2001 CHRYSLER VOYAGER ECU

CLEANING - ALUMINUM WHEEL CARE
Chrome plated and painted aluminum wheels
should be cleaned regularly using mild soap and
water to maintain their luster and to prevent corro-
sion.
Care must be taken in the selection of tire and
wheel cleaning chemicals and equipment to prevent
damage to the wheels. Any of the ªDO NOT USEº
items listed below WILL damage chrome plated and
painted aluminum wheels.
DO NOT USE:
²any abrasive metal cleaner
²any abrasive cleaning pad or brush
²any cleaner that contains an acid (this will
immediately react with and discolor the chromium
surface)
²chrome polish (unless it is buffed off immedi-
ately after application)
²oven cleaner
²a car wash that uses carbide-tipped wheel clean-
ing brushes
SPECIFICATIONS
WHEEL
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Wheel Mounting (Lug)
Nut Hex Size19 mm
Wheel Mounting Stud
SizeM12 x 1.5 mm
TORQUE SPECIFICATIONS
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Wheel Mounting (Lug ) Nut 135 100 Ð
WHEEL COVER
DESCRIPTION
This vehicle uses a bolt-on type wheel cover (Fig.
25).
This bolt-on wheel cover cannot be removed from
the wheel until three of the five wheel mounting nuts
shown are removed (Fig. 25). The bolt-on wheel cover
can then be removed with the remaining two wheel
nuts tightened in place.
REMOVAL
(1) Noting the location of the valve stem in rela-
tionship to the wheel mounting nuts, remove the
three wheel mounting nuts securing the wheel cover
to the wheel and hub (Fig. 25).
CAUTION: When removing the wheel cover, do not
pry the wheel cover from the wheel. This can result
in damage to the wheel cover. The wheel cover is
removed by pulling it off the wheel by hand.
(2) Grasp the wheel cover at the edges in line with
the remaining installed wheel nuts and pull straight
outward from the wheel. This will pop the wheel
cover retaining tabs over the two remaining wheel
nuts, removing the wheel cover from the wheel.
INSTALLATION
NOTE: Wheel mounting nuts must be installed on
the studs as shown to allow installation of the
wheel cover (Fig. 26).
(1) Place the wheel cover on the wheel in the fol-
lowing fashion:
(a) Align the valve notch in the wheel cover with
the valve stem on the wheel.
(b) At the same time, align the two holes in the
wheel cover having the retaining tabs with the two
installed wheel nuts (Fig. 27).
(c) Press in on center of wheel cover until wheel
cover retaining tabs push past and engage rear of
previously installed wheel mounting nuts (Fig. 27).
This will hold the wheel cover in place.
Fig. 25 Nuts Securing Wheel Cover
1 - VALVE STEM
2 - BOLT-ON WHEEL COVER
3 - NUTS SECURING WHEEL COVER
22 - 14 TIRES/WHEELSRS
WHEELS (Continued)

(2) Install andlightly tightenthe three remain-
ing wheel mounting nuts, securing the wheel cover in
place (Fig. 25).
(3) Tighten all five wheel mounting nuts in the
proper sequence (Fig. 28). Tighten wheel nuts to a
torque of 135 N´m (100 ft. lbs.).
WHEEL MOUNTING STUDS -
FRONT
REMOVAL
CAUTION: If a wheel mounting stud needs to be
replaced in the hub and bearing assembly, the
studs MUST NOT be hammered out of the hub
flange. If a stud is removed by hammering it out of
the bearing flange, damage to the hub and bearing
assembly will occur leading to premature bearing
failure.
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the front wheel and tire assembly from
the vehicle.
(3) Remove the two adapter mounting bolts secur-
ing both the disc brake caliper adapter to the steer-
ing knuckle (Fig. 29).
(4) Remove the disc brake caliper and adapter as
an assembly from the steering knuckle (Fig. 29).
Hang the assembly out of the way using wire or a
bungee cord. Use care not to overextend the brake
hose when doing this.
(5) Remove brake rotor from hub by pulling it
straight off wheel mounting studs (Fig. 29).
(6) On the wheel mounting stud to be removed,
install a wheel mounting (lug) nut far enough so the
threads on the stud are even with end of nut. Install
Remover, Special Tool C-4150A on hub and bearing
assembly flange and wheel stud (Fig. 30).
(7) Tighten down on special tool, pushing wheel
stud out of the hub flange. When shoulder of wheel
stud is past flange, remove special tool from hub and
bearing. Remove nut from stud and remove stud
from hub flange.
Fig. 26 Two Wheel Mounting Nuts Installed
1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
Fig. 27 Wheel Cover Installation Over Two Nuts
1 - RETAINING TABS
2 - VALVE STEM
3 - BOLT-ON WHEEL COVER
Fig. 28 Nut Tightening Sequence
RSTIRES/WHEELS22-15
WHEEL COVER (Continued)

INSTALLATION
(1) Install replacement wheel stud into flange of
hub and bearing assembly. Install washers on wheel
stud, then install a wheel mounting (lug) nut on stud
with flat side of lug nut against washers as shown
(Fig. 31).
(2) Tighten the nut, pulling the wheel stud into
the flange of the hub and bearing. When the head ofthe stud is fully seated against the rear of the hub
flange, remove nut and washers from stud.
(3) Install the brake rotor back on the hub and
bearing (Fig. 29).
(4) Install brake caliper and adapter back over
brake rotor aligning adapter with mounting holes on
steering knuckle (Fig. 29).
(5) Install the two adapter mounting bolts securing
the adapter to the steering knuckle. Tighten the
mounting bolts to 169 N´m (125 ft. lbs.) torque.
(6) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting lug nuts in proper
sequence until all nuts are torqued to half specifica-
tion, then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(7) Lower vehicle to the ground.
WHEEL MOUNTING STUDS -
REAR
REMOVAL
CAUTION: If a wheel attaching stud needs to be
replaced in the hub and bearing assembly the studs
MUST NOT be hammered out of the hub flange. If a
stud is removed by hammering it out of the bearing
flange, damage to the hub and bearing assembly
will occur leading to premature hub and bearing
failure.
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
Fig. 29 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
Fig. 30 Wheel Stud Removal (Typical)
1 - WHEEL MOUNTING (LUG) NUT
2 - HUB AND BEARING ASSEMBLY
3 - SPECIAL TOOL C-4150A
4 - STEERING KNUCKLE
5 - WHEEL STUD
Fig. 31 Installing Wheel Stud (Typical)
1 - WASHERS
2 - HUB AND BEARING ASSEMBLY
3 - WHEEL MOUNTING (LUG) NUT
4 - STEERING KNUCKLE
22 - 16 TIRES/WHEELSRS
WHEEL MOUNTING STUDS - FRONT (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
DESCRIPTION............................1
WARNING...............................2
DIAGNOSIS AND TESTING..................2
WATER LEAKS..........................2
WIND NOISE...........................3
STANDARD PROCEDURE...................4
PLASTIC BODY PANEL REPAIR.............4
HEAT STAKING.........................8
SPECIFICATIONS.........................9
SPECIAL TOOLS........................151DOOR - FRONT.........................152
DOORS - SLIDING.......................162
DECKLID/HATCH/LIFTGATE/TAILGATE.......180
EXTERIOR.............................184
HOOD................................199
INSTRUMENT PANEL....................202
INTERIOR.............................208
PAINT................................220
SEATS................................222
STATIONARY GLASS.....................243
WEATHERSTRIP/SEALS..................248
BODY
DESCRIPTION - LOCK CYLINDERS
Ignition, door, deck lid, and rear hatch lock cylin-
ders are all codable to the key. Lock barrels, tum-
blers, and tumbler springs are available to allow the
technician to change replacement locks cylinders to
match the customer's original key set. See the appro-
priate section in this manual for lock cylinder
removal. See the Moparž catalogue for part numbers
and lock coding procedures.
DESCRIPTION - VEHICLE IDENTIFICATION
Throughout this group, references to the
DaimlerChrysler Corporation vehicle family identifi-
cation code are used when describing a procedure
that is unique to that vehicle. Refer to Introduction
Group of this manual for detailed information on
vehicle identification. If a procedure is common to all
vehicles covered in this manual, no reference will be
made to a vehicle family code.
DESCRIPTION - PUSH-IN FASTENERS
DaimlerChrysler Corporation uses many different
types of push-in fasteners to secure the interior and
exterior trim to the body. Most of these fasteners can
be reused to assemble the trim during various repair
procedures. At times, a push-in fastener cannot be
removed without damaging the fastener or the com-
ponent it is holding. If it is not possible to remove a
fastener without damaging a component or body, cut
or break the fastener and use a new one when
installing the component. Never pry or pound on a
plastic or pressed-board trim component. Using a
suitable fork-type prying device, pry the fastener
from the retaining hole behind the component beingremoved. When installing, verify fastener alignment
with the retaining hole by hand. Push directly on or
over the fastener until it seats. Apply a low-force pull
to the panel to verify that it is secure.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges holding the component in
place.
DESCRIPTION
PAINT
The original equipment finish is a multi-step pro-
cess that involves cleaning, electrodeposition (e-coat),
base coat, and clear coat steps. Additionally, selected
areas of the vehicle may be coated with an anti-chip
finish.
On most vehicles a two-stage paint application
(base coat/clear coat) is used. Color that is applied to
primer is called base coat. The clear coat protects the
base coat from ultraviolet light and provides a dura-
ble high-gloss finish.
STATIONARY GLASS
Windshields are made of two pieces of glass with a
plastic inner layer. Windshields and selected station-
ary glass are structural members of the vehicle. The
windshield glass is bonded to the windshield frame
with urethane adhesive.
Windshields and other stationary glass protect the
occupants from the effects of the elements. Wind-
shields are also used to retain some airbags in posi-
tion during deployment. Urethane bonded glass is
difficult to salvage during removal. The urethane
bonding is difficult to cut or clean from any surface.
RSBODY23-1

(5) If desired, a thin film coat of poesy can be
applied to the back of the patch to cover mesh for
added strength.
PANEL PATCH INSTALLATION
(1) Make a paper or cardboard pattern the size
and shape of the cutout hole in the panel.
(2) Trim 3 mm (0.125 in.) from edges of pattern so
patch will have a gap between connecting surfaces.
(3) Using the pattern as a guide, cut the patch to
size.
(4) Cut scrap pieces of patch material into 50 mm
(2 in.) squares to use as patch supports to sustain
the patch in the cutout.
(5) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in
from edge of cutout hole (Fig. 8).
(6) Drill 3 mm (0.125 in.) holes in the support
squares 13 mm (0.5 in.) from the edge in the center
of one side.
(7) Scuff the backside of the body panel around the
cutout hole with a scuff pad or sandpaper.
(8) Mix enough epoxy to cover one side of all sup-
port squares.
(9) Apply epoxy to the support squares on the half
with the hole pre-drilled in it.
(10) Using number 8 sheet metal screws, secure
support squares to back side of body panel with
epoxy sandwiched between the panel and squares
(Fig. 10).
(11) Position patch in cutout against support
squares and adjust patch until the gap is equal along
all sides (Fig. 11).
(12) Drill 3 mm (0.125 in.) holes in the support
squares through the pre-drilled holes in the patch.
Fig. 9 FABRICATED PANEL
1 - STRUCTURAL ADHESIVE OR EPOXY RESIN
2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE
3 - WIDTH OF V-GROOVE
4 - WAXED PAPER
Fig. 10 Secure Support Squares To Body Panel
1 - SUPPORT SQUARES
2 - SCREWS
3 - DAMAGED BODY PANEL
Fig. 11 Position Patch In Cutout And Align
1 - CUTOUT
2 - SUPPORT SQUARES
Fig. 12 Apply Epoxy To Support Squares
1 - APPLICATOR
2 - SUPPORT SQUARES
3 - EPOXY
RSBODY23-7
BODY (Continued)

(13) Apply a coat of epoxy to the exposed ends of
the support squares (Fig. 12).
(14) Install screws to hold the patch to support
squares (Fig. 13). Tighten screws until patch surface
is flush with panel surface.
(15) Allow epoxy to cure, and remove all screws.
(16) Using a 125 mm (5 in.) 24 grit disc grinder,
grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2
mm (0.080 in.) deep path across the gaps around the
patch (Fig. 14). With compressed air, blow dust from
around patch.
(17) Apply adhesive backed nylon mesh (dry wall
tape) over gaps around patch (Fig. 15).
(18) Mix enough epoxy to cover the entire patch
area.
(19) Apply epoxy over the mesh around patch, and
smooth epoxy with a wide spreader to reduce finish
grinding. Use two to three layers of mesh and epoxy
to create a stronger repair (Fig. 16).
PATCHED PANEL SURFACING
After patch panel is installed, the patch area can
be finished using the same methods as finishing
other types of body panels. If mesh material is
exposed in the patched area, grind surface down, and
apply a coat of high quality rigid plastic body filler.
Prime, block sand, and paint as required.
STANDARD PROCEDURE - HEAT STAKING
(1) Remove trim panel.
(2) Bend or move the trim panel components at
the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.
(3) Heat stake the components.
(a) If the heat staked or component seam loca-
tion is loose, hold the two components tightlytogether and using a soldering gun with a flat tip,
melt the material securing the components
together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.
(b) If the heat staked material is broken or miss-
ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-
ing the glue. Once the new material is in place, it
may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
Fig. 13 INSTALL SCREWS
1 - PATCH
2 - GAP
Fig. 14 Grind Surface
1 - PATCH
2 - GAP
3 - DISC GRINDER
Fig. 15 COVER GAPS WITH MESH
1 - GROUND DOWN AREA
2 - PATCH
3 - MESH
23 - 8 BODYRS
BODY (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 attaching door latch to door end
frame. Tighten screws to 10 N´m (90 in. lbs.) torque.
(3) Insert linkage into door latch.
(4) Engage clips attaching 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 operation.
(11) Install watershield and front door trim panel.
LATCH STRIKER
REMOVAL
(1) Mark outline of door striker on B-pillar to aid
in installation.
(2) Remove screws attaching door latch striker to
B-pillar (Fig. 10) .
(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 attaching latch striker to
B-pillar.
(3) Align latch striker to outline on B-pillar made
previously.
(4) Tighten fasteners to 28 N´m (21 ft. lbs.) torque.
(5) Verify door fit and operation. Adjust latch
striker as necessary.
LOCK CYLINDER
REMOVAL
(1) Roll door glass up.
(2)
Remove front door watershield as necessary to
gain access to the outside door handle. (Refer to 23 -
BODY/DOOR - FRONT/WATERSHIELD - REMOVAL)
(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 attaching 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 attaching outside door handle to
door outer panel.
(10) Remove outside door handle from vehicle.
(11) Disengage clip holding lock cylinder into out-
side handle (Fig. 11).
(12) Pull lock cylinder from door handle.
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. 12).
(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 attaching VTSS
switch harness to inner door reinforcement bar, if
equipped.
(8) Connect VTSS switch connector into door har-
ness, if equipped.
Fig. 10 Door Latch Striker
1 - B-PILLAR
2 - SHIM
3 - DOOR LATCH STRIKER
RSDOOR - FRONT23 - 157
LATCH (Continued)

(11) Install screws to attach accessary switch
panel to door trim.
(12) Install screw cover into switch panel.
(13) If equipped, install window crank.
(14) If equipped, install screws to attach trim
panel to door inside map pocket.
(15) If equipped, install screw to attach door pull
cup to inner door panel.
(16) If equipped, install screws to attach door
assist handle to inner door panel.
(17) Connect wire connector into courtesy lamp.
(18) Install lamp in door trim.
TRIM PANEL REFLECTOR
REMOVAL
(1) Insert small, flat bladed pry tool between outer
edge of door reflector and HVAC outlet vent.
(2) Pry outward on outer edge of reflector.
(3) Remove reflector from vehicle (Fig. 14) .
INSTALLATION
(1) Position reflector on vehicle.
(2) Insert inner edge of reflector into slot in HVAC
outlet vent.
(3) Snap outer edge of reflector into slot in HVAC
outlet vent.
WATERSHIELD
REMOVAL
(1) Remove door trim panel.
(2) Remove the front door speaker.
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
INSTALLATION
(1) Insure that enough adhesive remains to
securely retain the water dam. Replace as necessary.
(2) Place the sound shield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(3) Install door trim panel.
WINDOW CRANK
REMOVAL
(1) Using a window crank removal tool, disengage
clip attaching window crank to regulator shaft (Fig.
15) .
NOTE: Wrap a shop towel around the window crank
to catch the clip when it springs out.
(2) Pull window crank from regulator shaft.
INSTALLATION
(1) Place the clip on to the window crank handle.
(2) Position window crank to regulator shaft.
(3) Push window crank onto regulator shaft to
engage retaining clip.
Fig. 14 Front Door Reflector
1 - HEVAC OUTLET VENT
2 - DOOR REFLECTOR
3 - DOOR TRIM PANEL
Fig. 15 Window Crank
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
RSDOOR - FRONT23 - 159
TRIM PANEL (Continued)