRUMENT PANEL TOP COVER
1 - INSTRUMENT PANEL TOP COVER
2 - INSTRUMENT PANEL SILENCER PAD
3 - INSTRUMENT PANEL
Fig. 13 INSTRUMENT PANEL FLOOR CONSOLE
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL FLOOR CONSOLE
RSINSTRUMENT PANEL23-73
INSTRUMENT PANEL TOP COVER (Continued)

LOWER STEERING COLUMN
COVER
REMOVAL
(1) Use trim stick to gently pry rt edge of steering
column cover from lower rt panel just enough to dis-
engage 'belt loops' (Fig. 16).
(2) Pull lower steering column cover rearward to
release spring clips and remove from the vehicle.
(3) Remove the three screws attaching the end cap
to instrument panel.
(4) Pull end cap outward to release spring clips
and remove from the vehicle
INSTALLATION
(1) Place the end cap into position and push spring
clips into position (Fig. 16).
(2) Attach left side of lower steering column cover
first. Align locating ribs into left end cap and rock
cover to right side and align belt loops into position
into instrument lower right panel.
Fig. 14 STEERING COLUMN COVER AND END CAP
1 - INSTRUMENT PANEL UPPER AND LOWER PANEL
2 - ATTACHING SCREW(S)
3 - END CAP
4 - INSTRUMENT PANEL STEERING COLUMN COVER5 - INSTRUMENT PANEL STEERING COLUMN COVER PLATE
6 - COWL PANEL
7 - COWL SIDE TAPPING PLATE
Fig. 15 LOWER INSTRUMENT PANEL
1 - INSTRUMENT PANEL
2 - LOWER INSTRUMENT PANEL
23 - 74 INSTRUMENT PANELRS
LOWER INSTRUMENT PANEL (Continued)

(3) Place the lower steering column cover into posi-
tion and push spring clips into position.
(4) Install the two screws attaching the lower
steering column cover to instrument panel.
BLOCKER- INFLATABLE KNEE
REMOVAL
(1) Remove lower steering column cover (Refer to
23 - BODY/INSTRUMENT PANEL/STEERING COL-
UMN OPENING COVER - REMOVAL).
(2) Remove the park brake release handle link
from the park brake release handle.
(3) Disengage inflatable knee blocker wire connec-
tor from lower instrument and disconnect the wire
connector (Fig. 17).(4) Remove screws attaching to instrument panel.
(5) Remove inflatable knee blocker from vehicle.
INSTALLATION
(1) Place inflatable knee blocker into position (Fig.
17).
(2) Connect inflatable knee blocker wire connector
and install inflatable knee blocker attaching screws.
(3) Install the steering column cover backing plate
into vehicle.
(4) Install park brake release handle link to park
brake release handle.
(5) Install the lower steering column cover (Refer
to 23 - BODY/INSTRUMENT PANEL/STEERING
COLUMN OPENING COVER - INSTALLATION).
Fig. 16 STEERING COLUMN COVER AND END CAP
1 - INSTRUMENT PANEL UPPER AND LOWER PANEL
2 - ATTACHING SCREW(S)
3 - END CAP
4 - INSTRUMENT PANEL STEERING COLUMN COVER5 - INSTRUMENT PANEL STEERING COLUMN COVER PLATE
6 - COWL PANEL
7 - COWL SIDE TAPPING PLATE
RSINSTRUMENT PANEL23-75
LOWER STEERING COLUMN COVER (Continued)

OVER STEERING COLUMN
COVER
REMOVAL
(1) Taking a firm grasp of the over steering col-
umn cover front edge, give a quick upward pulling
motion to disengage the cover from the instrument
panel (Fig. 18).
(2) Remove the over steering column cover from
the vehicle.
INSTALLATION
(1) Place the over steering column cover into posi-
tion over the retaining slots and firmly snap into
place (Fig. 18).
Fig. 17 INFLATABLE KNEE BLOCKER
1 - INSTRUMENT PANEL COLUMN COVER PLATE
2 - COWL SIDE TAPPING PLATE
3 - LOWER INSTRUMENT PANEL REINFORCEMENT4 - INFLATABLE KNEE BLOCKER WIRE CONNECTOR
5 - INFLATABLE KNEE BLOCKER
6 - KNEE LOCKER ATTACHING SCREWS
Fig. 18 OVER STEERING COLUMN COVER
1 - INSTRUMENT PANEL OVER STEERING COLUMN COVER
2 - INSTRUMENT PANEL
23 - 76 INSTRUMENT PANELRS
BLOCKER- INFLATABLE KNEE (Continued)

INSTRUMENT PANEL TOP PAD
ASSEMBLY
REMOVAL
(1)Remove the instrument cluster (Fig. 19). (Refer to 8
- ELECTRICAL/INSTRUMENT CLUSTER - REMOVAL)
(2) Remove the message center (Fig. 19). (Refer to
8 - ELECTRICAL/MESSAGE CENTER - REMOVAL)
(3) Remove the radio (Fig. 19). (Refer to 8 - ELEC-
TRICAL/AUDIO/RADIO - REMOVAL)
(4) Remove the headlamp switch (Fig. 19). (Refer
to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/HEADLAMP SWITCH - REMOVAL)
(5) Remove the lower console (Fig. 19). (Refer to 23
- BODY/INSTRUMENT PANEL/LOWER CONSOLE
- REMOVAL)
(6) Remove the lower panel. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER INSTRUMENT
PANEL TRIM - REMOVAL)
(7) Remove the instrument panel assembly. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL)
(8) Remove the instrument panel speakers.
(9) Remove the glove box light.
(10) Remove the two passenger air bag mounting
bolts (Fig. 20).
(11) Loosen the three passenger air bag support
bracket bolts to the hydro-form rail (Fig. 20).
(12) Remove the 16 screws along the upper edge of
the pad & panel assembly.(13) Remove the 19 screws along the lower edge of
the pad & panel assembly.
(14) Remove the pad and panel assembly (Fig. 19).
INSTALLATION
(1) Position the pan & panel assembly onto the
instrument panel support structure (Fig. 19).
(2) Install the 19 screws along the lower edge of
the pad & panel assembly (Fig. 19).
(3) Install the 16 screws along the upper edge of
the pad & panel assembly.
(4) Install and tighten the two passenger air bag
mounting screws (Fig. 20).
(5) Tighten the three passenger air bag support
bracket bolts to the hydro-form tube (Fig. 20).
(6) Install the glove box light.
(7) Install the instrument panel speakers.
(8) Install the instrument panel assembly. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION)
(9) Install the lower panel. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER INSTRUMENT
PANEL TRIM - INSTALLATION)
(10) Install the lower console. (Refer to 23 - BODY/
INSTRUMENT PANEL/LOWER CONSOLE -
INSTALLATION)
(11) Install the headlamp switch. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP SWITCH - INSTALLATION)
(12) Install the radio. (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - INSTALLATION)
(13)
Install the message center. (Refer to 8 - ELEC-
TRICAL/MESSAGE CENTER - INSTALLATION)
(14) Install the instrument cluster. (Refer to 8 -
ELECTRICAL/INSTRUMENT CLUSTER - INSTAL-
LATION)
Fig. 19 INSTRUMENT PANEL ASSEMBLY
1 - INSTRUMENT CLUSTER
2 - TOP COVER
3 - PAD AND PANEL ASSEMBLY
4 - LOWER CONSOLE
5 - LOWER PANEL
6 - RADIO
7 - HEADLAMP SWITCH
Fig. 20 AIRBAG MOUNTING HARDWARE
1 - AIR BAG SCREWS (2)
2 - ELECTRICAL CONNECTOR
3 - AIR BAG SUPPORT BRACKET BOLTS (3)
4 - HYDRO-FORM INSTRUMENT PANEL SUPPORT RAIL
RSINSTRUMENT PANEL23-77

INTERIOR
TABLE OF CONTENTS
page page
A-PILLAR LOWER EXTENSION TRIM
REMOVAL.............................79
INSTALLATION.........................79
A-PILLAR TRIM
REMOVAL.............................79
INSTALLATION.........................79
ASSIST HANDLE
REMOVAL.............................79
INSTALLATION.........................79
B-PILLAR LOWER TRIM
REMOVAL.............................79
INSTALLATION.........................80
B-PILLAR UPPER TRIM
REMOVAL.............................80
INSTALLATION.........................80
CARPETS AND FLOOR MATS
REMOVAL.............................81
INSTALLATION.........................81
CARPETS - FOLD-IN-FLOOR
REMOVAL.............................82
INSTALLATION.........................83
CARPET TRIM RING AND COVER - FOLD-IN-
FLOOR
REMOVAL.............................84
INSTALLATION.........................84
COWL TRIM
REMOVAL.............................88
INSTALLATION.........................88
C-PILLAR TRIM
REMOVAL.............................88
INSTALLATION.........................88
DOOR SILL TRIM PLATE
REMOVAL.............................89
INSTALLATION.........................89
FLOOR CONSOLE BASE TRAY
REMOVAL.............................89
INSTALLATION.........................89
FLOOR CONSOLE - FOLD-IN-FLOOR
REMOVAL.............................89
INSTALLATION.........................89
FLOOR CONSOLE KEY LOCK TUMBLER -
FOLD-IN-FLOOR
REMOVAL.............................90
INSTALLATION.........................90
FLOOR CONSOLE LID LATCH - FOLD-IN-
FLOOR
REMOVAL.............................90
INSTALLATION.........................90HEADLINER
REMOVAL.............................91
INSTALLATION.........................92
LEFT D-PILLAR TRIM PANEL
REMOVAL.............................94
INSTALLATION.........................94
LEFT QUARTER TRIM PANEL
REMOVAL.............................94
INSTALLATION.........................94
LIFTGATE SILL PLATE
REMOVAL.............................94
INSTALLATION.........................95
QUARTER TRIM BOLSTER
REMOVAL.............................95
INSTALLATION.........................95
REAR FLOOR TUB CARPETS INSERT -
FOLD-IN-FLOOR
REMOVAL.............................95
INSTALLATION.........................96
REAR HEADER TRIM
REMOVAL.............................96
INSTALLATION.........................96
REAR HVAC LOUVER
REMOVAL.............................96
INSTALLATION.........................97
RIGHT QUARTER TRIM PANEL
REMOVAL.............................97
INSTALLATION.........................97
REAR VIEW MIRROR
REMOVAL.............................97
INSTALLATION.........................97
RIGHT D-PILLAR TRIM PANEL
REMOVAL.............................97
INSTALLATION.........................98
SECOND ROW FLOOR TUB CARPET INSERT -
FOLD-IN-FLOOR
REMOVAL.............................98
INSTALLATION.........................98
SLIDING DOOR SILL PLATE
REMOVAL.............................98
INSTALLATION.........................99
SUN VISOR
REMOVAL.............................99
INSTALLATION.........................99
SUN VISOR SUPPORT
REMOVAL.............................99
INSTALLATION.........................99
23 - 78 INTERIORRS

A-PILLAR LOWER EXTENSION
TRIM
REMOVAL
(1) Remove instrument panel side cover.
(2) Remove A-pillar extension trim from vehicle by
disengaging hidden clips (Fig. 1).
INSTALLATION
(1) Place A-pillar extension trim in position on
vehicle (Fig. 1).
(2) Install instrument panel side cover.
A-PILLAR TRIM
REMOVAL
(1) Remove the assist handle if equipped. (Refer to
23 - BODY/INTERIOR/ASSIST HANDLE -
REMOVAL)
(2) Disengage hidden clips holding A-pillar trim
panel to A-pillar (Fig. 2).
(3) Remove A-pillar trim from vehicle.
INSTALLATION
(1) Position foot on A-pillar trim panel into instru-
ment panel top cover channel.
(2) Position A-pillar trim in vehicle.
(3) Align locator pins.
(4) Engage hidden clips.(5) Install the assist handle, if equipped. (Refer to
23 - BODY/INTERIOR/ASSIST HANDLE - INSTAL-
LATION)
ASSIST HANDLE
REMOVAL
(1) Using a trim stick (C-4755), remove screw
access covers from grab-handle.
(2) Remove screws holding grab-handle to roof rail.
(3) Remove grab-handle from vehicle.
INSTALLATION
(1) Place grab-handle in position on vehicle.
(2) Install screws to hold grab-handle to roof rail.
(3) Install screw access covers into grab-handle.
B-PILLAR LOWER TRIM
REMOVAL
NOTE: The driver's side a double ended stud is
used. A nut has to be removed for the seat belt
anchor removal and the stud for the retractor
removal.
NOTE: On the passenger side there is a belt tension
sensor.
Fig. 1 A-PILLAR LOWER EXTENSION TRIM
1 - FRONT LOWER EXTENSION TRIM
2 - FRONT EXTENSION TRIM TO INSTRUMENT PANEL
RETAINER
3 - CLIP
4 - COWL TRIM PANEL
Fig. 2 A-PILLAR TRIM
1 - A-PILLAR
2 - CLIPS
RSINTERIOR23-79

(1) Slide lower seat belt cover rearward to expose
anchor fastener.
(2) Remove bolt/nut attaching lower seat belt
anchor to floor.
(3) Remove upper B-pillar trim cover.
(4) Remove access panel from B-pillar trim (Fig.
3).
(5) Disengage hidden clips attaching lower trim
cover to B-pillar.
(6) Remove lower B-pillar trim cover from vehicle.
INSTALLATION
NOTE: The driver's side a double ended stud is
used. A nut has to be removed for the seat belt
anchor removal and the stud for the retractor
removal.
NOTE: On the passenger side there is a belt tension
sensor.
(1) On the passenger side secure grommet to seat
belt sensor connector into bottom of B-pillar lower
trim prior to install B-pillar lower trim cover.(2) Place lower B-pillar trim cover in position on
vehicle (Fig. 3).
(3) Insert seat belt through hole in lower B-pillar
trim.
(4) Engage hidden clips attaching lower trim cover
to B-pillar.
(5) Install access cover.
(6) Install upper B-pillar trim cover.
(7) Place seat belt anchor in position on floor so
webbing is pointed rearward and slightly outboard.
(8) Install bolt/nut attaching lower seat belt
anchor to floor. Tighten seat belt anchor bolt/nut to
39 N´m (29 ft. lbs.) torque.
(9) 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 or self
aligning tab on passenger side.
(8) Install bolt attaching lower seat belt anchor to
floor. Tighten seat belt bolt to 39 N´m (29 ft. lbs.)
torque.
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
23 - 80 INTERIORRS
B-PILLAR LOWER TRIM (Continued)

CARPETS AND FLOOR MATS
REMOVAL
(1) Remove front seats. (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL)
(2) Remove front center console.
(3) Remove heel blocker (plastic block below accel-
erator pedal).
(4) Remove the remaining seats. Refer to the Own-
er's Manual for the proper procedures.
(5) Remove front cowl panels and sill plates.
(6) Remove sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(7) Remove the cargo organizer, if equipped.
(8) Remove liftgate scuff plate. (Refer to 23 -
BODY/INTERIOR/LIFTGATE SCUFF PLATE -
REMOVAL)
(9) Remove lower B-pillar trim covers.
(10) Remove D-pillar trim covers.
(11) Remove Quarter trim panels.
(12) Remove floor escutcheons (Fig. 4).
(13) Remove the floor console trays. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE TRAY -
REMOVAL)
(14) Remove push pin fasteners attaching carpet to
floor in front seat and rear area.
(15) Roll carpet from under instrument panel to
center of sliding door.
(16) Roll and fold carpet forward away from rear
door opening.
(17) 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 heel blocker (plastic block below accel-
erator pedal).
(17) Install front seats. (Refer to 23 - BODY/
SEATS/SEAT - INSTALLATION)
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
RSINTERIOR23-81