torque CHRYSLER VOYAGER 2005 Service Manual

(2) Grasp the wheel cover at the edges in line with
the remaining installed wheel nuts and pull straight
outward from the wheel. This will pop the wheel
cover retaining tabs over the two remaining wheel
nuts, removing the wheel cover from the wheel.
INSTALLATION
NOTE: Wheel mounting nuts must be installed on
the studs as shown to allow installation of the
wheel cover (Fig. 30).
(1) Place the wheel cover on the wheel in the fol-
lowing fashion:(a) Align the valve notch in the wheel cover with
the valve stem on the wheel.
(b) At the same time, align the two holes in the
wheel cover having the retaining tabs with the two
installed wheel nuts (Fig. 31).
(c) Press in on center of wheel cover until wheel
cover retaining tabs push past and engage rear of
previously installed wheel mounting nuts (Fig. 31).
This will hold the wheel cover in place.
(2) Install andlightly tightenthe three remain-
ing wheel mounting nuts, securing the wheel cover in
place (Fig. 29).
(3) Tighten all five wheel mounting nuts in the
proper sequence (Fig. 32). Tighten wheel nuts to a
torque of 135 N´m (100 ft. lbs.).
Fig. 29 Nuts Securing Wheel Cover
1 - VALVE STEM
2 - BOLT-ON WHEEL COVER
3 - NUTS SECURING WHEEL COVER
Fig. 30 Two Wheel Mounting Nuts Installed
1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
Fig. 31 Wheel Cover Installation Over Two Nuts
1 - RETAINING TABS
2 - VALVE STEM
3 - BOLT-ON WHEEL COVER
Fig. 32 Nut Tightening Sequence
22 - 20 TIRES/WHEELSRS
WHEEL COVER (Continued)

WHEEL MOUNTING STUDS -
FRONT
REMOVAL
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING)(Refer to 5 - BRAKES - CAUTION).
CAUTION: Wheel mounting studs MUST NOT be
hammered out of hub flange of hub and bearing
assembly. If a stud is removed by hammering it out,
damage to hub and bearing assembly will occur
leading to premature bearing failure.
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove front wheel and tire assembly. (Refer
to 22 - TIRES/WHEELS - REMOVAL)
(3) Remove two adapter mounting bolts securing
disc brake caliper adapter to steering knuckle (Fig.
33).
(4) Remove disc brake caliper and adapter as
assembly from steering knuckle (Fig. 33). Hang
assembly out of way using wire or a bungee cord.
Use care not to overextend brake hose when doing
this.
(5) Remove brake rotor from hub by pulling it
straight off wheel mounting studs (Fig. 33).(6) On wheel mounting stud to be removed, install
a wheel mounting (lug) nut far enough so the threads
on the stud are even with end of nut. Install
Remover, Special Tool C-4150A, on hub and bearing
flange and wheel stud (Fig. 34).
(7) Tighten down on Remover, pushing wheel stud
out of hub flange. Once shoulder of wheel stud is
past flange, remove special tool. Remove nut from
stud and remove stud from hub flange.
INSTALLATION
(1) Install replacement wheel stud into flange of
hub and bearing from rear. Install washers on wheel
stud, then install a standard type wheel mounting
(lug) nut on stud with flat side of lug nut against
washers as shown (Fig. 35).
(2) Tighten nut, pulling wheel stud into hub
flange. Once head of stud is fully seated against rear
of hub flange, remove nut and washers from stud.
(3) Install brake rotor back on hub and bearing
(Fig. 33).
(4) Install brake caliper and adapter back over
brake rotor aligning adapter with mounting holes on
steering knuckle (Fig. 33).
(5) Install two adapter mounting bolts securing
adapter to steering knuckle. Tighten mounting bolts
to 169 N´m (125 ft. lbs.) torque.
(6) Install wheel and tire assembly. Tighten wheel
mounting (lug) nuts in proper sequence to 135 N´m
(100 ft. lbs.) torque.
(7) Lower vehicle.
Fig. 33 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
Fig. 34 Wheel Stud Removal (Typical)
1 - WHEEL MOUNTING (LUG) NUT
2 - HUB AND BEARING ASSEMBLY
3 - SPECIAL TOOL C-4150A
4 - STEERING KNUCKLE
5 - WHEEL STUD
RSTIRES/WHEELS22-21

(8) Road test vehicle to ensure proper operation of
the brakes.
WHEEL MOUNTING STUDS -
REAR
REMOVAL
CAUTION: If a wheel attaching stud needs to be
replaced in the hub and bearing assembly the studs
MUST NOT be hammered out of the hub flange. If a
stud is removed by hammering it out of the bearing
flange, damage to the hub and bearing assembly
will occur leading to premature hub and bearing
failure.
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the rear wheel and tire assembly.
(3) Remove the brake drum or disc brake caliper
and rotor. Refer to Brakes.
(4) Install a lug nut on the wheel stud to be
removed from the hub and bearing assembly (Fig. 36)
so the threads on stud are even with end of lug nut.
Install Remover, Special Tool C-4150A on hub and
bearing assembly flange and wheel stud (Fig. 36).
(5)
Tightening down on special tool will push wheel
stud out of the hub and bearing assembly flange.
(6) Remove lug nut from stud and remove wheel
stud from flange.
INSTALLATION
(1) Install replacement wheel stud into flange of
hub and bearing assembly. Install washers on wheelstud, then install a wheel lug nut on stud with flat
side of lug nut against washers (Fig. 37).
(2) Tighten the wheel lug nut, pulling the wheel
stud into the flange of the hub and bearing assembly.
When the head of the stud is fully seated against the
bearing flange, remove lug nut and washers from
wheel stud.
(3) Install the brake drum or disc brake rotor and
caliper on the hub and bearing assembly.
(4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica-
tion. Then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(5) Lower vehicle to the ground.
Fig. 35 Installing Wheel Stud (Typical)
1 - WASHERS
2 - HUB AND BEARING ASSEMBLY
3 - WHEEL MOUNTING (LUG) NUT
4 - STEERING KNUCKLE
Fig. 36 Wheel Stud Removal From Hub And Bearing
1 - HUB AND BEARING ASSEMBLY
2 - WHEEL MOUNTING (LUG) NUT
3 - WHEEL STUD
4 - SPECIAL TOOL C-4150A
Fig. 37 Wheel Stud Installation
1 - WHEEL MOUNTING (LUG) NUT
2 - HUB AND BEARING ASSEMBLY
3 - WASHERS
4 - WHEEL STUD
22 - 22 TIRES/WHEELSRS
WHEEL MOUNTING STUDS - FRONT (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
DESCRIPTION - VEHICLE IDENTIFICATION....1
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
WATER LEAKS........................1
WIND NOISE..........................2
STANDARD PROCEDURE
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR........................3
STANDARD PROCEDURE - HEAT STAKING . . 9
SPECIFICATIONS
TORQUE............................10
BODY LUBRICATION...................12
SPECIAL TOOLS
BODY..............................13DOOR - FRONT.........................14
DOORS - SLIDING.......................24
DECKLID/HATCH/LIFTGATE/TAILGATE.......40
EXTERIOR.............................45
HOOD.................................62
INSTRUMENT PANEL.....................65
INTERIOR..............................78
PAINT................................100
SEATS...............................102
STATIONARY GLASS....................161
WEATHERSTRIP/SEALS..................166
SUNROOF.............................169
BODY STRUCTURE.....................177
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
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

(a) If the heat staked or component seam loca-
tion is loose, hold the two components tightly
together and using a soldering gun with a flat tip,
melt the material securing the components
together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.
(b) If the heat staked material is broken or miss-
ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-ing the glue. Once the new material is in place, it
may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
(4) Allow the repaired area to cool and verify the
repair.
(5) Install trim panel.
SPECIFICATIONS
TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
All seat belt anchor bolts 39 29 Ð
Armrest shoulder bolt 29 21 Ð
Bench seat riser bolts 48 35 Ð
Bench seat track nuts 48 35 Ð
Quad bucket seat track to cushion frame bolts 40 30 Ð
Bucket seat back pivot bolts 33 24 Ð
Center seat to seat track bolts 24 17 Ð
Child seat module screws (bench seats) 7 Ð 62
Child seat module screws (quad seats) 13.5 10 Ð
Crossmember to radiator closure panel bolts 28 21 Ð
Door check strap to door end frame 12 Ð 105
Door latch to door end frame bolts 10 Ð 89
Floor latch to seat cushion frame bolts 27 19 Ð
Fig. 14 COVER GAPS WITH MESH
1 - GROUND DOWN AREA
2 - PATCH
3 - MESH
Fig. 15 COVER MESH WITH ADHESIVE
1 - ADHESIVE
2 - MESH
3 - PATCH
4 - SPREADER
23 - 10 BODYRS
BODY (Continued)

CHECK STRAP
REMOVAL
(1) Remove front door trim panel.
(2) Remove front door watershield (Refer to 23 -
BODY/DOOR - FRONT/WATERSHIELD -
REMOVAL).
(3) Remove front door speaker, if equipped.
(4) Remove bolts attaching door check strap to
A-pillar.
(5) Remove nuts attaching check strap to door end
frame (Fig. 2).
(6) Remove check strap from door through speaker
hole.
INSTALLATION
(1) Position check strap on door through speaker
hole.
(2) Install nuts to attach check strap to door end
frame. Tighten nuts to 11 N´m (90 in. lbs.) torque.
(3) Install bolts to attach check strap to A-pillar.
Tighten bolts to 12 N´m (105 in. lbs.) torque.
(4) Install door speaker, if equipped.
(5) Install front door trim panel.
DOOR
REMOVAL
(1) Remove front wheelhouse splash shield. (Refer
to 23 - BODY/EXTERIOR/LF WHEELHOUSE
SPLASH SHIELD - REMOVAL)
(2) Disengage clips attaching door harness wire
connector to inner fender brace.
(3) Disconnect positive lock slide on the side of the
wire connectors (Fig. 3).
(4) Depress lock tab attaching wire connector
halves together.
(5) Disconnect door harness from body wiring har-
ness.
(6) Remove bolts attaching door check strap to
A-pillar (Fig. 4).
(7) Support door on suitable lifting device.
(8) Remove bolts attaching lower hinge to door end
frame (Fig. 5).
(9) Steady door on lifting device and remove bolts
attaching upper hinge to door end frame.
(10) Remove door from vehicle.
INSTALLATION
NOTE: If new hinge pins are to be used, verify that
the knurling on the hinge pin is aligned with the
knurling on in the door hinge prior to driving in the
pin. Also, verify that the hinge pin is fully seated to
the door hinge and a new retaining clip is installed.
(1) Support door on suitable lifting device.
Fig. 1 FRONT DOOR APPLIQUE
1 - GLASS RUN WEATHERSTRIP
2 - CLIPS
3 - APPLIQUE
4 - FRONT DOOR
Fig. 2 FRONT DOOR CHECK STRAP
1 - FRONT DOOR
2 - DOOR CHECK STRAP
RSDOOR - FRONT23-15
APPLIQUE (Continued)

(2) Position door to vehicle. Verify net pierce nub-
bin is engaged if reusing original hinges. Applies to
body half of hinge only.
(3) Steady door on lifting device and install bolts
attaching upper hinge to door end frame. Tighten
bolts to 34 N´m (25 ft. lbs.) torque.
(4) Install bolts attaching lower hinge to door end
frame. Tighten bolts to 34 N´m (25 ft. lbs.) torque.
Align door to achieve equal spacing to surrounding
body panels. Panels should be flush across all gaps.
(5) Install bolts attaching door check strap to
A-pillar. Tighten bolts to 12 N´m (105 in. lbs.) torque.
(6) Connect door harness into body wiring harness.
(7) Connect positive lock slide on the side of the
wire connectors.
(8) Connect clips attaching door harness wire con-
nector to inner fender brace.
(9) Install front wheelhouse splash shield.
(10) Verify door operation and alignment. Adjust
as necessary.
DOOR GLASS
REMOVAL
(1) Remove watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(2) Remove inner belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - REMOVAL)
Fig. 3 FRONT DOOR WIRE CONNECTORS
1 - LOCK TAB
2 - POSITIVE LOCK
3 - BODY HARNESS CONNECTOR
4 - FRONT FENDER
5 - DOOR HARNESS CONNECTOR
6 - BODY HARNESS
Fig. 4 FRONT DOOR - HINGE PIN REMOVAL
1 - FRONT DOOR
2 - CLIP
3 - A-PILLAR
4 - HINGE PIN
5 - CLIP
6 - DOOR CHECK STRAP
Fig. 5 FRONT DOOR - HINGE BOLT REMOVAL
1 - FRONT DOOR
2 - UPPER HINGE
3 - CHECK STRAP
4 - LOWER HINGE
23 - 16 DOOR - FRONTRS
DOOR (Continued)

INSTALLATION
CAUTION: When installing a new hinge, make sure
that the head of each hinge pin is fully seated into
the door hinge. Also, remove the plastic shipping
clip and replace it with the correct metal retaining
clip once the hinge pin is seated.
(1) Paint hinge prior to installation, if necessary.
(2) Position door to vehicle. Verify net pierce nub-
bin is engaged if reusing original hinges. Applies to
body half of hinge only.
(3) Install bolts attaching hinge to pillar. Tighten
bolts to 34 N´m (25 ft. lbs.).
(4) Install bolts attaching front door to door hinge.
Tighten bolts to 34 N´m (25 ft. lbs.).
(5) Align door to achieve equal spacing to sur-
rounding body panels. Panels should be flush across
all gaps.
(6) Verify door alignment and operation. Adjust as
necessary.
LATCH
REMOVAL
(1) Roll door glass up.
(2) Remove front door trim panel. (Refer to 23 -
BODY/DOOR - FRONT/TRIM PANEL - REMOVAL)
(3) Remove watershield as necessary to gain access
to the outside door handle.
(4) Through access hole at rear of inner door
panel, disconnect wire connector from power door
lock motor, if equipped.
(5) Disengage clips holding linkage to door latch
(Fig. 8).
(6) Remove linkages from door latch.
(7) Remove screws attaching door latch to door end
frame (Fig. 9).
(8) Remove door latch from door.
INSTALLATION
NOTE: The screws attaching the door latch to the
door end frame have nylon patches on the threads.
All screws must be replaced when the latch has
been removed.
(1) Insert inside handle latch link to door latch
and engage clip (Fig. 8).
(2) Place door latch in position on door end frame.
(3) Install screws attaching door latch to door end
frame. Tighten screws to 10 N´m (90 in. lbs.) torque
(Fig. 9).
(4) Insert other linkages to door latch and engage
clips.(5) Connect wire connector into power door lock
motor, if equipped.
(6) Insert a hex wrench through the elongated hole
located in the door shut face above the latch.
(7) Loosen allen head screw.
(8) Pull outward on the outside door handle and
release.
(9) Tighten allen head screw.
Fig. 8 LATCH ASSEMBLY
1 - OUTSIDE HANDLE TO LATCH LINK
2 - KEY CYLINDER TO LATCH LINK
3 - LATCH ASSEMBLY
4 - INSIDE HANDLE LINK AND SLEEVE
5 - LOCK KNOB LINK
Fig. 9 FRONT DOOR LATCH
1 - FRONT DOOR
2 - LATCH ASSEMBLY
3 - INSIDE HANDLE LINK
23 - 18 DOOR - FRONTRS
HINGE (Continued)

(10) Verify door latch and power door lock opera-
tion.
(11) Install watershield and front door trim panel.
LATCH STRIKER
REMOVAL
(1) Mark outline of door striker on B-pillar to aid
in installation.
(2) Remove screws attaching door latch striker to
B-pillar (Fig. 10).
(3) Remove door latch striker from vehicle.
(4) Retrieve any shims found between latch striker
and B-pillar.
INSTALLATION
(1) Position latch striker and any shims retrieved
on vehicle.
(2) Loosely install screws attaching latch striker to
B-pillar.
(3) Align latch striker to outline on B-pillar made
previously.
(4) Tighten fasteners to 28 N´m (21 ft. lbs.) torque.
(5) Verify door fit and operation. Adjust latch
striker as necessary.
LOCK CYLINDER
REMOVAL
(1) Roll door glass up.
(2) Remove front door watershield as necessary to
gain access to the outside door handle. (Refer to 23 -
BODY/DOOR - FRONT/WATERSHIELD -
REMOVAL)
(3) Through access hole at rear of inner door
panel, disconnect Vehicle Theft Security System
(VTSS) switch connector from door harness, if
equipped.
(4) Disengage push in fasteners attaching VTSS
switch harness to inner door reinforcement bar, if
equipped.
(5) Disengage clip holding door latch linkage to
door latch (Fig. 11).
(6) Remove latch linkage from latch.
(7) Disengage clip holding door lock linkage to
door latch.
(8) Remove lock linkage from latch.
(9) Remove nuts attaching outside door handle to
door outer panel.
(10) Remove outside door handle from vehicle.
(11) Disengage clip holding lock cylinder into out-
side handle.
(12) Pull lock cylinder from door handle.
INSTALLATION
(1) Engage clip into outside handle to hold lock
cylinder (Fig. 11).
(2) With link arm toward rear of vehicle, push lock
cylinder into door handle until clip snaps into place.
(3) Insert lock linkage into door latch.
(4) Engage clip to hold door lock linkage to latch.
(5) Insert latch linkage into door latch.
(6) Engage clip to hold door latch linkage to latch.
(7) Install push in fasteners attaching VTSS
switch harness to inner door reinforcement bar, if
equipped.
(8) Connect VTSS switch connector into door har-
ness, if equipped.
(9) Verify door latch operation.
(10) Install watershield and door trim panel.
Fig. 10 DOOR LATCH STRIKER
1 - B-PILLAR
2 - SHIM
3 - DOOR LATCH STRIKER
RSDOOR - FRONT23-19
LATCH (Continued)

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)