1996 CHRYSLER VOYAGER Service Manual

diagram boot drain bolt trunk fuel type wiring diagram

Page 1793 of 1938

CHRYSLER VOYAGER 1996 Service Manual (6) Remove bolt attaching turning loop to exten-
sion bracket above quarter glass.
(7) Remove turning loop from extension bracket.
(8) Remove D-pillar trim panel.
(9) Remove quarter trim bolster.
(10)

(6) Remove bolt attaching turning loop to exten-
sion bracket above quarter glass.
(7) Remove turning loop from extension bracket.
(8) Remove D-pillar trim panel.
(9) Remove quarter trim bolster.
(10) Remove quarter trim panel as necessary to
gain access to HVAC unit.
(11) Route seat belt webbing and turning loop
through access hole in quarter trim.
(12) Loosen HVAC unit enough to gain access to
seat belt retractor fasteners.
(a) Remove bracket around HVAC unit (Fig. 91).
(b) Remove air duct (Fig. 92).
(c) Remove fasteners holding HVAC unit to
inner quarter panel (Fig. 93).
(d) Remove screws attaching upper evaporator
housing to lower evaporator housing.
(e) Remove coolant line retaining bracket hold-
down bolt.
(13) Remove bolts attaching seat belt guide loop to
inner quarter panel.
(14) Pull outward on HVAC unit and remove bolt
holding retractor to inner quarter panel.
(15) Remove screw attaching retractor to inner
quarter panel.
(16) Remove second rear seat belt retractor from
vehicle.
INSTALLATION
(1) Position second rear seat belt retractor to vehi-
cle.
(2) I
nstall screw attaching retractor to inner
quarter panel.
(3) Pull outward on HVAC unit and install bolt
attaching retractor to inner quarter panel.
(4) Install bolts attaching seat belt guide loop to
inner quarter panel.
(5) Install coolant line retaining bracket holdown
bolt.(6) Install screws holding upper evaporator hous-
ing to lower evaporator housing.
(7) Install fasteners attaching HVAC unit to inner
quarter panel.
(8) Install air duct.
(9) Install bracket around HVAC unit.
(10) Route seat belt webbing and turning loop
through access hole in quarter trim.
(11) Install quarter trim panel as necessary to gain
access to HVAC unit.
(12) Install quarter trim bolster.
(13) Install D-pillar trim panel.
(14) Position turning loop to extension bracket.
(15) Install bolt attaching turning loop to exten-
sion bracket above quarter glass.
(16) Pull upper turning loop extension cover
upward over anchor bolt.
(17) Install lower anchor shoulder-nut.
(18) S
lide lower anchor cover over anchor shoulder-
nut.
(19) Install second rear seat from vehicle. Refer to
Owner's Manual for proper procedures.
Fig. 91 Trim Panel Mounting Bracket
Fig. 92 Lower Heater Duct
Fig. 93 Rear HVAC Mounting
NSBODY 23 - 63
REMOVAL AND INSTALLATION (Continued)

Page 1794 of 1938

CHRYSLER VOYAGER 1996 Service Manual SHOULDER BELT HEIGHT ADJUSTER±BOR
C-PILLAR
REMOVAL
(1) Remove B or C-pillar trim cover.
(2) Remove screws holding shoulder belt height
adjuster to pillar.
(3) Remove height adjuster from vehicle (Fig

Page 1795 of 1938

CHRYSLER VOYAGER 1996 Service Manual REMOVAL
(1) Apply masking tape to outside surface of quar-
ter panel below the center roller channel, rearward of
the door opening.
(2) Release sliding door latch and open door.
(3) Apply masking tape

Page 1796 of 1938

CHRYSLER VOYAGER 1996 Service Manual (8) Install center roller channel end cover (Fig.
100).
(9) Install center stop on sliding door (Fig. 98).
(10) Install center stop bumper trim cover on slid-
ing door.
(11) Place upper roller stop bu

Page 1797 of 1938

CHRYSLER VOYAGER 1996 Service Manual SLIDING DOOR CENTER STRIKER ASSEMBLY
REMOVAL
(1) Remove sliding door trim panel.
(2) Remove screws attaching center striker assem-
bly to door end frame (Fig. 104).
(3) Remove center striker assembly

Page 1798 of 1938

CHRYSLER VOYAGER 1996 Service Manual SLIDING DOOR INSIDE LATCH HANDLE
REMOVAL
(1) Remove sliding door upper molding as neces-
sary to gain access to upper door handle fastener.
(2) Remove sliding door trim panel.
(3) Remove screws holdin

SLIDING DOOR INSIDE LATCH HANDLE
REMOVAL
(1) Remove sliding door upper molding as neces-
sary to gain access to upper door handle fastener.
(2) Remove sliding door trim panel.
(3) Remove screws holding bottom of inside latch
handle to sliding door (Fig. 107).
(4) Remove screw holding top of inside latch han-
dle to sliding door.
(5) Disengage cable end from clip on bellcrank
assembly.
(6) Disengage cable end from bellcrank assembly.
(7) Remove latch handle from sliding door.
(8) Remove push-in fastener holding cable end to
latch handle.
(9) Disengage cable casing end from latch handle
(Fig. 108).
(10) Disengage cable end from latch handle.
(11) Remove handle from vehicle.
INSTALLATION
(1) Place inside latch handle in position on vehicle.
(2) Engage cable end into latch handle.
(3) Engage cable casing end into latch handle.
(4) Install push-in fastener to hold cable into latch
handle.
(5) Place latch handle in position on sliding door.
(6) Install screw to hold top of inside latch handle
to sliding door.
(7) Install screws to hold bottom of inside latch
handle to sliding door.
(8) Engage cable end into bellcrank assembly.
(9) Engage clip to hold cable end into bellcrank
assembly.
(10) Verify sliding door operation. Adjust as neces-
sary.(11) Install sliding door trim panel.
(12) Install sliding door upper molding.
SLIDING DOOR INSIDE LATCH HANDLE
BELLCRANK
REMOVAL
(1) Remove sliding door trim panel.
(2) Remove watershield as necessary to gain access
to latch bellcrank.
(3) Remove latch/lock control cover.
(4) Disengage clip holding inside release bellcrank
link to latch/lock control.
(5) Separate bellcrank link from latch/lock control.
(6) Disengage clip holding release handle latch
cable to bellcrank.
(7) Remove cable from bellcrank.
(8) Remove screw holding bellcrank to inner door
panel (Fig. 109).
(9) Remove bellcrank from vehicle.
Fig. 107 Sliding Door Inside Handle
Fig. 108 Sliding Door Handle Cable
Fig. 109 Inside Latch Handle Bellcrank
23 - 68 BODYNS
REMOVAL AND INSTALLATION (Continued)

Page 1799 of 1938

CHRYSLER VOYAGER 1996 Service Manual INSTALLATION
(1) Position bellcrank on vehicle.
(2) Install screw holding bellcrank to inner door
panel.
(3) Position cable from bellcrank.
(4) Engage clip to hold release handle latch cable
to bellcr

INSTALLATION
(1) Position bellcrank on vehicle.
(2) Install screw holding bellcrank to inner door
panel.
(3) Position cable from bellcrank.
(4) Engage clip to hold release handle latch cable
to bellcrank.
(5) Position bellcrank link on latch/lock control.
(6) Engage clip to hold inside release bellcrank
link to latch/lock control.
(7) Install latch/lock control cover.
(8) Install watershield.
(9) Install sliding door trim panel.
SLIDING DOOR INSIDE LATCH RELEASE
MECHANISM
REMOVAL
(1) Remove sliding door inside latch handle.
(2) Remove push-in fastener holding cable end to
release mechanism (Fig. 108).
(3) Disengage cable end from release mechanism.
(4) Disengage latch cable from assist handle.
(5) Remove screws holding release mechanism to
handle (Fig. 110).
(6) Remove release mechanism from handle.
(7) Rotate latch release button away from mecha-
nism until flats on button pivots align with slots in
mechanism (Fig. 111).
(8) Remove button from release mechanism.
INSTALLATION
(1) Position button on release mechanism.
(2) Align and engage flats on button pivots into
slots in mechanism (Fig. 111).
(3) Rotate latch release button into mechanism.(4) Place release mechanism in position on handle.
(5) Install screws to hold release mechanism to
handle (Fig. 110).
(6) Engage latch cable into handle.
(7) Engage cable end from release mechanism.
(8) Install push-in fastener holding cable end to
release mechanism.
(9) Install sliding door inside latch handle.
SLIDING DOOR LATCH STRIKER
REMOVAL
(1) Open sliding door.
(2) Mark outline of striker on C-pillar door jamb
face to aid installation.
(3) Remove screws holding striker to C-pillar (Fig.
112).
(4) Remove striker from vehicle.
INSTALLATION
(1) Place striker in position on vehicle.
(2) Align striker to outline marks on C-pillar.
(3) Install screws to hold striker to C-pillar.
(4) Verify sliding door alignment and operation.
Fig. 110 Sliding Door Inside Latch Release
Mechanism
Fig. 111 Sliding Door Inside Latch Button
Fig. 112 Sliding Door Latch Striker
NSBODY 23 - 69
REMOVAL AND INSTALLATION (Continued)

Page 1800 of 1938

CHRYSLER VOYAGER 1996 Service Manual SLIDING DOOR LATCH/LOCK CONTROL
REMOVAL
(1) Remove sliding door trim panel.
(2) Remove sliding door stop bumper.
(3) Remove sound pad, if equipped.
(4) Remove latch/lock control cover (Fig. 113).
(5)

SLIDING DOOR LATCH/LOCK CONTROL
REMOVAL
(1) Remove sliding door trim panel.
(2) Remove sliding door stop bumper.
(3) Remove sound pad, if equipped.
(4) Remove latch/lock control cover (Fig. 113).
(5) With sliding door ajar, disengage clip holding
rear latch link to latch/lock control (Fig. 114) (Fig.
115).
(6) Place a flat head screw driver between metal
clip ears and bottom of link.
NOTE: Rotate screw driver to remove link.
CAUTION: Replace the latch/lock control if any of
the metal clips on the latch/lock control are bent or
broken. DO NOT attempt to repair the clips to retain
the links.
(7) Remove rear latch link from latch/lock control.
(8) Disengage clip holding outside door handle link
to latch/lock control (Fig. 115).
(9) Remove outside door handle link from latch/
lock control.
(10) Disengage clip holding inside door handle
bellcrank link to latch/lock control (Fig. 115).
(11) Separate inside door handle bellcrank link
from latch/lock control.
(12) Disengage clip holding lock cylinder link to
latch/lock control.
(13) Remove lock cylinder link from control.
(14) Disengage clip holding inside lock link to
latch/lock control.
(15) Remove inside lock link from control.
(16) Disengage lock tabs holding hold open latch
cable case to latch/lock control.
(17) Remove hold open latch cable ball end from
latch/lock control.
(18) Loosen bolts holding latch/lock control to slid-
ing door.
(19) If equipped, disconnect wire connector from
power door lock motor.
(20) Remove latch/lock from vehicle.
INSTALLATION
(1) Position latch/lock locking lever in unlocked
position.
(2) Engage rigging cam (Fig. 114).
(3) Place latch/lock in position on vehicle.
(4) If equipped, engage wire connector into power
door lock motor.
(5) Insert bolt heads into slots in sliding door
inner panel.
(6) Tighten bolts to hold latch/lock control to slid-
ing door.(7) Engage hold open latch cable ball end into
latch/lock control.
(8) Engage lock tabs to hold the hold open latch
cable case to latch/lock control.
(9) Insert lock cylinder link into control.
(10) Engage clip to hold lock cylinder link to latch/
lock control.
(11) Insert inside lock link into control.
(12) Engage clip to hold inside lock link to latch/
lock control.
(13) Lift clip for inside door handle bellcrank link
to top of slot in mechanism (Fig. 114).
(14) Engage clip to hold bellcrank link to latch/lock
control.
(15) Lower clip for outside door handle link to bot-
tom of slot in mechanism and engage link to clip
(Fig. 114).
NOTE: Move link rearward until movement stops
before engaging link to clip.
(16) Place rear latch link in position on control by
moving link rearward until movement stops.
(17) Engage clip to hold rear latch release link to
latch/lock control.
(18) Push inside lock link button downward to dis-
engage rigging cam.
(19) Verify sliding door operation.
(20) Install latch/lock cover.
(21) Install sound pad, if equipped.
(22) Install sliding door stop bumper.
(23) Install sliding door trim panel.
Fig. 113 Latch/Lock Cover
23 - 70 BODYNS
REMOVAL AND INSTALLATION (Continued)

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