1996 CHRYSLER VOYAGER Service Manual

INSTALLATION
(1) Insert link into clip on fuel fill door.
(2) Engage clip to hold link to fuel fill door.
(3) Insert lockout link through grommet in panel
between inner and outer quarter panel.
(4) Close fuel fill door.
(5) Install fuel filler housing to outer quarter
panel.
(6) Verify that all clips on fuel filler housing are
fully engaged to outer quarter panel.
(7) Engage fuel filler lockout link into clip on fuel
fill blocker latch arm.
(8) Install water shield patch covering access hole
in C-pillar.
(9) Install left quarter trim panel.
FUEL FILLER HOUSING ± WITH BLOCKER LATCH
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. 38).
(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. 40).
(8) Remove fuel fill door from vehicle.
(9) Disengage clip holding link to fuel fill door
(Fig. 39).
(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.
(11) Engage latch release link into clip on fuel fill
blocker latch arm.
(12) Verify fuel fill blocker latch operation.
(13) Install water shield patch to cover access hole
in C-pillar.
(14) Install left quarter trim panel.
GRILLE
REMOVAL
(1) Remove front fascia. Refer to Group 13, Frame
and Bumpers, for proper procedures.
(2) Disengage clips holding grille to front fascia
(Fig. 41).
(3) Remove plastic rivets holding grille to fascia.
(4) Remove grille from fascia.
INSTALLATION
(1) Position grille on fascia.
(2) Install plastic rivets to hold grille to fascia.
(3) Install clips to hold grille to fascia along bot-
tom of grille.
(4) Install front fascia. Refer to Group 13, Frame
and Bumpers, for proper procedure.
HEADLINING
REMOVAL
(1) Remove sun visors and vanity mirrors.
(2) Remove sun visor center supports.
(3) If equipped, remove coat hooks.
(4) If equipped, remove roof rail modules.
Fig. 39 Fuel Filler Lockout LinkFig. 40 Fuel Filler Housing and Door
NSBODY 23 - 39
REMOVAL AND INSTALLATION (Continued)

(5) Remove A-pillar trim covers.
(6) Remove B-pillar upper trim covers.
(7) Remove C-pillar upper trim covers.
(8) Remove D-pillar upper trim covers.
(9) Remove rear door opening header trim.
(10) If equipped, remove overhead console.
(11) If equipped, remove reading lamp.
(12) Remove dome lamp.
(13) Remove push-in locking fasteners holding
headlining to rear roof header (Fig. 42) or (Fig. 43).
(14) Remove headlining from roof.
(15) Extract headlining through rear door opening.
INSTALLATION
(1) Insert headlining through rear door opening.
(2) Place headlining in position on roof.
(3) Install left sun visor support.(4) Install push-in locking fasteners to hold head-
lining to rear roof header (Fig. 42) or (Fig. 43).
(5) Install right sun visor support.
(6) Install sun visors and vanity mirrors.
(7) If equipped, install roof rail modules.
(8) If equipped, install coat hooks.
(9) Install dome lamp.
(10) If equipped, install reading lamp.
(11) If equipped, install overhead console.
(12) Install rear door opening header trim.
(13) Install D-pillar upper trim covers.
(14) Install C-pillar upper trim covers.
(15) Install B-pillar upper trim covers.
(16) Install A-pillar trim covers.
HOOD
REMOVAL
(1) Raise hood to full up position.
(2) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation.
(3) Remove the top bolts holding hood to hinge and
loosen the bottom bolts until they can be removed by
hand (Fig. 44).
(4) With assistance from a helper at the opposite
side of the vehicle to support the hood, remove bot-
tom bolts holding hood to hinge.
(5) Remove the hood from the vehicle.
INSTALLATION
(1) Place hood in position on vehicle. With assis-
tance from a helper at the opposite side of the vehicle
Fig. 41 Grille
Fig. 42 Headlining ± SWB
Fig. 43 Headlining ± LWB
23 - 40 BODYNS
REMOVAL AND INSTALLATION (Continued)

to support the hood, install bottom bolts to hold hood
to hinge finger tight.
(2) Install top bolts to hold hood to hinge finger
tight.
(3) Position bolts at marks and tighten bolts. The
hood should be aligned to 4 mm (0.160 in.) gap to the
front fenders and flush across the top surfaces along
fenders.
(4) Verify hood operation and alignment.
HOOD HINGE
REMOVAL
(1) Remove hood.
(2) Remove wiper unit. Refer to Group 8K, Wind-
shield Wipers and Washers, for procedure.
(3) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation.
(4) Remove bolts attaching body half of hood hinge
to front fender flange and remove hinge from vehicle
(Fig. 45).
INSTALLATION
(1) If necessary, paint new hinge before installa-
tion.
(2) Place body half of hood hinge in position on
vehicle.
(3) Install bolts to hold hood hinge to front fender
flange.
(4) Install wiper unit. Refer to Group 8K, Wind-
shield Wipers and Washers, for proper procedures.
(5) Install hood.
(6) Align all marks and secure bolts. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers. Shims can be added or removed under hood
hinge to achieve proper hood height.
HOOD LATCH
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts holding hood latch to radiator clo-
sure panel crossmember (Fig. 46).
(3) Remove hood latch from crossmember.
(4) Disconnect hood release cable from hood latch
(Fig. 47).
(5) Remove hood latch from vehicle.
INSTALLATION
(1) Position hood latch on vehicle.
(2) Connect hood release cable from hood latch.
(3) Position hood latch on crossmember.
(4) Align hood latch by placing latch over net-
pierced tabs. If alignment is required, flatten tabs.
(5) Install bolts attaching hood latch to radiator
closure panel crossmember.
(6) Verify hood operation and alignment. Adjust as
necessary.
Fig. 44 HoodFig. 45 Hood Hinge
Fig. 46 Hood Latch
NSBODY 23 - 41
REMOVAL AND INSTALLATION (Continued)