2002 CHRYSLER VOYAGER wheel

EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL.............................44
INSTALLATION.........................45
COWL GRILLE
REMOVAL.............................50
INSTALLATION.........................50
EXTERIOR NAME PLATES - TAPE ATTACHED
REMOVAL.............................50
INSTALLATION.........................51
EXTERIOR NAME PLATES - ADHESIVE
ATTACHED
REMOVAL.............................51
INSTALLATION.........................51
FRONT FENDER
REMOVAL.............................51
INSTALLATION.........................51
FUEL FILL DOOR
REMOVAL.............................52
INSTALLATION.........................52
FUEL FILL DOOR BLOCKER LATCH
REMOVAL.............................52
INSTALLATION.........................52
FUEL FILL DOOR BLOCKER LATCH STRIKER
REMOVAL.............................53
INSTALLATION.........................53
FUEL FILL DOOR BLOCKER LOCKOUT LINK
REMOVAL.............................53INSTALLATION.........................54
GRILLE OPENING REINFORCEMENT
REMOVAL.............................54
INSTALLATION.........................54
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL.............................55
INSTALLATION.........................55
LUGGAGE RACK RISER
REMOVAL.............................55
INSTALLATION.........................56
LUGGAGE RACK CROSSBAR
REMOVAL.............................56
INSTALLATION.........................57
REAR QUARTER PANEL/FENDER AIR
EXHAUSTER
DESCRIPTION.........................57
REMOVAL.............................57
INSTALLATION.........................58
ROOF JOINT MOLDING
REMOVAL.............................58
INSTALLATION.........................58
SIDE VIEW MIRROR
REMOVAL.............................58
INSTALLATION.........................58
SIDE VIEW MIRROR GLASS
REMOVAL.............................59
INSTALLATION.........................59
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.
23 - 44 EXTERIORRS
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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 MopartSuper
Kleen, or equivalent.
(c) Wipe molding dry with lint free cloth.
(d) Apply a single coat of MopartTPO 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 MopartSuper 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.
(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 edge to
wheelhouse lip, if necessary.
Fig. 1 BODY SIDE MOLDINGS - BASE TYPICAL
1 - GUIDE PINS
2 - FRONT DOOR MOLDING3 - SLIDING DOOR MOLDING
4 - QUARTER PANEL MOLDING
RSEXTERIOR23-45
BODY SIDE MOLDINGS (Continued)
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FRONT WHEELHOUSE
SPLASH SHIELD
REMOVAL
(1) Hoist and support vehicle on safety stands.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE).
(2) Remove front wheel.
(3) Remove push pin fasteners attaching splash
shield to frame rail forward of suspension.
(4) Remove push pin fasteners attaching splash
shield to frame rail rearward of suspension.
(5) Remove screws attaching wheelhouse splash
shield to front fender and front bumper fascia.
(6) Remove splash shield from vehicle (Fig. 15).
INSTALLATION
(1) Place splash shield in position on vehicle (Fig.
15).
(2) Install push pin fasteners attaching splash
shield to frame rail forward of suspension.
(3) Install push pin fasteners attaching splash
shield to frame rail rearward of suspension.
(4) Install screws attaching wheelhouse splash
shield to front fender.
(5) Install front wheel.
(6) Lower vehicle.
LUGGAGE RACK RISER
REMOVAL
(1) Remove two fasteners from the front riser.
Gently pull up on the luggage rack side rail and
detach the riser snap to remove riser from the rail
(Fig. 16).
(2) Repeat for the opposite side, if necessary.
(3) Remove front riser(s) from vehicle (Fig. 17).
Fig. 15 FRONT WHEELHOUSE SPLASH SHIELD
1 - FRONT FENDER WHEELHOUSE SPLASH SHIELD
2 - PUSH PIN FASTENERS
3 - ACCESSORY DRIVE SPLASH SHIELD
4 - SCREWSFig. 16 LUGGAGE RACK RISER COVER
1 - FRONT RISER COVER
2 - LOCK TABS
3 - LUGGAGE RACK SIDE RAIL
4 - FRONT RISER
RSEXTERIOR23-55
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INSTALLATION
NOTE: The crossbar assemblies are designed to be
installed in only one way. Check top and bottom
surfaces of the crossbar for the word FRONT and
directional arrows. The directional arrows must
point toward the front of the vehicle.
(1) Place crossbar in position on vehicle.
(2) Work from side to side sliding the crossbar
assembly back a little at a time to ensure it remains
perpendicular to the side rails.
(3) Position first crossbar assembly crossbar at the
second most rearward locator holes. Press the top of
the stanchion lever to lock it into position.
(4) Position the second crossbar assembly in the
second hole from the front. Lock into place.
(5) Place luggage rack riser into position.
(6) Install two fasteners into riser. Tighten fasten-
ers to 4 mm (35 in. lbs.) torque.
REAR QUARTER PANEL/
FENDER AIR EXHAUSTER
DESCRIPTION
Air exhausters, designed to conform to the body
structure, allow air entering at the front of the vehi-
cle to flow out the back. By reducing air pressure
within the vehicle, the exhausters also reduce blower
noise at any given air flow level compared to operat-
ing without them and help reduce door closing effort.
They are located in the lower rear comers of the
body.
REMOVAL
SHORT WHEELBASE
(1) Remove the rear fascia from the body. (Refer to
13 - FRAMES & BUMPERS/BUMPERS/REAR FAS-
CIA - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 19).
(3) Remove the air exhauster from the hole in the
lower aperture panel.
LONG WHEELBASE
NOTE: Models with the optional rear heater and air
conditioner do not have an air exhauster on the
right side of the vehicle, but have a plastic plug
installed in the right lower aperture panel. This plug
is removed using the same procedure used toremove the air exhauster from the short wheelbase
model. Refer to SHORT WHEELBASE .
(1) Remove the quarter trim panel from the inside
of the left or right quarter inner panel (Refer to 23 -
BODY/INTERIOR/RIGHT QUARTER TRIM PANEL
- REMOVAL) or (Refer to 23 - BODY/INTERIOR/
LEFT QUARTER TRIM PANEL - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 20).
(1) Remove the air exhauster from the hole in the
lower aperture panel.
Fig. 19 AIR EXHAUSTER - SWB
1 - LOWER APERTURE PANEL
2 - AIR EXHAUSTER
Fig. 20 AIR EXHAUSTER - LWB
1 - AIR EXHAUSTER
2 - PLUG
3 - LOWER APERTURE PANEL
RSEXTERIOR23-57
LUGGAGE RACK CROSSBAR (Continued)
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INSTALLATION
SHORT WHEELBASE
(1) Position the air exhauster to the hole in the
lower aperture panel (Fig. 19).
(2) Using hand pressure, press the air exhauster
into the opening in the lower aperture panel until
the snap features are fully engaged.
(3) Reinstall the rear fascia onto the body. (Refer
to 13 - FRAMES & BUMPERS/BUMPERS/REAR
FASCIA - INSTALLATION).
LONG WHEELBASE
NOTE: Models with the optional rear heater and air
conditioner do not have an air exhauster on the
right side of the vehicle, but have a plastic plug
installed in the right lower aperture panel. This plug
is installed using the same procedure used to
install the air exhauster onto the short wheelbase
model. Refer to SHORT WHEELBASE .
(1) Position the air exhauster to the hole in the
lower aperture panel (Fig. 20).
(2) Using hand pressure, press the air exhauster
into the opening in the lower aperture panel until
the snap features are fully engaged.
(3) Reinstall the quarter trim panel onto the inside
of the left or right quarter inner panel. (Refer to 23 -
BODY/INTERIOR/RIGHT QUARTER TRIM PANEL
- INSTALLATION) or (Refer to 23 - BODY/INTERI-
OR/LEFT QUARTER TRIM PANEL - INSTALLA-
TION).
ROOF JOINT MOLDING
REMOVAL
The RAP molding is set with body side molding
tape. The temperature in the work area and the vehi-
cle should be at least 21É C (70É F) to avoid damag-
ing the RAP moldings.
(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) Pull stick-on molding from painted surface.(3) Remove adhesive tape residue from painted
surface of vehicle. Use a 3M Scotch-BriteŸ Molding
Adhesive and Stripe Removal Discs, or equivalent, to
clean adhesive residue from painted surfaces. The
adhesive removal discs are available from automotive
paint suppliers. Refer to instructions supplied with
the discs for proper usage.
INSTALLATION
The RAP molding is set with body side molding
tape. The temperature in the work area and the vehi-
cle should be at least 21É C (70É F) to avoid damag-
ing the RAP moldings.
(1) If molding is to be reused;
(a) Remove tape residue from molding.
(b) Clean back of molding with MopartSuper
Kleen solvent, or equivalent.
(c) Wipe molding dry with lint free cloth.
(d) Apply new body side molding (two sided
adhesive) tape to back of molding.
(2) Clean body surface with MopartSuper Kleen
solvent, 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 of vehicle to
rear.
(5) Using a roller tool, roll molding onto body
panel with enough force to assure adhesion and not
bend roof panels.
SIDE VIEW MIRROR
REMOVAL
(1) Using a trim stick or equivalent, remove the
trim cover (Fig. 21).
(2) Remove the bolts.
(3) Remove 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. 21).
(3) Install the bolts.
(4) Install the trim cover.
23 - 58 EXTERIORRS
REAR QUARTER PANEL/FENDER AIR EXHAUSTER (Continued)
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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.
Fig. 3 INSTRUMENT PANEL CENTER STACK RIGHT
& LEFT REINFORCEMENTS
1 - INSTRUMENT PANEL
2 - CENTER STACK RIGHT & LEFT REINFORCEMENT
Fig. 4 INSTRUMENT PANEL LEFT SILENCER
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL LEFT SILENCER
Fig. 5 INSTRUMENT PANEL LOWER
REINFORCEMENT
1 - LOWER RIGHT REINFORCEMENT
2 - STEERING WHEEL ASSEMBLY
3 - INSTRUMENT PANEL LOWER REINFORCEMENT
Fig. 6 STEERING COLUMN MOUNTING BRACKET
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL STEERING BRACKET
3 - DASH PANEL REINFORCEMENT
4 - DASH PANEL STEERING COLUMN MOUNTING BRACKET
23 - 66 INSTRUMENT PANELRS
INSTRUMENT PANEL ASSEMBLY (Continued)
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(12) If equipped, install overhead console.
(13) Install liftgate opening header trim.
(14) Install D-pillar trim covers.
(15) Install C-pillar upper trim covers.
(16) Install B-pillar upper trim covers.
(17) Install A-pillar trim covers.
LEFT 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
lower anchor to quarter on short wheel base vehicle.
(5) Disengage hidden clips attaching trim to D-pil-
lar.
(6) Disconnect speaker wire connector, if equipped.
(7) Pass seat belt through slot in D-pillar trim
panel on short wheel base vehicle.
(8) Remove D-pillar trim from vehicle.
INSTALLATION
(1) Pass seat belt through slot in D-pillar trim
panel on short wheel base vehicle.
(2) Position D-pillar trim panel on vehicle.
(3) Connect speaker wire connector to speaker, if
equipped.
(4) Align locating pins on backside of trim panel to
mating holes in inner quarter panel.(5) Engage hidden clips attaching trim to D-pillar.
(6) Install bolt attaching second row seat belt
lower anchor to quarter on short wheel base vehicle.
Tighten all seat belt bolts to 39 N´m (29 ft. lbs.).
(7) Install second row seat belt turning loop on
long wheel base vehicle.
(8) Install liftgate sill plate.
(9) Install rear header trim cover.
LIFTGATE SILL PLATE
REMOVAL
(1) Disengage hidden clips holding sill plate to lift-
gate door opening sill (Fig. 9).
(2) Remove sill plate from vehicle.
INSTALLATION
(1) Place sill plate in position on vehicle.
(2) Align engage hook tabs at end of liftgate sill
plate to D-pillar trim.
(3) Engage hidden clips to hold sill plate to liftgate
door opening sill.
QUARTER TRIM BOLSTER
REMOVAL
The speaker grille in the quarter trim panel is not
removable. The trim panel must be removed to ser-
vice the speaker.
(1) Disengage hidden clips attaching trim bolster
to quarter trim panel.
(2) Remove quarter trim panel from vehicle.
INSTALLATION
The speaker grille in the quarter trim bolster is
not removable. The trim bolster must removed to ser-
vice the speaker.
(1) Place quarter trim bolster in position on vehi-
cle.
Fig. 8 HEADLINING
1 - ROOF
2 - OVERHEAD CONSOLE BRACKET
3 - HEADLINING ASSEMBLY
Fig. 9 LIFTGATE SILL PLATE
1 - LIFTGATE SILL PLATE
2 - LIFTGATE SILL
RSINTERIOR23-77
HEADLINER (Continued)
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(2) Engage hook retainer attaching front of trim
bolster to quarter trim panel, if applicable.
(3) Engage hidden clips attaching trim bolster to
quarter trim panel.
RIGHT QUARTER TRIM PANEL
REMOVAL
CAUTION: Disconnect the battery negative cable.
Damage to accessory feed circuit can result.
(1) Remove first row seat.
(2) Remove second row seat.
(3) Remove sliding door sill trim panel.
(4) Remove quarter trim bolster.
(5) Remove D-pillar trim panel.
(6) Remove first row seat belt anchor.
(7) Remove second row seat belt anchor.
(8) Remove screws attaching quarter trim to quar-
ter panel from bolster area.
(9) Remove screws attaching rear edge of quarter
trim to attaching bracket.
(10) Disengage hidden clips attaching front of
quarter trim to quarter panel rearward of sliding
door opening and at locators.
(11) Remove quarter trim from quarter panel.
(12) Disconnect speaker wire connector on LWB
quarter trim panel with rear air conditioning.
(13) Pass second row seat belt through slot in trim
panel on long wheel base vehicle.
(14) Pass first row seat belt through slot in trim
panel.
(15) Remove quarter trim panel from vehicle.
INSTALLATION
(1) Position quarter trim panel on vehicle.
(2) Pass first row seat belt through slot in trim
panel.
(3) Pass second row seat belt through access hole
in trim panel on long wheel base vehicle.
(4) Connect wire connector into speaker on LWB
with rear air conditioning.
(5) Align locating pins on backside of trim panel to
mating holes in inner quarter panel.
(6) Engage hidden clips attaching front of quarter
trim to quarter panel rearward of sliding door open-
ing and at locators.
(7) Install screws attaching rear edge of quarter
trim to attaching bracket.
(8) Install screws attaching quarter trim to inner
quarter panel in bolster area.
(9) Install second row seat belt anchor on long
wheel base vehicle. Tighten all seat belt bolts to 39
N´m (29 ft. lbs.) torque.
(10) Install first row seat belt anchor.(11) Install D-pillar trim panel.
(12) Install C-pillar trim panel.
(13) Install quarter trim bolster.
(14) Install sliding door sill trim panel.
(15) Install second row seat, if equipped.
(16) Install first row seat.
(17) Connect the battery negative cable.
LEFT QUARTER TRIM PANEL
REMOVAL
CAUTION: Disconnect the negative cable clamp
from battery post. Damage to accessory feed circuit
can result.
(1) Remove first row seat.
(2) Remove second row seat, if equipped.
(3) Remove front door sill plate on three door vehi-
cle.
(4) Remove sliding door sill plate on four door
vehicle.
(5) Remove left quarter trim bolster.
(6) Remove C-pillar trim panel.
(7) Remove left D-pillar trim panel.
(8) Remove first row seat belt anchor.
(9) Remove second row seat belt anchor on long
wheel base vehicle.
(10) Remove screws attaching quarter trim to
quarter panel from bolster area.
(11) Remove screws attaching rear edge of quarter
trim to attaching bracket or inner quarter trim
panel.
(12) Disconnect wire connector from accessory
power outlet, if equipped.
(13) Remove quarter trim from quarter panel.
(14) Pass front seat belt and turning loop through
slot in quarter trim panel on three door vehicle.
(15) Pass first row seat belt through slot in quar-
ter trim panel.
(16) Pass second row seat belt, if equipped,
through slot in quarter trim panel on long wheel
base vehicle.
(17) Remove quarter trim panel from vehicle.
INSTALLATION
(1) Position quarter trim panel on vehicle.
(2) Pass second row seat belt, if equipped, through
slot in quarter trim panel on long wheel base vehicle.
(3) Pass first row seat belt through slot in quarter
trim panel.
(4) Connect wire connector into accessory power
outlet, if equipped.
(5) Align locating pins on backside of trim panel to
mating holes in inner panels.
23 - 78 INTERIORRS
QUARTER TRIM BOLSTER (Continued)
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