2001 CHRYSLER VOYAGER Service Manual

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Page 3385 of 4284

CHRYSLER VOYAGER 2001 Service Manual Smooth the filler with a spatula, wooden tongue
depressor, or squeegee. For fine texturing, a small
amount of water can be applied to the filler surface
while smoothing. The cured filler can be sanded

Smooth the filler with a spatula, wooden tongue
depressor, or squeegee. For fine texturing, a small
amount of water can be applied to the filler surface
while smoothing. The cured filler can be sanded as
necessary and, as a final step, cleanup can be done
withy soapy water. Wipe the surface clean with a dry
cloth allowing time for the panel to dry before mov-
ing on with the repair.
PANEL REINFORCEMENT
Structural repair procedures for rigid panels such
as Sheet Molded compound (SMC) or Resin Transfer
Molded (RTM) with large cracks and holes will
require a reinforcement backing. Reinforcements can
be made with several applications of glass cloth sat-
urated with epoxy structural adhesive, semirigid or
flexible repair materials should be used for semirigid
or flexible part repairs (Fig. 3) and (Fig. 4). Open
meshed fiberglass dry wall tape can be used to form
a reinforcement. The dry wall tape allows the resin
to penetrate through and make a good bond between
the panel and the epoxy adhesive. Structurally, the
more dry wall tape used, the stronger the repair.
Another kind of repair that can be done to repair
large cracks and holes is to use a scrap piece of sim-
ilar plastic and bond with structural adhesive. The
reinforcement should cover the entire break and
should have a generous amount of overlap on either
side of the cracked or broken area.
When repairing plastic, the damaged area is first
ªV'dº out, or beveled. Large bonding areas are desir-
able when repairing plastic because small repairs are
less likely to hold permanently. Beveling the area
around a crack at a 20 degree angle will increase the
bonding surface for a repair (Fig. 5). It is recom-
mended that sharp edges be avoided because the
joint may show through after the panel is refinished.²Panel repair for both flexible and rigid panels
are basically the same. The primary difference
between flexible panel repair and rigid panel repair
is in the adhesive materials used (Fig. 6).
²The technician should first decide what needs to
be done when working on any type of body panel.
One should determine if it is possible to return the
damage part to its original strength and appearance
without exceeding the value of the replacement part.
²When plastic repairs are required, it is recom-
mended that the part be left on the vehicle when
every possible. That will save time, and the panel
will remain stationary during the repair. Misalign-
ment can cause stress in the repair areas and can
result in future failure.
Fig. 3 Softened Edges
1 - SOFTENED EDGES
2 - PANEL ADHESIVE
3 - BONDING STRIP
Fig. 4 Panel Reinforcement
1 - PANEL ADHESIVE
2 - REINFORCEMENT
Fig. 5 Beveling Angle
Fig. 6 Fiberglass Tape
RSBODY23-5
BODY (Continued)

Page 3386 of 4284

CHRYSLER VOYAGER 2001 Service Manual VISUAL INSPECTION
Sheet Molded Compound (SMC) and Resin Trans-
fer Molded (RTM), because they are composites, react
differently to impact that sheet metal does. Compos-
ite materials can mask the seve

VISUAL INSPECTION
Sheet Molded Compound (SMC) and Resin Trans-
fer Molded (RTM), because they are composites, react
differently to impact that sheet metal does. Compos-
ite materials can mask the severity of an accident.
Adhesive bond lines, interior structure of the doors,
and steel structure need to be inspected carefully to
get a true damage assessment. Close inspection may
require partial removal of interior trim or inner pan-
els.
Identify the type of repair:
Puncture or Crack ± Damage that has penetrated
completely through the panel. Damage is confined to
one general area; a panel section is not required.
However, a backer panel, open fiberglass tape, or
matted material must be bonded from behind (Fig.
7).
PANEL SURFACE PREPARATION
If a body panel has been punctured, cracked, or
crushed, the damaged area must be removed from
the panel to achieve a successful repair. All spider
web cracks leading away from a damaged area must
be stopped or removed. To stop a running crack in a
SMC or RTM panel, drilla6mm(0.250 in.) hole at
the end of the crack farthest away from the damage.
If spider web cracks can not be stopped, the panel
would require replacement. The surfaces around the
damaged area should be stripped of paint and freed
from was and oil. Scuff surfaces around repair area
with 360 grit wet/dry sand paper, or equivalent, to
assure adhesion of epoxy repair materials.
PATCHING PANELS
An RTM or SMC panel that has extensive punc-
ture type damage can be repaired by cutting out the
damaged material (Fig. 8). Use a suitable reciprocat-
ing saw or cut off wheel to remove the section of the
SMC or RTM panel that is damaged. The piece cut
out can be used as a template to shape the new
patch. It is not necessary to have access to the back
of the panel to install a patch. Bevel edges of cutout
at 20 degrees to expose a larger bonding area on the
outer side. This will allow for an increased reinforce-
ment areas.
PANEL PATCH FABRICATIONS
A patch can be fabricated from any rigid fiberglass
panel that has comparable contour with the repair
area. discard SMC or RTM panels. Lift gates and
fenders can be used to supply patch material. If
existing material is not available or compatible, a
patch can be constructed with epoxy and reinforce-
ment mesh (dry wall tape). Perform the following
operation if required:
(1) Cover waxed paper or plastic with adhesive
backed nylon mesh (dry wall tape) larger than the
patch required (Fig. 9).
(2) Tape waxed paper or plastic sheet with mesh to
a surface that has a compatible contour to the repair
area.
(3) Apply a liberal coat of epoxy adhesive over the
reinforcement mesh (Fig. 9). If necessary apply a sec-
ond or third coat of epoxy and mesh after firs coat
has cured. The thickness of the patch should be the
same as the repair area.
(4) After patch has cured, peel waxed paper or
plastic from the back of the patch.
Fig. 7 Damage Component
1 - PUNCTURE
Fig. 8 DAMAGED PANEL CUTOUT AND PATCH
1 - CUTOUT
2 - DAMAGED BODY PANEL
3 - 4MM (0.160 IN.) HOLES
4 - PATCH CUT TO SIZE
23 - 6 BODYRS
BODY (Continued)

Page 3387 of 4284

CHRYSLER VOYAGER 2001 Service Manual (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

Page 3388 of 4284

CHRYSLER VOYAGER 2001 Service Manual (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 pa

(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)

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CHRYSLER VOYAGER 2001 Service Manual (4) Allow the repaired area to cool and verify the
repair.
(5) Install trim panel.
SPECIFICATIONS
BODY LUBRICATION SPECIFICATIONS
LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be
inspec

Page 3390 of 4284

CHRYSLER VOYAGER 2001 Service Manual LUBRICANT USAGE
COMPONENT SERVICE INTERVAL LUBRICANT
Door Hinges - Hinge Pin and Pivot
Contact AreasAs Required Engine Oil
Hood Hingers - Pivot Points As Required Engine Oil
Lifgate Hinges As Required

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CHRYSLER VOYAGER 2001 Service Manual GAP AND FLUSH MEASUREMENTS
GAP & FLUSH MEASUREMENTS
RSBODY23-11
BODY (Continued)

Page 3392 of 4284

CHRYSLER VOYAGER 2001 Service Manual SPECIFICATIONS
ITEM LOCATION GAP FLUSH
A HOOD TO FASCIA (VOYAGER ONLY)
8.0 2.0
PARALLEL WITHING 2.0 RIGHT TO
LEFT2.5 OVERFLUSH TO HOOD
1.5 CONSISTENT WITHIN 2.0
B HEADLAMP MODULE TO
HOOD8.0 2

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