2003 CHRYSLER VOYAGER Service Manual

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Page 1345 of 2177

CHRYSLER VOYAGER 2003 Service Manual (4) Insert muffler pipe into catalytic converter pipe
until the hangers are positioned as shown in (Fig. 11)
CAUTION: Band clamps should never be tightened
such that the two sides of the clamps are bo

Page 1346 of 2177

CHRYSLER VOYAGER 2003 Service Manual RESONATOR
REMOVAL
(1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER -
REMOVAL)
INSTALLATION
(1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER -
INSTALLATION)
RSEXHAUST SYSTEM11-9
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Page 1347 of 2177

CHRYSLER VOYAGER 2003 Service Manual ProCarManuals.com

Page 1348 of 2177

CHRYSLER VOYAGER 2003 Service Manual FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
FRONT BUMPER REIN

FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
FRONT BUMPER REINFORCEMENT
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................2
INSTALLATION..........................2
REAR BUMPER REINFORCEMENT
REMOVAL.............................3
INSTALLATION..........................3
REAR FASCIA - SCUFF PAD
REMOVAL.............................3INSTALLATION..........................4
FRAME
SPECIFICATIONS
FRAME DIMENSIONS...................4
SPECIFICATIONS - TORQUE.............4
FRONT CRADLE CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER.......................9
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR.........9
REMOVAL.............................9
INSTALLATION.........................11
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL.............................12
INSTALLATION.........................12
BUMPERS
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper reinforcement attaching nut 54 40 Ð
Rear bumper reinforcement attaching nut 27 20 Ð
FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - REMOVAL).
(3) Hoist vehicle and support with safety stands.
(4) Remove the five bolts attaching bottom of fas-
cia/air dam to radiator closure panel.
(5) Remove front wheels.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts attaching
front fascia to fender. (Refer to 23 - BODY/EXTERI-
OR/ WHEELHOUSE SPLASH SHIELD - REMOV-
AL).
(7) Remove the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1).
(8) Disconnect fog lamp wire connectors, if neces-
sary.
(9) Lower vehicle.(10) Remove two bolts attaching the upper grille
support to the headlamp mounting panel at each side
of the grille.
(11) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle.
(2) Install the two bolts attaching fascia to head-
lamp mounting panel at each side of grille.
(3) Hoist vehicle and support with safety stands.
(4) Install the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1). The fascia should
be flush to fender.
(5) Install front wheelhouse splash shields fasten-
ers. (Refer to 23 - BODY/EXTERIOR/ WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION).
(6) Install front wheels.
(7) Connect fog lamp wire connectors, if necessary.
(8) Install the five bolts attaching bottom of fascia
to radiator closure panel.
(9) Lower the vehicle.
RSFRAME & BUMPERS13-1
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Page 1349 of 2177

CHRYSLER VOYAGER 2003 Service Manual (10) Install the headlamp assemblies. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - INSTALLATION).
FRONT BUMPER
REINFORCEMENT
REMOVAL
(1) Remove front bumper fascia. (Refer to 13 -
FR

Page 1350 of 2177

CHRYSLER VOYAGER 2003 Service Manual (5) Install the six screws attaching rear fascia to
rear fascia brackets.
(6) Install the four plastic push pins attaching bot-
tom of rear fascia to fascia support.
(7) Lower vehicle.
(8) Install the

(5) Install the six screws attaching rear fascia to
rear fascia brackets.
(6) Install the four plastic push pins attaching bot-
tom of rear fascia to fascia support.
(7) Lower vehicle.
(8) Install the two screws attaching the upper fas-
cia to the fascia support.
REAR BUMPER
REINFORCEMENT
REMOVAL
(1) Remove rear bumper fascia. (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/REAR FASCIA -
REMOVAL)
(2) Support rear bumper reinforcement on a suit-
able lifting device.
(3) Remove the six nuts attaching rear bumper
reinforcement to frame rail extensions (Fig. 4).
(4) Remove rear bumper reinforcement from vehi-
cle.
INSTALLATION
(1) Support rear bumper reinforcement using a
suitable lifting device to lift into position.
(2) Position rear bumper reinforcement on vehicle.(3) Install the six nuts attaching rear bumper rein-
forcement to frame rail extensions and tighten to 27
N´m (20 ft. lbs.) torque (Fig. 4).
(4) Install rear bumper fascia. (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/REAR FASCIA -
INSTALLATION).
REAR FASCIA - SCUFF PAD
REMOVAL
The scuff pad may not be salvageable during the
removal process. The scuff pad should be replaced if
damaged or broken. Check availability before servic-
ing. The scuff pad serviceability is improved if the
rear fascia is to be removed for service.
NOTE: If the rear fascia is to be removed for other
service issues or If the scuff pad is to be reused
use the steps below.
(1) Remove rear bumper fascia.(Refer to 13 -
FRAMES & BUMPERS/BUMPERS/REAR FASCIA -
REMOVAL)
(2) Using a trim stick, pry up the rear edge of the
scuff pad while squeezing the rear locking tabs from
underneath the fascia to release the rear edge of
scuff pad from the rear bumper fascia. Pull the scuff
pad up and squeeze the remaining tabs to release the
remaining of the scuff pad. (Fig. 5).
Fig. 3 REAR BUMPER FASCIA
1 - REAR FASCIA
2 - PUSH PINS
3 - REAR BUMPER REINFORCEMENT
4 - REAR FASCIA BRACKET
Fig. 4 REAR BUMPER REINFORCEMENT
1 - REAR BUMPER REINFORCEMENT
2 - FRAME RAIL EXTENSIONS
3 - NUTS
RSFRAME & BUMPERS13-3
REAR FASCIA (Continued)
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Page 1351 of 2177

CHRYSLER VOYAGER 2003 Service Manual NOTE: If the rear fascia is to not to be removed for
other service issues use the step below.
(3) Using a trim stick, pry up the rear edge of the
scuff pad to release tabs from the rear bumper fascia

Page 1352 of 2177

CHRYSLER VOYAGER 2003 Service Manual Fig. 6 CROSSMEMBER DIMENSIONS
RSFRAME & BUMPERS13-5
FRAME (Continued)
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