2001 CHRYSLER VOYAGER frame

(3) Close and then reopen sliding door.
(4) Tighten all stabilizers bolts.
STABILIZER
REMOVAL
(1) Open sliding door.
(2) Remove screws attaching stabilizer to door end
frame (Fig. 23).
(3) Remove stabilizer from vehicle.
INSTALLATION
(1) Place stabilizer in position on vehicle.
NOTE: Loose install screws first. Fit should be
snug but free to move when closing door to align to
body half stabilizer.
(2) Install screws attaching stabilizer to door end
frame.
(3) Open door and final tighten screws.
(4) Verify sliding door operation.
STABILIZER SOCKET
REMOVAL
(1) Open sliding door.
(2) Remove screws holding stabilizer socket to
B-pillar (Fig. 24) .
(3) Remove stabilizer socket from vehicle.
INSTALLATION
(1) Place stabilizer socket in position on vehicle.
(2) Install screws to hold stabilizer socket to B-pil-
lar.
(3) Close sliding door and verify operation.
Fig. 22 Sliding Door Lower Roller Arm
1 - SLIDING DOOR
2 - LOWER ROLLER ARM
3-LATCH
Fig. 23 Sliding Door Stabilizer
1 - SLIDING DOOR
2 - STABILIZER
Fig. 24 Sliding Door Stabilizer Socket
1 - B-PILLAR
2 - STABILIZER SOCKET
3 - SEAT BELT
RSDOORS - SLIDING23 - 173
SLIDING DOOR (Continued)

TRIM PANEL
REMOVAL
(1) Remove sliding door upper frame molding.
(2) If removing the left sliding door trim panel,
remove screw from inside ash receiver bezel.
(3) Remove screw from pull cup.
(4) Disengage push-in fasteners holding trim to
door panel around perimeter and upper edge of door
(Fig. 25).
(5) Remove sliding door trim panel from vehicle.
INSTALLATION
(1) Place sliding door trim panel in position on
vehicle.
(2) Align locating pins on backside of trim panel to
mating holes in the inner door panel.
(3) Engage push-in fasteners to hold trim to door
panel around perimeter and upper edge of door (Fig.
25).
(4) Install pull cup screw.
(5) If necessary, install screw from inside ash
receiver bezel on left sliding door trim panel.
(6) Install sliding door upper frame molding.
INSIDE LATCH HANDLE
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove screws holding bottom of inside latch
handle to sliding door (Fig. 26).
(3) Remove screw holding top of inside latch han-
dle to sliding door.
(4) Disengage cable end from clip on bellcrank
assembly.
(5) Disengage cable end from bellcrank assembly.
(6) Remove latch handle from sliding door.
(7) Remove push-in fastener holding cable end to
latch handle.
(8) Disengage cable casing end from latch handle
(Fig. 27).
(9) Disengage cable end from latch handle.
(10) 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.
Fig. 25 Sliding Door Trim Panel
1 - PUSH-IN FASTENERS
2 - SLIDING DOOR UPPER FRAME MOLDING
3 - SLIDING DOOR TRIM PANEL
4 - PUSH-IN FASTENERS
5 - PUSH-IN FASTENERS
6 - SLIDING DOOR
Fig. 26 Sliding Door Inside Handle
1 - INSIDE ASSIST HANDLE
2 - SLIDING DOOR
3 - LATCH BELLCRANK
4 - LATCH CABLE
23 - 174 DOORS - SLIDINGRS

(3) Disconnect liftgate wire harness from body
wire harness.
(4) Remove liftgate upper frame molding.
(5) Disconnect rear window washer hose from
spray nozzle.
(6) Support liftgate on a suitable lifting device.
(7) Remove screws attaching support cylinders to
liftgate.
(8) Remove bolts attaching liftgate hinge to roof
header (Fig. 4) .
(9) With assistance, remove liftgate from vehicle.
INSTALLATION
(1) With assistance, place liftgate in position on
vehicle.
(2) Install bolts attaching liftgate hinge to roof
header. Tighten bolts to 33 N´m (24 ft. lbs.) torque.
(3) Install screws attaching support cylinders to
liftgate. Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(4) Remove lifting device from under liftgate.
(5) Connect liftgate wire harness into body wire
harness.
(6) Install screws attaching wire connector to rear
header.
(7) Connect rear window washer hose onto spray
nozzle.
(8) Install liftgate upper frame molding.
(9) Verify liftgate alignment. The liftgate should
have a gap to adjacent panels and fit flush across the
gaps. The gap is;
²7 mm (0.280 in.) to the fascia,
²6 mm (0.240 in.) to the roof,
²4 mm (0.160 in.) to the aperture.
LIFTGATE SPOILER
REMOVAL
(1) Remove nuts (Fig. 5).
(2) Remove spoiler from vehicle.
INSTALLATION
(1)Place liftgate spoiler in position and install nuts.
(2) Tighten nuts to 9 N´m (80 in. lbs.) torque.
LOCK CYLINDER
REMOVAL
(1) Remove the liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the electrical connector.
(3) Disconnect the latch rod.
(4) Rotate plastic lock cylinder nut one quarter
turn and remove nut and spring washer.
(5) Remove the lock cylinder from the liftgate.
INSTALLATION
(1) Install lock cylinder into liftgate.
(2) Install the plastic lock cylinder lock nut, spring
washer and rotate one quarter turn.
(3) Connect the electrical connector.
(4) Connect the latch rod.
(5) Install the trim panel. (Refer to 23 - BODY/
DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM
PANEL - INSTALLATION)
(6) Verify lock cylinder operation.
Fig. 4 Liftgate
1 - HINGE
2 - ROOF
3 - NET HOLE OR SLOT
Fig. 5 Liftgate Spoiler
1 - RETAINER SEALER WASHER
2 - LIFT GATE SPOILER
23 - 182 DECKLID/HATCH/LIFTGATE/TAILGATERS
LIFTGATE (Continued)

SUPPORT CYLINDER
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device in
the full open position.
(3) Pull liftgate opening weatherstrip from D-pillar
flange next to prop assembly end pivot.
(4) Remove bolt attaching end pivot to D-pillar
(Fig. 6) .
(5)
Remove bolt attaching prop assembly to liftgate.
(6) Remove prop assembly from vehicle.
INSTALLATION
Ensure that the cylinder end is attached to the
D-pillar and the shaft end is attached to the liftgate.
(1) Place prop assembly in position.
(2) Install bolt attaching prop assembly to liftgate.
(3) Install bolt attaching end pivot to D-pillar.
Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(4) Install liftgate opening weatherstrip to D-pillar
flange next to prop assembly end pivot.
(5) Close liftgate. Check liftgate operation.
TRIM PANEL
REMOVAL
(1) Remove the bolt attaching the lift motor link, if
equipped (Fig. 7).
(2) Remove liftgate upper frame molding (Fig. 8).
(3) Remove assist handle screws.
(4) Disengage hidden clips holding trim panel to
liftgate from around perimeter or liftgate (Fig. 8).(5) Disconnect wire connector from lamps.
(6) Remove liftgate trim panel from vehicle.
INSTALLATION
(1) Place liftgate trim panel in position on vehicle.
(2)
Engage hidden clips to hold trim panel to liftgate
and fasteners around perimeter of liftgate (Fig. 8).
(3) Connect wire connector into lamp.
(4) Install courtesy lamps into liftgate trim.
(5) Install screws to hold assist handle to liftgate.
(6) Install upper frame side moldings.
(7) Install liftgate upper frame molding.
(8) Install the bolt attaching the lifgate motor link
and tighten to 28 N´m (21 ft. lbs.)
Fig. 6 Liftgate Prop Assembly
1 - LIFTGATE
2 - PROP ASSEMBLY
Fig. 7 LIFTGATE MOTOR
1 - LIFTGATE MOTOR LINK BOLT
2 - LIFTGATE MOTOR
3 - LIFTGATE
Fig. 8 LIFTGATE TRIM
1 - LIFTGATE
2 - LOWER TRIM PANEL
3 - ASSIST HANDLE SCREWS
4 - UPPER TRIM
5 - UPPER TRIM CLIPS
RSDECKLID/HATCH/LIFTGATE/TAILGATE23 - 183

FUEL FILL DOOR BLOCKER
LATCH STRIKER
REMOVAL
(1) Remove sliding door trim panel.
(2) Remove sound shield as necessary to access
striker
(3) Remove screws attaching fuel fill door blocker
latch striker to sliding door rear end frame (Fig. 11) .
(4) Remove fuel fill door blocker latch striker from
vehicle.
INSTALLATION
(1) Position fuel fill door blocker latch striker on
vehicle.
(2) Install screws attaching fuel fill door blocker
latch striker to sliding door rear end frame.
(3) Install sliding door sound shield.
(4) Install sliding door trim panel.
FUEL FILL DOOR BLOCKER
LOCKOUT LINK
REMOVAL
(1) Remove left quarter trim panel.
(2) Remove water shield patch covering access hole
in C-pillar.
(3) Disengage fuel filler lockout link from clip on
fuel fill blocker latch arm (Fig. 12).
(4) Open fuel fill door.
(5) Remove screws holding fuel filler housing to
fuel filler tube neck.
(6) Reaching inside fuel filler housing, release clips
holding housing to outer quarter panel.(7) Remove fuel filler housing and lockout link
from vehicle.
(8) Disengage clip holding link to fuel fill door
(Fig. 13).
(9) Remove link from fuel fill door.
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.
Fig. 11 Fuel Fill Door Blocker Latch Striker
1 - LEFT SLIDING DOOR
2 - FUEL FILLER STOP STRIKER
Fig. 12 Fuel Filler Lockout Link at Latch Arm
1 - FUEL FILLER LOCKOUT LINK
2 - C-PILLAR
3 - FUEL FILLER BLOCKER LATCH ARM
4 - PLASTIC LINK CLIP
5 - INNER QUARTER PANEL
Fig. 13 Fuel Filler Lockout Link
1 - FUEL FILLER LOCKOUT LINK
2 - FUEL FILLER OPENING
3 - QUARTER PANEL
RSEXTERIOR23 - 193

(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.
GRILLE OPENING
REINFORCEMENT
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching hood latch to cross-
member and position latch out of the way.
(3) Remove radiator sight shield.
(4) Remove engine air inlet resonator.
(5) Remove hood cable.
(6) Remove hood prop rod.
(7) Remove screw attaching coolant recovery bottle
to crossmember.
(8) Remove bolts attaching radiator isolators to
crossmember.
(9) Remove bolts attaching ends of crossmember to
radiator closure panel (Fig. 14) .
(10) Lift crossmember upward and away from
radiator closure panel.
(11) Remove crossmember from vehicle.
INSTALLATION
(1) Place radiator closure panel crossmember in
position on vehicle.
(2) Insert ends of crossmember between layered
metal sections of radiator closure panel at each side
of radiator.
(3) Align with paint breaks around bolt heads.
(4) Install bolts attaching ends of crossmember to
radiator closure panel (Fig. 14) . Tighten bolts to 19
N´m (14 ft. lbs.) torque.
(5) Install bolts attaching radiator isolators to
crossmember.
(6) Install screw attaching coolant recovery bottle
to crossmember.
(7) Install bolt attaching air cleaner housing to
crossmember.
(8) Install engine air inlet resonator.
(9) Install radiator sight shield.
(10) Install hood prop rod.
(11) Align hood latch by placing latch over net
pierce tabs. If alignment is required, flatten tabs.
(12) Install bolts attaching hood latch to cross-
member. Tighten bolts to 13.5 N´m (10 ft. lbs.)
torque.
(13) Verify hood latch operation and hood align-
ment.
FRONT WHEELHOUSE
SPLASH SHIELD
REMOVAL
(1) Hoist and support vehicle on safety stands.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE)
(2) Remove front wheel. Refer to section 22, Tires/
Wheels, for recommended procedures.
(3) Remove push-in fasteners holding splash shield
to frame rail forward of suspension.
(4) Remove push-in fasteners holding splash shield
to frame rail rearward of suspension.
(5) Remove screws holding wheelhouse splash
shield to front fender.
(6) Remove splash shield from vehicle (Fig. 15).
Fig. 14 Radiator Closure Panel Crossmember
1 - RADIATOR CLOSURE PANEL CROSSMEMBER
2 - FRONT FASCIA
23 - 194 EXTERIORRS
FUEL FILL DOOR BLOCKER LOCKOUT LINK (Continued)

INSTALLATION
(1) Place splash shield in position on vehicle (Fig.
15) .
(2) Install screws to hold wheelhouse splash shield
to front fender.
(3) Install push-in fasteners to hold splash shield
to frame rail rearward of suspension.
(4) Install push-in fasteners to hold splash shield
to frame rail forward of suspension.
(5) Install front wheel. Refer to Group 22, Wheels
and Tires, for proper procedures.
(6) Lower vehicle.
LUGGAGE RACK RISER
REMOVAL
(1) Remove two fasteners from the front riser.
Gently pull up on the luggage rack side rail and
detach the riser snap to remove riser from the rail.
(2) Repeat for the opposite side, if necessary.
(3) Remove front riser(s) from vehicle (Fig. 16) .
INSTALLATION
(1) Place front riser into position on luggage rack
side rail.
(2) Install two fasteners into the riser.
(3) Repeat for the opposite side, if necessary.
LUGGAGE RACK CROSSBAR
REMOVAL
(1) Remove luggage rack front risers.
(2) Depress stanchion levers down until they click
into the unlock position. (Fig. 17) . Work from side to
side sliding the crossbar assembly forward moving a
little at a time to ensure it remains perpendicular to
the side rails.
(3) Remove crossbar from vehicle.
Fig. 15 Front Wheelhouse Splash Shield
1 - BUMPER FASCIA
2 - FRONT WHEELHOUSE SPLASH SHIELD
3 - FRONT FENDER
Fig. 16 Luggage Rack Riser Cover
1 - FRONT RISER COVER
2 - LOCK TABS
3 - LUGGAGE RACK SIDE RAIL
4 - FRONT RISER
Fig. 17 Luggage Rack Crossbar
1 - CROSSBAR
2 - SLIDE LOCK
3 - LOCK BUTTON
4 - LUGGAGE RACK SIDE RAIL
RSEXTERIOR23 - 195
FRONT WHEELHOUSE SPLASH SHIELD (Continued)

INSTALLATION
NOTE: The crossbar assemblies are designed to be
installed in only one way. Check top and bottom
surfaces of the crossbar for the word FRONT and
directional arrows. The directional arrows must
point toward the front of the vehicle.
(1) Place crossbar in position on vehicle.
(2) Work from side to side sliding the crossbar
assembly back a little at a time to ensure it remains
perpendicular to the side rails.
(3) Position first crossbar assembly crossbar at the
second most rearward locator holes. Press the top of
the stanchion lever to lock it into position.
(4) Position the second crossbar assembly in the
second hole from the front. Lock into place.
(5) Place luggage rack riser into position.
(6) Install two fasteners into riser. Tighten fasten-
ers to 4 mm (35 in. lbs.) torque.
REAR QUARTER PANEL/
FENDER AIR EXHAUSTER
DESCRIPTION
Air exhausters, designed to conform to the body
structure, allow air entering at the front of the vehi-
cle to flow out the back. By reducing air pressure
within the vehicle, the exhausters also reduce blower
noise at any given air flow level compared to operat-
ing without them and help reduce door closing effort.
They are located in the lower rear comers of the
body.
REMOVAL
SHORT WHEELBASE
(1) Remove the rear fascia from the body. (Refer to
13 - FRAMES & BUMPERS/BUMPERS/REAR FAS-
CIA - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 18).
(3) Remove the air exhauster from the hole in the
lower aperture panel.
LONG WHEELBASE
NOTE: Models with the optional rear heater and air
conditioner do not have an air exhauster on the
right side of the vehicle, but have a plastic plug
installed in the right lower aperture panel. This plug
is removed using the same procedure used toremove the air exhauster from the short wheelbase
model. Refer to SHORT WHEELBASE .
(1) Remove the quarter trim panel from the inside
of the left or right quarter inner panel (Refer to 23 -
BODY/INTERIOR/RIGHT QUARTER TRIM PANEL
- REMOVAL) or (Refer to 23 - BODY/INTERIOR/
LEFT QUARTER TRIM PANEL - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 19).
(1) Remove the air exhauster from the hole in the
lower aperture panel.
Fig. 18 Air Exhauster - Short Wheelbase
1 - LOWER APERTURE PANEL
2 - AIR EXHAUSTER
Fig. 19 Air Exhauster - Long Wheelbase
1 - AIR EXHAUSTER
2 - PLUG
3 - LOWER APERTURE PANEL
23 - 196 EXTERIORRS
LUGGAGE RACK CROSSBAR (Continued)