2003 CHRYSLER VOYAGER door switch

EXTERIOR HANDLE
REMOVAL
(1) Roll door glass up.
(2) Remove the 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 (Fig. 11).
(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 holding outside door handle to
door outer panel.
(10) Remove outside door handle from vehicle.
INSTALLATION
If outside door handle replacement is necessary,
transfer lock cylinder from the original handle to the
new one.
(1) Place outside door handle in position on vehi-
cle.
(2) Install nuts attaching outside door handle to
door outer panel (Fig. 11). Tighten nuts to 6 N´m (50
in. lbs.).
(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 to hold VTSS switch
harness to inner door reinforcement bar, if equipped.
(8) Connect VTSS switch connector into door har-
ness, if equipped.
(9) Verify door latch operation.
(10) Install sound shield and door trim panel.
WINDOW REGULATOR -
POWER
REMOVAL
(1) Remove watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(2) Remove inner belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - REMOVAL)(3) Remove door glass. (Refer to 23 - BODY/DOOR
- FRONT/DOOR GLASS - REMOVAL).
(4) Disconnect wire connector from power window
motor.
(5) Loosen screws attaching front and rear window
guide rails to inner door panel.
(6) Remove screw heads on guide rails from key
hole slots in inner door panel.
(7) Loosen screws attaching motor/housing to inner
door panel.
(8) Remove regulator from inner door panel.
(9) Extract rear guide rail through inner door
panel rear access hole (Fig. 14).
(10) Extract front guide rail through front access
hole.
INSTALLATION
(1) Insert front guide rail through front access
hole.
(2) Insert rear guide rail through rear access hole.
(3) Place window regulator in position on inner
door panel.
(4) Place screw heads on guide rails in position
through key hole slots in inner door panel.
(5) Tighten screws to attach front and rear guide
rails to inner door panel to 8.5±10.7 N´m (75±95 in
lbs).
(6) Tighten screws to attach motor/housing to
inner door panel to 2.8 N´m (25 in lbs).
(7) Connect wire connector into power window
motor.
(8) Install door glass. (Refer to 23 - BODY/DOOR -
FRONT/DOOR GLASS - INSTALLATION)
(9) Verify door glass alignment and operation.
Fig. 14 FRONT DOOR POWER WINDOW - TYPICAL
1 - POWER WINDOW MOTOR
2 - FRONT DOOR
3 - GUIDE RAILS
23 - 22 DOOR - FRONTRS
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DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL.............................39
INSTALLATION.........................39
HINGE
REMOVAL.............................39
INSTALLATION.........................39
LATCH
REMOVAL.............................40
INSTALLATION.........................40
LATCH STRIKER
REMOVAL.............................40
INSTALLATION.........................40
LIFTGATE
REMOVAL.............................41
INSTALLATION.........................41
LIFTGATE SPOILER
REMOVAL.............................41INSTALLATION.........................41
LOCK CYLINDER
REMOVAL.............................41
INSTALLATION.........................41
SUPPORT CYLINDER
REMOVAL.............................42
INSTALLATION.........................42
TRIM PANEL
REMOVAL.............................42
INSTALLATION.........................43
SLAM BUMPER
REMOVAL
REMOVAL...........................43
REMOVAL - LIFTGATE SIDE.............43
INSTALLATION
INSTALLATION.......................43
INSTALLATION - LIFTGATE SIDE.........43
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 out screws and tighten to 20
N´m (15 ft. lbs.).
(3) Install the two inner bolts and tighten to 40
N´m (30 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.
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 (Fig. 1).
Tighten bolts to 33 N´m (24 ft. lbs.) torque.
(5) Align hinge to marks on roof header.
(6) Install bolts attaching liftgate hinge to roof
header. Tighten outer two bolts to 33 N´m (24 ft. lbs.)
torque. The sheet medal screw at center 12 N´m (105
in. lbs.)
(7) Remove duct tape from roof and liftgate.
RSDECKLID/HATCH/LIFTGATE/TAILGATE23-39
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CUP HOLDER
REMOVAL
(1) Remove the screw access cover from the bottom
of the center bezel.
(2) Remove the center bezel attaching screws.
(3) Using a trim stick (special tool #C-4755) or
equivalent, gently pry out on the edge of the instru-
ment panel center bezel. Hang off to the side leaving
the accessory switches connected.
(4) Pull the cup holder assembly rearward to dis-
engage the rear guide studs from instrument panel
(Fig. 2).
(5) Remove the cup holder assembly from lower
instrument panel.
INSTALLATION
(1) Ensure the cup holder assembly is in the closed
position. The cup holder assembly must be installed
as an assembly to ensure proper track position.
(2) Place the cup holder assembly into position in
the lower instrument panel and slide into opening
until the rear guide struts snap into place (Fig. 2).
(3) Install the center bezel.
(4) Install the center bezel attaching screws
(5) Install the screw access cover to the bottom of
the center bezel.
GLOVE BOX
REMOVAL
(1) Open glove box.
(2) Push in on sides of glove box bin and lower
door.
(3) Pivot glove box downward and disengage hinge
hooks from instrument panel.
(4) Remove glove box.
INSTALLATION
(1) Place glove box in position.
(2) Engage hinge hooks into instrument panel and
pivot glove box upward.
(3) Push in sides of glove box bin and snap glove
box assembly into instrument panel.
(4) Close glove box door.
GLOVE BOX LATCH
REMOVAL
(1) Open glove box.
(2) Push in on sides of glove box bin and lower
door.
(3) Pivot glove box downward and disengage hinge
hooks from instrument panel.
(4) Remove glove box.
(5) Remove the assembly screws.
(6) Disassemble the glove box.
(7) Separate the latch from the glove box assembly.
INSTALLATION
(1) Install the latch onto the glove box assembly.
(2) Assemble the glove box.
(3) Install the assembly screws.
(4) Engage hinge hooks into instrument panel and
pivot glove box upward.
(5) Push in sides of glove box bin and snap glove
box assembly into instrument panel.
(6) Close glove box door.
Fig. 2 CUP HOLDER
1 - LOWER INSTRUMENT PANEL
2 - CUP HOLDER AND TRACK
RSINSTRUMENT PANEL23-63
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GLOVE BOX LATCH STRIKER
REMOVAL
(1) Open glove box door.
(2) Remove screws holding lock striker to instru-
ment panel.
(3) Remove glove box latch striker.
INSTALLATION
(1) Install the glove box latch striker.
(2) Install the screws holding latch striker to
instrument panel.
(3) Close glove box door.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the lower console:
(a) Remove six retaining screws.
(b) Pull rearward and disconnect the auxiliary
power outlet.
(c) Remove lower console from vehicle.
(3) Remove the bolts attaching the lower supports
to the instrument panel frame (Fig. 3).
(4) Remove the bolts attaching the lower supports
to the floor pan.
(5) Disconnect the wire connectors from the Pas-
senger Airbag.
(6) Remove the two screws to each right and left
cowl trim covers.
(7) Remove the both left and right side A-pillar
trim covers using a trim stick (special tool #C-4755)
or equivalent gently pry out on the trim covers and
remove.
(8) Remove the glove box:
(a) Push in on sides of glove box bin and lower
door.
(b) Pivot glove box downward and disengage
hinge hooks from instrument panel.
(c) Remove glove box from vehicle.
(9) Disconnect the antenna lead connector from
behind the glove box.
(10) Remove the four screws to the lower steering
column cover.
(11) Remove the eight screws to the steering col-
umn backing plate.
(12) Unclip the Data Link Connector (DLC) from
the steering column backing plate.
(13) Disconnect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.(c) Five harness connectors.
(d) Driver airbag connector.
(14) Remove the two screws to the hood release
handle.
(15) Remove five screws to steering column back-
ing plate and remove (Refer to 23 - BODY/INSTRU-
MENT PANEL/KNEE BLOCKER - REMOVAL).
(16) Remove the two steering column shroud
retaining screws. Separate the shrouds and remove
from vehicle.
(17) Remove the screws attaching the instrument
panel reinforcement and remove (Fig. 4).
(18) Disconnect the steering column wiring. There
are seven connectors and then unclip the harness
from the column.
(19) Disconnect the Occupant Restraint Controller
(ORC) harness connector.
(20) Remove the four nuts retaining the steering
column to the dash panel steering column mounting
bracket and lower column to the floor (Fig. 5).
(21) Remove the four nuts attaching the instru-
ment panel to the brake pedal support bracket.
(22) Loosen the left side roll down bolt (Fig. 6).
(23) Remove the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(24) If equipped with a mechanical transmission
range indicator:
(a) Remove the indicator cable loop.
(b) Remove the clip holding gear shift cable end
to the gear selector adapter.
(c) Pull the cable end from gear selector.
(d) Disconnect the clip for the indicator cable
and guide tube from the shift cable bracket and
move out of the way.
(25) Remove the instrument panel top cover. Using
a trim stick or equivalent, gently pry up on the front
edge of the top cover, pull rearward and remove from
vehicle.
(26) Disconnect the right side wire connectors from
the HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(27) Remove the right end cover by pulling out-
board.
(28) Remove the right side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(29) Loosen the right side roll down bolt.
(30) Disconnect the two front window defroster
grid wire connectors. One on each side of vehicle.
(31) Remove both the left and right power mirrors:
(a) Using a trim stick or equivalent, gently pry
out on mirror trim cover.
(b) Open door and remove the three torx retain-
ing screws.
(c) Disconnect the wire connector and remove
mirror from the vehicle.
23 - 64 INSTRUMENT PANELRS
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(11) If equipped with a mechanical transmission
range indicator:
(a) Connect the clip for the indicator cable and
guide tube to the shift cable bracket.
(b) Install the cable end to the gear selector.
(c) Install the clip holding the gear shift cable
end to the gear selector adapter.
(d) Install the indicator cable loop.
(12) Tighten the left side roll down bolt.
(13) Install the four nuts attaching the instrument
panel to the brake pedal support bracket.
(14) Install the four nuts retaining the steering
column and lower to the floor (Fig. 5).
(15) Connect the Occupant Restraint Controller
(ORC) harness connector.
(16) Connect the steering column wiring. There
are seven connectors and then clip the harness to the
column.
(17) Install the screws attaching the instrument
panel reinforcement (Fig. 4).
(18) Connect the shrouds and install the two steer-
ing column shroud retaining screws.
(19) Install five screws to the left under column
instrument panel reinforcement brace.
(20) Install the two screws to the hood release
handle.
(21) Connect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.(c) Five harness connectors.
(d) Driver airbag connector.
(22) Clip the Data Link Connector (DLC) to the
steering column backing plate.
(23) Install the eight screws to the steering column
backing plate.
(24) Install the four screws to the lower steering
column cover.
(25) Install the glove box:
(a) Install glove box into the vehicle. Line up the
hinges and firmly snap together.
(b) Push in on sides of glove box bin and raise
door.
(26) Install the both left and right side A-pillar
trim covers. Position trim cover over slots and firmly
snap into place.
(27) Install the two screws to each right and left
cowl trim covers.
(28) Connect the wire connectors to the Passenger
Airbag.
(29) Install the bolts attaching the lower supports
to the floor pan.
(30) Install the bolts attaching the lower supports
to the instrument panel frame (Fig. 3).
(31) Install the lower console:
(a) Install lower console to vehicle.
(b) Connect the auxiliary power outlet.
(c) Install the six retaining screws.
(32) Connect the battery negative cable.
Fig. 6 INSTRUMENT PANEL REMOVAL
1 - INSTRUMENT PANEL
2 - FIVE ATTACHING SCREWS
3 - 13 mm BOLT - TWO ON EACH SIDE4 - ROLL DOWN BRACKET
5 - 10 mm BOLT - STARTING BOLT ONE EACH SIDE
23 - 66 INSTRUMENT PANELRS
INSTRUMENT PANEL ASSEMBLY (Continued)
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INSTRUMENT PANEL CENTER
BEZEL
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Insert the trim stick (special tool #C-4755) or
equivalent between access cover and center bezel
gently pry outward.
(3) Carefully pry the access cover from the instru-
ment panel (Fig. 7).
(4) Remove the two center bezel attaching screws.
(5) Using a trim stick or equivalent, gently pry out
on the edge of the instrument panel center bezel and
pull outward.
(6) Disconnect the wire connectors to the accessory
switches and HVAC control.
(7) Remove the instrument panel center bezel from
the vehicle.
INSTALLATION
(1) Place center bezel near opening and connect
the wire connectors to the accessory switches and
HVAC control.
(2) Position the center bezel over the retaining
slots and firmly snap the instrument panel center
bezel into place (Fig. 7).
(3) Install the two center bezel attaching screws.
(4) Install the screw access cover to the bottom of
the center bezel.
INSTRUMENT PANEL END CAP
REMOVAL
(1) Open passenger side front door.
(2) Using a trim stick, disengage clips holding end
cover to instrument panel (Fig. 8).
INSTALLATION
(1) Position end cover over retaining slots and
firmly snap into place (Fig. 8).
(2) Close passenger side front door.
INSTRUMENT PANEL TOP
COVER
REMOVAL
(1) Remove A-pillar trim. Using a trim stick (spe-
cial tool #C-4755) or equivalent, gently pry out and
remove.
(2) Using a trim stick, disengage clips attaching
rear edge of top cover to instrument panel (Fig. 9).
NOTE: The Instrument Panel Top Cover may be
hard to unsnap from the instrument panel. Be sure
not to mar, scuff, or damage the instrument panel
pad.
(3) Pull top cover rearward to disengage hooks
attaching front of top cover to instrument panel.
(4) Remove top cover from vehicle.
INSTALLATION
(1) Place instrument panel top cover in position on
vehicle (Fig. 9).
Fig. 7 INSTRUMENT PANEL CENTER BEZEL
1 - LOWER INSTRUMENT PANEL
2 - INSTRUMENT PANEL CENTER BEZEL
3 - CUPHOLDER
Fig. 8 INSTRUMENT PANEL END CAP
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL END CAP
RSINSTRUMENT PANEL23-67
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(6) Remove lower B-pillar trim cover from vehicle.
INSTALLATION
(1) Place lower B-pillar trim cover in position on
vehicle (Fig. 3).
(2) Insert seat belt through hole in lower B-pillar
trim.
(3) Engage hidden clips attaching lower trim cover
to B-pillar.
(4) Install access cover.
(5) Install upper B-pillar trim cover.
(6) Place seat belt anchor in position on floor so
webbing is pointed rearward and slightly outboard.
(7) Install bolt attaching lower seat belt anchor to
floor. Tighten all seat belt bolts to 39 N´m (29 ft. lbs.)
torque.
(8) Verify that seat belt anchor does not interfere
with seat track travel.
B-PILLAR UPPER TRIM
REMOVAL
(1) Remove bolt attaching lower seat belt anchor to
floor.
(2) Lower shoulder belt height adjuster to the bot-
tom of travel.
(3) Remove shoulder belt turning loop from height
adjuster.(4) Use a Snap-ontTrim Pad Remover tool
(A179A), or equivalent, and remove shoulder belt
height adjuster knob.
(5) Remove shoulder belt bezel from trim cover
(Fig. 3).
(6) Remove screw attaching trim cover to B-pillar
from inside bezel cavity.
(7) Disengage hidden clips attaching trim cover to
B-pillar.
(8) Remove B-pillar trim cover from vehicle.
INSTALLATION
(1) Insert seat belt through B-pillar trim and web
guide (Fig. 3).
(2) Place B-pillar trim cover in position on vehicle.
(3) Engage hidden clips attaching trim cover to
B-pillar.
(4) Install shoulder belt bezel into trim cover.
(5) Install height adjuster knob.
(6) Install shoulder belt turning loop onto height
adjuster. Tighten bolt to 39 N´m (29 ft. lbs.) torque.
(7) Place seat anchor in position on floor so web-
bing is pointed rearward and slightly outboard.
(8) Install bolt attaching lower seat belt anchor to
floor. Tighten seat belt bolt to 39 N´m (29 ft. lbs.)
torque.
CARPETS AND FLOOR MATS
REMOVAL
(1) Remove front seats. (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL)
(2) Remove front center console.
(3) Remove the remaining seats. Refer to the Own-
er's Manual for the proper procedures.
(4) Remove front cowl panels and sill plates.
(5) Remove sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(6) Remove the cargo organizer, if equipped.
(7) Remove liftgate scuff plate. (Refer to 23 -
BODY/INTERIOR/LIFTGATE SCUFF PLATE -
REMOVAL)
(8) Remove lower B-pillar trim covers.
(9) Remove D-pillar trim covers.
(10) Remove Quarter trim panels.
(11) Remove floor escutcheons (Fig. 4).
(12) Remove the floor console trays. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE TRAY -
REMOVAL)
(13) Remove push pin fasteners attaching carpet to
floor in front seat and rear area.
(14) Roll carpet from under instrument panel to
center of sliding door.
Fig. 3 LOWER B-PILLAR TRIM COVER
1 - B-PILLAR UPPER TRIM
2 - B-PILLAR UPPER PLUG
3 - POWER SLIDING DOOR SWITCH AND BEZEL
4 - BELT ASSEMBLY
5 - B-PILLAR LOWER TRIM
23 - 74 INTERIORRS
B-PILLAR LOWER TRIM (Continued)
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²air recirculation button. The Recirculate button
contains an LED that illuminates to show when the
function is in operation.
²an air conditioning button that allows the com-
pressor to be turned on/off. The Snowflake button
contains an LED that illuminates to shown when the
function is in operation.
²rotary knobs for front and rear fan speed selec-
tion.
²a rotary knob for mode control.
REAR CONTROL PANEL
A rear control panel centrally mounted on the
headliner has a rotary adjustment for temperature
and fan speed control of the rear unit by intermedi-
ate seat passengers when the front control rear knob
is set to the rear position.
DESCRIPTION - AUTOMATIC TEMPERATURE
CONTROL
The Automatic Temperature Control (ATC) allows
occupants to select a comfort temperature, which is
the perceived temperature level not the actual pas-
senger compartment air temperature.
The Automatic Temperature Control system
includes a dust and odor air filter. The filter element
is the same size as the air conditioning evaporator to
ensure ample capacity. A door at the base of the
heater and air conditioning housing below the glove
box provides easy access to the filter element.
The ATC computer utilizes integrated circuitry and
information carried on the Programmable Communi-
cations Interface (PCI) data bus network to monitor
many sensors and switch inputs throughout the vehi-
cle. In response to those inputs, the internal circuitry
and programming of the ATC computer allow it to
control electronic functions and features of the ATC
system. The inputs to the ATC computer are:
²Vehicle Speed/Engine RPM± The ATC com-
puter monitors engine RPM, vehicle speed and Man-
ifold Absolute Pressure information from the PCM.
²Coolant Temperature± ATC computer moni-
tors Coolant temperature received from the PCM and
converts it to degrees Fahrenheit.
²Ambient Temperature± ATC computer moni-
tors Ambient temperature from the Compass Mini
Trip Computer (CMTC) and converts it to degrees
Fahrenheit.
²Engine Miscellaneous Sensor Status±ATC
computer monitors A/C disable information from the
PCM.
²Refrigerant Pressure± ATC computer moni-
tors Barometric Pressure, Intake Air Temperature,
High Side Pressure and Methanol Content as broad-
cast by the PCM.²Door Ajar Status± The ATC computer moni-
tors Driver Front Door, Passenger Front Door, Left
Rear Door, Right Rear Door and Liftgate ajar infor-
mation, as identified by the Body Control Module
(BCM), to determine if all in-car temperatures should
be maintained.
²Dimming± The ATC computer monitors dim-
ming status from the BCM to determine the required
level of brightness and will dim accordingly.
²Vehicle Odometer± The ATC computer moni-
tors the vehicle odometer information from the BCM
to prevent flashing the VF tube icons if the manual
motor calibration or manual cool down tests have
failed. Flashing of the display icons will cease when
the vehicle odometer is greater than 3 miles.
²English/Metric± The ATC computer monitors
the English/Metric information broadcast by the
CMTC. The set temp displays for both the front and
rear control heads will be set accordingly.
²Vehicle Identification Number± The ATC
computer monitors the last eight characters of the
VIN broadcast by the PCM and compares it to the
information stored in EEPROM. If it is different, the
new number will be stored over the old one and a
motor calibration shall be initiated.
²A/C System Information± The ATC computer
will send a message for Evaporator Temperature too
Low, Fan Blower Relay status, Evaporator Sensor
Failure, Rear Window Defogger Relay and A/C Select.
FRONT CONTROL PANEL
The front control panel and integral computer is
mounted in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²A power button which allows the system to be
completely turned off. The display is blank when the
system is off.
²Three rocker switches that select comfort tem-
peratures from 15É to 30É C (59É to 85É F), which are
shown in the vacuum-fluorescent digital control dis-
play. If the set temp is 59 and the down button is
pressed, the set temp value will become 55 but the
display will show LO. If the set temp is 85 and the
up button is pressed, the set temp value will become
90 but the display will show HIGH. Temperatures
can be displayed in either metric or Fahrenheit,
which is controlled from the overhead console.
²A rocker switch that selects a cool-down rate.
LO-AUTO or HI-AUTO are displayed when the sys-
tem is in automatic operation.
²A defroster button which turns on the defroster
independently during full automatic control. A
defroster symbol illuminates in the display when the
button is pressed.
24 - 2 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)
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