2001 CHRYSLER VOYAGER Service Manual

service indicator drain bolt reset infotainment system USB port washer fluid wheel bolt torque

Page 3553 of 4284

CHRYSLER VOYAGER 2001 Service Manual (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 stab

Page 3554 of 4284

CHRYSLER VOYAGER 2001 Service Manual 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) Disen

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

Page 3555 of 4284

CHRYSLER VOYAGER 2001 Service Manual (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 d

(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. (Refer to 23 - BODY/DOORS - SLIDING/SLID-
ING DOOR - ADJUSTMENTS)
(11) Install sliding door trim panel.(Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
INSIDE LATCH HANDLE
BELLCRANK
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Peel watershield away from adhesive around
perimeter of inner door panel 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) Remove bellcrank link from latch/lock control.
(6) Disengage clip holding release handle latch
cable to bellcrank.
(7) Remove cable from bellcrank.
(8) Remove screw attaching bellcrank to inner door
panel (Fig. 28).
(9) Remove bellcrank from vehicle.
INSTALLATION
(1) Position bellcrank on vehicle.
(2) Install screw attaching 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) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(9) Install sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
INSIDE LATCH RELEASE
MECHANISM
REMOVAL
(1) Remove sliding door inside latch handle. (Refer
to 23 - BODY/DOORS - SLIDING/INSIDE LATCH
HANDLE - REMOVAL)
(2) Remove push-in fastener holding cable end to
release mechanism (Fig. 27).
(3) Disengage cable end from release mechanism.
(4) Disengage latch cable from assist handle.
(5) Remove screws holding release mechanism to
handle (Fig. 29).
(6) Remove release mechanism from handle.
Fig. 27 Sliding Door Handle Cable
1 - ASSIST HANDLE MECHANISM
2 - SLIDING DOOR INSIDE ASSIST HANDLE
3 - CABLE
4 - FASTENERFig. 28 Inside Latch Handle Bellcrank
1 - SLIDING DOOR
2 - INSIDE RELEASE HANDLE LATCH BELL CRANK
3 - INSIDE RELEASE BELL CRANK LINK
RSDOORS - SLIDING23 - 175
INSIDE LATCH HANDLE (Continued)

Page 3556 of 4284

CHRYSLER VOYAGER 2001 Service Manual (7) Rotate latch release button away from mecha-
nism until flats on button pivots align with slots in
mechanism (Fig. 30).
(8) Remove button from release mechanism.
INSTALLATION
(1) Position button o

(7) Rotate latch release button away from mecha-
nism until flats on button pivots align with slots in
mechanism (Fig. 30).
(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. 30).
(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. 29).
NOTE: The inside handle cable is marked with blue
tape and must be attached to the latch at the center
(just above the lower cable). This position is
marked with a ªBº on the latch.
(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. (Refer
to 23 - BODY/DOORS - SLIDING/INSIDE LATCH
HANDLE - INSTALLATION)
EXTERIOR HANDLE
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel as necessary to access
outside release handle fasteners.
(4) Remove latch/lock control cover.
(5) Disengage clip holding outside door handle
linkage to door handle.
(6) Remove linkage from outside door handle.
(7) Remove linkage from latch/lock control.
(8) Remove nuts holding outside door handle to
outer door panel (Fig. 31).
(9) Remove outside door handle from vehicle.
INSTALLATION
(1) Position outside door handle on vehicle.
(2) Install nuts attaching outside door handle to
outer door panel.
(3) Insert linkage into outside door handle.
(4) Engage clip to hold linkage to outside door
handle.
Fig. 29 Sliding Door Inside Latch Release
Mechanism
1 - INSIDE HANDLE RELEASE MECHANISM
Fig. 30 Sliding Door Inside Latch Button
1 - ROLLER
2 - RELEASE MECHANISM
3 - BUTTON
Fig. 31 Sliding Door Outside Latch Release Handle
1 - DOOR PANEL
2 - OUTSIDE DOOR HANDLE
23 - 176 DOORS - SLIDINGRS
INSIDE LATCH RELEASE MECHANISM (Continued)

Page 3557 of 4284

CHRYSLER VOYAGER 2001 Service Manual (5) Engage rigging cam to latch/lock control mech-
anism.
(6) Move clip on latch/lock control to bottom of slot
and engage linkage to latch/lock control.
(7) Verify sliding door operation. Adjust as n

(5) Engage rigging cam to latch/lock control mech-
anism.
(6) Move clip on latch/lock control to bottom of slot
and engage linkage to latch/lock control.
(7) Verify sliding door operation. Adjust as neces-
sary.
(8) Install latch/lock cover.
(9) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(10) Install sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(11) Install sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
UPPER ROLLER
REMOVAL
(1) Open sliding door, do not latch open.
(2) Remove screw holding upper stop bracket to
upper roller bracket (Fig. 32).
(3) Remove stop bracket from vehicle.
(4) Place a padded block between the open sliding
door and the roof rail.
(5) Mark outline of upper roller bracket on sliding
door.
(6) Remove bolts holding upper roller to sliding
door (Fig. 33).
(7) Remove upper roller from door.
(8) Slide roller out of rear end of roof rail channel.
(9) Remove upper roller from vehicle.
INSTALLATION
(1) Place upper roller in position on vehicle.
(2) Slide roller into rear end of roof rail channel.
(3) Place upper roller in position on door.
(4) Align outline marks on sliding door to upper
roller bracket
(5) Install bolts to hold upper roller to sliding door.
(6) Remove padded block from between sliding
door and roof rail.
(7) Place stop bracket in position on vehicle.
(8) Install screw to hold upper stop bracket to
upper roller bracket.
(9) Verify sliding door alignment and operation.
Adjust as necessary. (Refer to 23 - BODY/DOORS -
SLIDING/SLIDING DOOR - ADJUSTMENTS)
OUTSIDE HANDLE CABLE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate side door trim panel.
(Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
(4) Open the side door and remove the latch
assembly. Refer to the Power Side Doors section for
the procedure.
CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
Fig. 32 Sliding Door Upper Stop
1 - SLIDING DOOR
2 - UPPER STOP
3 - UPPER ROLLER ARM
Fig. 33 Sliding Door Upper Roller
1 - SLIDING DOOR UPPER ROLLER
2 - SLIDING DOOR
RSDOORS - SLIDING23 - 177
EXTERIOR HANDLE (Continued)

Page 3558 of 4284

CHRYSLER VOYAGER 2001 Service Manual (5) Trace the outside handle cable along its routing
path and disconnect from its retaining clips.
(6) Disconnect the outside handle cable from the
latch assembly. Gently pry cable sleeve retainer out

(5) Trace the outside handle cable along its routing
path and disconnect from its retaining clips.
(6) Disconnect the outside handle cable from the
latch assembly. Gently pry cable sleeve retainer out
of the latch mounting braket and then unhook
swedged cable end from the latch link.
(7) Disconnect the outside handle cable from the
handle assembly. Gently pry cable sleeve retainer out
of the handle bracket and then unhook swedged
cable end from the handle link.
(8) Remove the outside handle cable from the side
door.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Match the replacement cable up against the old
cable to verify the correct part.
(2) Position the outside handle cable on the side
door.
(3) Connect the outside handle cable on the handle
assembly. Hook the swedged cable end on the handle
link and gently push the cable sleeve retainer in the
handle bracket.
NOTE: The outside handle cable is marked with red
tape. It must be attached to the latch at the lowest
point. This is marked with a ªRº on the latch.
(4) Connect the outside handle cable on the latch
assembly. Hook the swedged cable end on the latch
link and gently push the cable sleeve retainer in the
latch bracket.
(5) Trace the outside handle cable along its routing
path and install on its retaining clips and position
foam insulators. Use previously made schematic as a
guide or remove the opposite side door trim panel
and use that door as a guide.
CAUTION: Be certain replacement cable is routed
and retained correctly and foam insulators are
properly positioned.
(6) Install the latch assembly. (Refer to 8 - ELEC-
TRICAL/POWER DOORS/LATCH - REMOVAL)
(7) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(8) Install the appropriate side door trim panel on
the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - INSTALLATION)
(9) Connect the negative battery cable.
INSIDE HANDLE CABLE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1)
Disconnect and isolate the negative battery cable.
(2) Remove the appropriate side door trim panel
from the vehicle. (Refer to 23 - BODY/DOORS -
SLIDING/TRIM PANEL - REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
(4) Remove the inside handle assembly from the
side door. (Refer to 23 - BODY/DOORS - SLIDING/
INSIDE LATCH HANDLE - REMOVAL)
(5) Disconnect the inside handle cable from the
handle assembly. Gently pry cable sleeve retainer out
of the handle bracket and then unhook swedged
cable end from the handle link.
(6) Open the side door and remove the latch
assembly. Refer to the Power Side Doors section for
the procedure.
CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
(7) Trace the inside handle cable along its routing
path and disconnect from its retaining clips.
(8) Disconnect the inside handle cable from the
latch assembly. Gently pry cable sleeve retainer out
of the latch mounting bracket and then unhook
swedged cable end from the latch link.
(9) Remove the inside handle cable from the side
door.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Match the replacement cable up against the old
cable to verify the correct part.
(2) Position the inside handle cable on the side
door.
(3) Connect the inside handle cable on the handle
assembly. Hook the swedged cable end on the handle
link and gently push the cable sleeve retainer in the
handle bracket.
(4) Install the inside handle assembly on the side
door. (Refer to 23 - BODY/DOORS - SLIDING/IN-
SIDE LATCH HANDLE - INSTALLATION)
23 - 178 DOORS - SLIDINGRS
OUTSIDE HANDLE CABLE (Continued)

Page 3559 of 4284

CHRYSLER VOYAGER 2001 Service Manual NOTE: The inside handle cable is marked with blue
tape and must be attached to the latch at the center
(just above the lower cable). This position is
marked with a ªBº on the latch.
(5) Connect the

NOTE: The inside handle cable is marked with blue
tape and must be attached to the latch at the center
(just above the lower cable). This position is
marked with a ªBº on the latch.
(5) Connect the inside handle cable on the latch
assembly. Hook the swedged cable end on the latch
link and gently push the cable sleeve retainer in the
latch bracket.
(6) Trace the inside handle cable along its routing
path and install on its retaining clips and position
foam insulators. Use previously made schematic as a
guide or remove the opposite side door trim panel
and use that door as a guide.
CAUTION: Be certain replacement cable is routed
and retained correctly and foam insulators are
properly positioned.
(7) Install the latch assembly. Refer to the Power
Side Doors section for the procedure.
(8) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(9) Install the appropriate side door trim panel on
the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - INSTALLATION)
(10) Connect the negative battery cable.
HOLD OPEN LATCH CABLE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1)
Disconnect and isolate the negative battery cable.
(2) Remove the appropriate side door trim panel
from the vehicle. (Refer to 23 - BODY/DOORS -
SLIDING/TRIM PANEL - REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
(4) Open the side door and remove the latch
assembly. (Refer to 8 - ELECTRICAL/POWER
DOORS/LATCH - REMOVAL)
CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
(5) Trace the hold open latch cable along its rout-
ing path and disconnect from its retaining clips.
(6) Disconnect the hold open latch cable from the
latch assembly. Gently pry cable sleeve retainer out
of the latch mounting bracket and then unhook
swedged cable end from the latch link.(7) Remove the hold open latch from the side door.
(Refer to 23 - BODY/DOORS - SLIDING/HOLD
OPEN LATCH - REMOVAL)
(8) Disconnect the hold open latch cable from the
hold open latch. Gently pry cable sleeve retainer out
of the handle bracket and then unhook swedged
cable end from the latch link.
(9) Remove the hold open latch cable from the side
door.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Match the replacement cable up against the old
cable to verify the correct part.
(2) Position the hold open latch cable on the side
door.
NOTE: The hold open latch cable is marked with
white tape. It must be attached to the upper most
cable attachment at the latch. This position is
marked with a ªWº on the latch.
(3) Connect the hold open latch cable on the hold
open latch assembly. Hook the swedged cable end on
the latch link and gently push the cable sleeve
retainer in the latch bracket.
(4) Install the hold open latch on the side door.(Re-
fer to 23 - BODY/DOORS - SLIDING/HOLD OPEN
LATCH - INSTALLATION)
(5) Connect the hold open latch cable on the latch
assembly. Hook the swedged cable end on the latch
link and gently push the cable sleeve retainer in the
latch bracket.
(6) Trace the outside handle cable along its routing
path and install on its retaining clips and position
foam insulators. Use previously made schematic as a
guide or remove the opposite side door trim panel
and use that door as a guide.
CAUTION: Be certain replacement cable is routed
and retained correctly and foam insulators are
properly positioned.
(7) Install the latch assembly. (Refer to 8 - ELEC-
TRICAL/POWER DOORS/LATCH - INSTALLATION)
(8) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(9) Install the appropriate side door trim panel on
the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - INSTALLATION)
(10) Connect the negative battery cable.
RSDOORS - SLIDING23 - 179
INSIDE HANDLE CABLE (Continued)

Page 3560 of 4284

CHRYSLER VOYAGER 2001 Service Manual DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL.............................180
INSTALLATION..........................180
HINGE
REMOVAL.............................

DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL.............................180
INSTALLATION..........................180
HINGE
REMOVAL.............................180
INSTALLATION..........................181
LATCH
REMOVAL.............................181
INSTALLATION..........................181
LATCH STRIKER
REMOVAL.............................181
INSTALLATION..........................181
LIFTGATE
REMOVAL.............................181INSTALLATION..........................182
LIFTGATE SPOILER
REMOVAL.............................182
INSTALLATION..........................182
LOCK CYLINDER
REMOVAL.............................182
INSTALLATION..........................182
SUPPORT CYLINDER
REMOVAL.............................183
INSTALLATION..........................183
TRIM PANEL
REMOVAL.............................183
INSTALLATION..........................183
EXTERIOR HANDLE
REMOVAL
(1) Remove liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the exterior handle electrical con-
nectors.
(3) Remove the two outer screws and the two inner
screws.
(4) Remove the exterior handle/license plate light
assembly.
INSTALLATION
(1) Route the exterior handle electrical connector
through the door and position handle.
(2) Install the two inner bolts and tighten to 40
N´m (30 ft. lbs.).
(3) Install the two out screws and tighten to 20
N´m (15 ft. lbs.).
(4) Connect the electrical connector.
(5) Install the trim panel. (Refer to 23 - BODY/
DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM
PANEL - INSTALLATION)
HINGE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device in
the full open position.(3) Apply several layers of duct tape on the outside
of to roof across the gap to the lift gate to hold the
liftgate in position.
(4) Remove bolts attaching liftgate hinge to roof
header.
(5) Disconnect VTSS switch from the body har-
ness.
(6) Remove bolts attaching hinge to liftgate (Fig.
1).
(7) Remove hinge from vehicle.
Fig. 1 Liftgate Hinge
1 - LIFTGATE
2 - HINGE
3 - REAR ROOF HEADER
23 - 180 DECKLID/HATCH/LIFTGATE/TAILGATERS

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