1996 CHRYSLER VOYAGER Service Manual

NOTE: If both hinges on one door are to be
replaced, remove and install one hinge completely
prior to beginning the second hinge.
REMOVAL
(1) Release front door latch and open door.
(2) Support door on suitable lifting device.
(3) Remove bolts holding front door to door hinge.
(4) Remove bolts holding hinge to pillar.
(5) Remove door hinge from vehicle.
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 hinge on vehicle.
(3) Install bolts to hold hinge to pillar.
(4) Install bolts to hold front door to door hinge.
(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.
FRONT DOOR INNER BELT MOLDING
REMOVAL
(1) Remove door trim panel.
(2) Peel upper corner seals away form inner belt
molding to clear removal path.
(3) Pull inner belt molding upward to disengage
retaining channel in bottom of molding from door
panel flange (Fig. 17).
(4) Remove inner belt molding from vehicle.
INSTALLATION
(1) Place inner belt molding in position on door.
(2) Push inner belt molding downward to engage
retaining channel onto door panel flange.
(3) Install upper corner seals in proper location.
(4) Install door trim panel.
FRONT DOOR LATCH
REMOVAL
(1) Remove front door trim panel.
(2) Remove water shield as necessary to gain
access to the outside door handle.
(3) Roll door glass up.
(4) Through access hole at rear of inner door
panel, disengage wire connector from power door lock
motor, if equipped.
(5) Disengage clips holding linkage to door latch.
(6) Remove linkages from door latch.
(7) Remove screws holding door latch to door end
frame (Fig. 18).
(8) Remove door latch from door.
Fig. 17 Front Door Inner Belt MoldingFig. 18 Front Door Latch
NSBODY 23 - 31
REMOVAL AND INSTALLATION (Continued)

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) Place door latch in position on door end frame.
(2) Install screws to hold door latch to door end
frame.
(3) Insert linkage into door latch.
(4) Engage clips to hold linkage to door latch.
(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.
(10) Verify door latch and power door lock opera-
tion.
(11) Install water shield and front door trim panel.
FRONT DOOR LATCH STRIKER
REMOVAL
(1) Mark outline of door striker on B-pillar to aid
in installation.
(2) Remove screws holding door latch striker to
B-pillar (Fig. 19).
(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 to hold latch striker to
B-pillar.
(3) Align latch striker to outline on B-pillar made
previously.
(4) Tighten all fasteners.
(5) Verify door fit and operation. Adjust latch
striker as necessary.
FRONT DOOR LOCK CYLINDER
REMOVAL
(1) Remove front door trim panel and water shield
as necessary to gain access to the outside door han-
dle.
(2) Roll door glass up.
(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 holding VTSS
switch harness to inner door reinforcement bar, if
equipped.
(5) Disengage clip holding door latch linkage to
door latch.
(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 holding outside door handle to
door outer panel (Fig. 23).
(10) Remove outside door handle from vehicle.
(11) Disengage clip holding lock cylinder into out-
side handle (Fig. 20).
(12) Pull lock cylinder from door handle.
Fig. 19 Door Latch StrikerFig. 20 Remove Front Door Lock Cylinder
23 - 32 BODYNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Engage clip into outside handle to hold lock
cylinder.
(2) With link arm toward rear of vehicle, push lock
cylinder into door handle until clip snaps into place
(Fig. 21).
(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 to hold 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 water shield and door trim panel.
FRONT DOOR OUTER BELT MOLDING
REMOVAL
(1) Remove door trim panel.
(2) Roll door glass down.
(3) Using a hook tool, disengage interlocking lip at
the base of the inward edge of the belt molding (Fig.
22).
(4) Remove belt molding from door.
INSTALLATION
(1) Place belt molding in position on door.
(2) Engage interlocking lip at the base of the
inward edge of the belt molding on door panel.
(3) Install door trim panel.
FRONT DOOR OUTSIDE HANDLE
REMOVAL
(1) Remove front door trim panel and water shield
as necessary to gain access to the outside door han-
dle.
(2) Roll door glass up.(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 holding VTSS
switch harness to inner door reinforcement bar, if
equipped.
(5) Disengage clip holding door latch linkage to
door latch.
(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 holding outside door handle to
door outer panel (Fig. 23).
(10) Remove outside door handle from vehicle.
Fig. 21 Install Front Door Lock Cylinder
Fig. 22 Front Door Outer Belt Molding
Fig. 23 Front Door Outside Handle
NSBODY 23 - 33
REMOVAL AND INSTALLATION (Continued)