2001 CHRYSLER VOYAGER Service Manual

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Page 3561 of 4284

CHRYSLER VOYAGER 2001 Service Manual INSTALLATION
(1) If necessary, paint replacement hinge before
installation.
(2) Place hinge in position on vehicle.
(3) Align hinge to marks on liftgate.
(4) Install bolts attaching hinge to liftgate

Page 3562 of 4284

CHRYSLER VOYAGER 2001 Service Manual (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 lifti

(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)

Page 3563 of 4284

CHRYSLER VOYAGER 2001 Service Manual 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

Page 3564 of 4284

CHRYSLER VOYAGER 2001 Service Manual EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL.............................184
INSTALLATION..........................184
COWL GRILLE
REMOVAL.............................190
INSTALLATI

EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL.............................184
INSTALLATION..........................184
COWL GRILLE
REMOVAL.............................190
INSTALLATION..........................190
EXTERIOR NAME PLATES - TAPE ATTACHED
REMOVAL.............................191
INSTALLATION..........................191
EXTERIOR NAME PLATES - ADHESIVE
ATTACHED
REMOVAL.............................191
INSTALLATION..........................191
FRONT FENDER
REMOVAL.............................191
INSTALLATION..........................191
FUEL FILL DOOR
REMOVAL.............................191
INSTALLATION..........................192
FUEL FILL DOOR BLOCKER LATCH
REMOVAL.............................192
INSTALLATION..........................192
FUEL FILL DOOR BLOCKER LATCH STRIKER
REMOVAL.............................193
INSTALLATION..........................193
FUEL FILL DOOR BLOCKER LOCKOUT LINK
REMOVAL.............................193INSTALLATION..........................193
GRILLE OPENING REINFORCEMENT
REMOVAL.............................194
INSTALLATION..........................194
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL.............................194
INSTALLATION..........................195
LUGGAGE RACK RISER
REMOVAL.............................195
INSTALLATION..........................195
LUGGAGE RACK CROSSBAR
REMOVAL.............................195
INSTALLATION..........................196
REAR QUARTER PANEL/FENDER AIR
EXHAUSTER
DESCRIPTION..........................196
REMOVAL.............................196
INSTALLATION..........................197
ROOF JOINT MOLDING
REMOVAL.............................197
INSTALLATION..........................197
SIDE VIEW MIRROR
REMOVAL.............................198
INSTALLATION..........................198
BODY SIDE MOLDINGS
REMOVAL
Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig.
5)for proper location of fasteners holding the molding
to the wheelhouse lip and rocker panels.
(1) Warm the affected stick-on molding and body
metal to approximately 38É C (100É F) using a suit-
able heat lamp or heat gun.
(2) If equipped, remove pop-rivets holding molding
edge to wheelhouse lip.
(3) Pull stick-on molding from painted surface.
(4) Remove adhesive tape residue from painted
surface of vehicle. Use a 3M Scotch-BriteŸ Molding
Adhesive and Stripe Removal Disc, or equivalent, to
clean adhesive residue from painted surfaces. These
products are available from automotive paint suppli-
ers. Refer to instructions supplied with the specific
product for proper usage.
INSTALLATION
Refer to (Fig. 1) , (Fig. 2), (Fig. 3), (Fig. 4) or (Fig.
5)for proper location of fasteners to hold the molding
to the wheelhouse lip and rocker panels.
(1) If molding is to be reused;
(a) Remove tape residue from molding.
(b) Clean back of molding with Moparž Super
Kleen, or equivalent.
(c) Wipe molding dry with lint free cloth.
(d) Apply a single coat of Moparž TPO Molding
Prep to tape side of molding and allow to dry thor-
oughly.
(e) Apply new body side molding (two sided
adhesive) tape to back of molding.
(2) Clean body surface with Moparž Super Kleen,
or equivalent. Wipe surface dry with lint free cloth.
(3) Remove protective cover from tape on back of
molding.
(4) Apply molding to body from front to rear,
inserting locator pins into hole in body panel.
23 - 184 EXTERIORRS

Page 3565 of 4284

CHRYSLER VOYAGER 2001 Service Manual (5) Using a roller tool, roll molding onto body
panel with enough force to assure adhesion. Do not
apply excessive force, or damage to body panels may
result.(6) Install pop-rivets to hold molding edg

Page 3566 of 4284

CHRYSLER VOYAGER 2001 Service Manual Fig. 2 Body Side Moldings ± Highline Typical
1 - QUARTER PANEL
2 - FRONT FENDER
3 - POP-RIVET
4 - FENDER MOLDING
5 - FRONT DOOR MOLDING
6 - SLIDING DOOR MOLDING7 - GUIDE PINS
8 - QUARTER PANEL MOLDIN

Page 3567 of 4284

CHRYSLER VOYAGER 2001 Service Manual Fig. 3 Body Side Moldings ± Premium Typical
1 - QUARTER PANEL
2 - FRONT FENDER
3 - POP-RIVET
4 - FENDER MOLDING
5 - POP-RIVET
6 - FASCIA7 - FRONT DOOR MOLDING
8 - SLIDING DOOR MOLDING
9 - QUARTER PAN

Page 3568 of 4284

CHRYSLER VOYAGER 2001 Service Manual Fig. 4 Body Side Moldings ± Luxury Typical
1 - QUARTER PANEL
2 - FRONT FENDER
3 - POP-RIVET
4 - FENDER MOLDING
5 - POP-RIVET
6 - FASCIA7 - FRONT DOOR MOLDING
8 - SLIDING DOOR MOLDING
9 - QUARTER PANE

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