2001 CHRYSLER VOYAGER mirror

SIDE VIEW MIRROR
REMOVAL
(1) Using a trim stick or equivalent, remove the
trim cover (Fig. 20).
(2) Remove the bolts.
(3) Seperate the mirror from the pillar.
(4) Disconnect the electrical connector, if equipped.
INSTALLATION
(1) Connect the electrical connector, if equipped.
(2) Place side view mirror in position on vehicle
(Fig. 20).
(3) Install the bolts.
(4) Install the trim cover.
Fig. 20 SIDE VIEW MIRROR
1 - MIRROR
2 - MIRROR TRIM COVER
3 - A-PILLAR
4 - BOLTS
23 - 198 EXTERIORRS

(17) Remove the two steering column shroud
retaining screws. Separate the shrouds and remove
from vehicle.
(18) Disconnect the steering column wiring. There
are seven connectors and then unclip the harness
from the column.
(19) Disconnect the ORC harness connector.
(20) Remove the four nuts retaining the steering
column and lower to the floor.
(21) Remove the four nuts attaching the instru-
ment panel to the brake pedal support bracket.
(22) Loosen the left side roll down bolt.
(23) Remove the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(24) If equipped with a mechanical transmission
range indicator:
(a) Remove the indicator cable loop.
(b) Remove the clip holding gear shift cable end
to the gear selector adapter.
(c) Pull the cable end from gear selector.
(d) Disconnect the clip for the indicator cable
and guide tube from the shift cable bracket and
move out of the way.
(25) Remove the instrument panel top cover. Using
a trim stick or equivalent, gently pry up on the front
edge of the top cover, pull rearward and remove from
vehicle.
(26) Disconnect the right side wire connectors from
the HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(27) Remove the right end cover by pulling out-
board.
(28) Remove the right side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(29) Loosen the right side roll down bolt.
(30) Disconnect the two front window defroster
grid wire connectors. One on each side of vehicle.
(31) Remove both the left and right power mirrors:
(a) Using a trim stick or equivalent, gently pry
out on mirror trim cover.
(b) Open door and remove the three torx retain-
ing screws.
(c) Disconnect the wire connector and remove
mirror from the vehicle.
(32) Feed power mirror wire harness inboard
through the A-pillar.
(33) Remove the bolts holding the instrument
panel frame to the dash panel below windshield
opening.
(34) With the help of an assistant remove the
instrument panel from vehicle. Lift the instrument
panel up off the HVAC so you won't damage the seal-
ing surface of the distribution duct.
If the instrument panel is being replaced, transfer
all parts to the new instrument panel assembly.INSTALLATION
(1) With the help of an assistant place the instru-
ment panel into vehicle on roll down bolts. As you
roll the instrument panel up, lift the instrument
panel up so the duct work does not bind or bend and
you can set it down on the HVAC housing to get the
proper seal at the distribution duct. Get one bolt
started in the dash panel.
(2) Install the bolts holding the instrument panel
frame to the dash panel below windshield opening.
(3) Feed power mirror wire harness outboard
through the A-pillar.
(4) Install both the left and right power mirrors:
(a) Connect the wire connector and install the
mirror onto the vehicle.
(b) Install the three torx retaining screws.
(c) Using a firm push, snap the mirror trim
cover into place.
(5) Connect the two front window defroster grid
wire connectors. One on each side of vehicle.
(6) Tighten the right side roll down bolt.
(7) Install the right side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(8) Install the right end cover. Position over retain-
ing slots and firmly snap into place.
(9) Connect the right side wire connectors to the
HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(10) Install the instrument panel top cover. Slide
the front edge of the top cover toward dash panel,
and firmly snap down the rear edge of the to cover to
engage clips.
(11) If equipped with a mechanical transmission
range indicator:
(a) Connect the clip for the indicator cable and
guide tube to the shift cable bracket.
(b) Install the cable end to the gear selector.
(c) Install the clip holding the gear shift cable
end to the gear selector adapter.
(d) Install the indicator cable loop.
(12) Install the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(13) Tighten the left side roll down bolt.
(14) Install the four nuts attaching the instrument
panel to the brake pedal support bracket.
(15) Install the four nuts retaining the steering
column and lower to the floor.
(16) Connect the ORC harness connector.
(17) Connect the steering column wiring. There
are seven connectors and then clip the harness to the
column.
(18) Connect the shrouds and install the two steer-
ing column shroud retaining screws.
(19) Install five screws to the left under column
instrument panel reinforcement brace.
23 - 204 INSTRUMENT PANELRS
INSTRUMENT PANEL ASSEMBLY (Continued)

INTERIOR
TABLE OF CONTENTS
page page
A-PILLAR LOWER EXTENSION TRIM
REMOVAL.............................209
INSTALLATION..........................209
A-PILLAR TRIM
REMOVAL.............................209
INSTALLATION..........................209
ASSIST HANDLE
REMOVAL.............................209
INSTALLATION..........................209
B-PILLAR LOWER TRIM
REMOVAL.............................209
INSTALLATION..........................210
B-PILLAR UPPER TRIM
REMOVAL.............................210
INSTALLATION..........................210
CARPETS AND FLOOR MATS
REMOVAL.............................211
INSTALLATION..........................211
COWL TRIM
REMOVAL.............................212
INSTALLATION..........................212
C-PILLAR TRIM
REMOVAL.............................212
INSTALLATION..........................212
DOOR SILL TRIM PLATE
REMOVAL.............................212
INSTALLATION..........................212
HEADLINER
REMOVAL.............................213
INSTALLATION..........................213
JACK STORAGE COVER
REMOVAL.............................213
INSTALLATION..........................214
LEFT D-PILLAR TRIM PANEL
REMOVAL.............................214
INSTALLATION..........................214
LIFTGATE SCUFF PLATE
REMOVAL.............................214INSTALLATION..........................214
QUARTER TRIM BOLSTER
REMOVAL.............................214
INSTALLATION..........................214
RIGHT QUARTER TRIM PANEL
REMOVAL.............................215
INSTALLATION..........................215
LEFT QUARTER TRIM PANEL
REMOVAL.............................215
INSTALLATION..........................215
REAR HEADER TRIM
REMOVAL.............................216
INSTALLATION..........................216
REAR HVAC LOUVER
REMOVAL.............................216
INSTALLATION..........................216
REAR VIEW MIRROR
REMOVAL.............................217
INSTALLATION..........................217
RIGHT D-PILLAR TRIM PANEL
REMOVAL.............................217
INSTALLATION..........................217
SLIDING DOOR SILL PLATE
REMOVAL.............................218
INSTALLATION..........................218
SUN VISOR
REMOVAL.............................218
INSTALLATION..........................218
SUN VISOR SUPPORT
REMOVAL.............................219
INSTALLATION..........................219
FLOOR CONSOLE TRAY
REMOVAL.............................219
INSTALLATION..........................219
FLOOR CONSOLE TRAY - BRACKET
ASSEMBLY
REMOVAL.............................219
INSTALLATION..........................219
23 - 208 INTERIORRS

HEADLINER
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.
(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 liftgate 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 attaching
headlining to rear roof header and roof bows (Fig. 9)
or (Fig. 10).
(14) Remove headlining from roof.
(15) Extract headlining through liftgate opening.
INSTALLATION
(1) Insert headlining through liftgate opening.
(2) Place headlining in position on roof.
(3) Install left sun visor support.
(4) Install push in locking fasteners attaching
headlining to rear roof header and bows (Fig. 9) or
(Fig. 10).
(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 liftgate 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.
JACK STORAGE COVER
REMOVAL
LONG WHEEL BASE
(1) Depress latch handle at top of jack storage
cover.
(2) Pull outward at top of cover to disengage latch.
(3) Remove jack storage cover from vehicle.
SHORT WHEEL BASE
(1) Open quarter panel bin storage cover.
(2) Lift upward and rearward on jack storage cover
retaining latch to disengage.
(3) Remove jack storage cover from vehicle.
Fig. 9 Headlining ± SWB
1 - ROOF
2 - REAR HEADER TRIM
3 - PUSH-IN FASTENER
4 - HEADLINING
Fig. 10 Headlining ± LWB
1 - ROOF
2 - HEADLINING
3 - SUN VISOR SUPPORTS
4 - PUSH-IN FASTENERS
RSINTERIOR23 - 213

(2) Push inward on bezel until clips snap in place.
Verify that all four clips have been engaged to the
bezel and that the bezel is flush to the headlining
(3) Position HVAC louver to bezel.
(4) Snap both ends of the louver into HVAC bezel.
REAR VIEW MIRROR
REMOVAL
(1) If equipped, disconnect mirror harness connec-
tor (Fig. 14).
(2) Loosen the mirror base set screw (Fig. 15).
(3) Slide the mirror base upward and off the
bracket.
INSTALLATION
(1) Position the mirror base at the bracket and
slide it downward onto the support bracket.
(2) Tighten the setscrew 1 N´m (15 in. lbs.) torque.
(3) If equipped, connect mirror harness connector.
RIGHT D-PILLAR TRIM PANEL
REMOVAL
(1) Remove rear header trim cover.
(2) Remove liftgate sill plate.
(3) Remove second row seat belt turning loop on
long wheel base vehicle.
(4) Remove bolt attaching second row seat belt, if
equipped, anchor to quarter on short wheel base
vehicle.
(5) Remove quarter trim bolster on short wheel
base vehicle.
(6) Remove screws attaching trim panel to attach-
ing bracket on short wheel base vehicle.
(7) Disengage hidden clips attaching trim to D-pil-
lar.
(8) Remove D-pillar trim panel from D-pillar.
(9) Disconnect speaker wire connector, if equipped.
(10) Pass second row seat belt, if equipped,
through slot in trim panel on short wheel base vehi-
cle.
(11) Remove D-pillar trim from vehicle.
INSTALLATION
(1) Position D-pillar trim on vehicle.
(2) Pass second row seat belt, if equipped, through
slot in trim panel on short wheel base vehicle.
(3) Connect speaker wire connector to speaker, if
equipped.
(4) Align locating pins on backside of trim panel to
mating holes in D-pillar.
(5) Engage hidden clips attaching trim to D-pillar.
(6) Install screws attaching trim panel to attach-
ing bracket on short wheel base vehicle.
(7) Install quarter trim bolster on short wheel base
vehicle.
(8) Install bolt to attach second row seat belt, if
equipped, anchor to quarter on short wheel base
vehicle. Tighten all seat belt bolts to 39 N´m (29 ft.
lbs.) torque.
(9) Install second row seat belt turning loop on
long wheel base vehicle.
(10) Install liftgate sill plate.
(11) Install rear header trim cover.
Fig. 14 Rear View Mirror Assembly
1 - HEADLINER
2 - WIRE COVER
3 - MIRROR
4 - MIRROR ASSEMBLY
5 - WIRE CONNECTOR
6 - WINDSHIELD
Fig. 15 Rear View Mirror
1 - MIRROR
2 - WINDSHIELD
RSINTERIOR23 - 217
REAR HVAC LOUVER (Continued)

SLIDING DOOR SILL PLATE
REMOVAL
(1) Disengage hidden clips holding sill plate to
sliding door opening sill.
(2) Disengage hooks holding outside edge of sill
plate to door sill (Fig. 16) .
(3) Remove sill plate from vehicle.
INSTALLATION
(1) Place sill plate in position on vehicle.
(2) Engage hooks to hold outside edge of sill plate
to door sill.
(3) Align guide pins to holes in door sill.
(4) Engage hidden clips to hold sill plate to sliding
door opening sill.
SUN VISOR
REMOVAL
All vehicles with driver and passenger side air
bags must have a colored coded five Bullet point airbag warning label applied to the sun visor, verify
label availability and ensure the label is installed.
(1) Disengage sun visor from center support.
(2) Remove screws attaching sun visor to roof
header (Fig. 17) .
(3) Remove sun visor from roof.
(4) If equipped, disconnect illuminated vanity mir-
ror wire connector from body harness.
(5) Remove sun visor from vehicle.
INSTALLATION
All vehicles with driver and passenger side air
bags must have a colored coded five Bullet point air
bag warning label applied to the sun visor, verify
label availability and ensure the label is installed.
(1) Place sun visor in position on vehicle.
(2) Connect illuminated vanity mirror wire connec-
tor into body harness.
(3) Place sun visor in position on roof.
(4) Install screws to hold sun visor to roof header
(Fig. 17) .
(5) Engage sun visor into center support.
Fig. 16 Sliding Door Sill Plate
1 - HOOKS
2 - SILL PLATE
3 - CLIPS
4 - SLIDING DOOR SILL
5 - CLIPS
Fig. 17 Sun Visor
1 - HEADLINING
2 - SUN VISOR
23 - 218 INTERIORRS

STATIONARY GLASS
TABLE OF CONTENTS
page page
WINDSHIELD
DESCRIPTION..........................243
WARNING.............................243
REMOVAL.............................243
INSTALLATION..........................244
SLIDING DOOR GLASS
REMOVAL.............................245INSTALLATION..........................245
QUARTER WINDOW
REMOVAL.............................246
INSTALLATION..........................246
REAR DOOR GLASS
REMOVAL.............................246
INSTALLATION..........................246
WINDSHIELD
DESCRIPTION
The windshield is attached to the window frame
with urethane adhesive. The urethane adhesive is
applied cold and seals the surface area between the
window opening and the glass. The primer adheres
the urethane adhesive to the windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
structural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficult
to cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLEWITH THE PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
REMOVAL
WINDSHIELD REMOVAL ± EXTERIOR METHOD
The urethane adhesive holding the windshield to
the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
(1) Remove inside rear view mirror.
(2) Remove windshield wiper arms.
(3) Remove cowl cover.
(4) Remove A-pillar trim panels.
(5) Disconnect wire connectors to windshield
defroster grid.
RSSTATIONARY GLASS23 - 243

(6) Place protective covers over instrument panel
and hood.
(7) Remove windshield molding. Using pliers, pull
outward on molding at the bottom of A-pillars.
(8) Using a sharp cold knife, cut urethane adhe-
sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 1). A power
cutting device can be used if available.
(9) Remove windshield from vehicle.
WINDSHIELD REMOVAL ± INTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Remove instrument panel top cover. Refer to
Group 8E, Instrument Panel and Systems.
(3) Remove A-pillar trim covers.
(4) Disconnect wire connectors to windshield
defroster grid.
(5) Place protective covers over instrument panel
and hood.
(6) Using a reciprocating or oscillating power
knife, cut urethane adhesive holding the windshield
to the A-pillars, roof header and cowl pinch weld
fences. Refer to instructions provided with the equip-
ment being used.
(7) Remove windshield from vehicle.
INSTALLATION
The urethane adhesive holding the windshield to
the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment. If a door is slammed before
urethane bonding is cured, water leaks can result.Allow the urethane at least 24 hours to cure before
returning the vehicle to use.
To avoid stressing the replacement windshield, the
urethane bonding material on the windshield fence
should be smooth and consistent to the shape of
the replacement windshield . The support spacers
should be cleaned and properly installed on weld
studs or repair screws at bottom of windshield
opening.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the compression spacers.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement windshield. If not, the pinch weld fence
must be formed to the shape of the new glass.
(3) Remove replacement windshield from wind-
shield opening.
(4) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 2).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(5) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.
(6) Install molding to perimeter of windshield.
(7) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of windshield and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.
(8) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying time.
(9) Using a razor knife, remove as much original
urethane as possible. Do not damage paint on wind-
shield fence.
(10) Apply pinch weld primer 19 mm (0.75 in.)
wide around the windshield fence. Allow at least
three minutes drying time.
(11) If a low viscosity urethane adhesive is used,
install compression spacers on the fence around the
windshield opening (Fig. 3).
(12) Apply a 10 mm (0.4 in.) bead of urethane on
center line of windshield fence.
(13) With the aid of a helper, position the wind-
shield over the windshield opening.
(14) Slowly lower windshield glass to windshield
opening fence. Guide the molding into proper position
as necessary. Push windshield inward until molding
is flush to roof line and A-pillars (Fig. 3).
Fig. 1 Cut Urethane Around Windshield
1 - COLD KNIFE
2 - WINDSHIELD
23 - 244 STATIONARY GLASSRS
WINDSHIELD (Continued)