2004 CHRYSLER VOYAGER tow

(6) Depress the spring feet clips on one side of the
sun shade.
(7) Remove sunshade.
INSTALLATION
(1) Place one side of the sunshade spring feet clips
into the top track U-frame.
(2) Depress the both releasing clips on the other
side to allow them to go into the top track U-frame.
(3) Move sunshade to the open position.
(4) Install water channel (Fig. 1).
(5) Verify that the sunshade move back and forth
properly.
(6) Cycle sunroof towards the closed position.
(7) Install glass panel (Refer to 23 - BODY/SUN-
ROOF/GLASS PANEL - INSTALLATION).
WIND DEFLECTOR
REMOVAL
(1) Fully open sunroof glass panel.
(2) Disconnect negative battery cable.
(3) Remove sunroof assembly (Refer to 23 - BODY/
SUNROOF/MODULE ASSEMBLY - REMOVAL).
(4) Depress the front deflector retaining tabs. (Fig.
2)
(5) Remove wind deflector.
INSTALLATION
(1) Place wind deflector arms in upward position
engage the wind deflector blade into the U-frame.
(2) Engage the retaining clips (Fig. 1).
(3) Verify wind deflector operation.
(4) Install the sun roof assembly (Refer to 23 -
BODY/SUNROOF/MODULE ASSEMBLY - INSTAL-
LATION).
WATER CHANNEL
REMOVAL
(1) Remove glass panel (Refer to 23 - BODY/SUN-
ROOF/GLASS PANEL - REMOVAL).
(2) Remove the retaining screws (Fig. 1).
(3) Carefully slide water channel forward to
release tabs from U-frame and remove from vehicle.
INSTALLATION
(1) Carefully place water channel onto U-frame
and slide it rearward to lock tabs (Fig. 1).
(2) Install the water channel attaching screws
(Fig. 1).
(3) Position glass panel on to mechanism lift arms.
(4) Start the glass attaching screws, and hand
tighten.
(5) Adjust sunroof glass (Refer to 23 - BODY/SUN-
ROOF/GLASS PANEL - ADJUSTMENTS).
(6) Verify sunroof operation and alignment.
SUNROOF MOTOR
REMOVAL
(1) Remove the sunroof (Refer to 23 - BODY/SUN-
ROOF/MODULE ASSEMBLY - REMOVAL).
(2) Remove the sunroof motor retaining bolts and
remove motor (Fig. 1).
INSTALLATION
CAUTION: THE SUNROOF MOTOR MUST BE TIMED
WITH THE SUNROOF ASSEMBLY. FAILURE TO DO
SO WILL RESULT IN IMPROPER SUNROOF OPERA-
TION AND POSSIBLE LEAKAGE OR DAMAGE TO
THE ASSEMBLY.
(1) Assure proper sunroof motor timing before
installation (Refer to 23 - BODY/SUNROOF/DRIVE
MOTOR - ADJUSTMENTS).
(2) Position the sunroof motor to the sunroof
assembly and install the retaining bolts (Fig. 1).
Tighten sunroof motor retaining bolts to 4.2Nm (40
lbs.in.).
Fig. 2 WIND DEFLECTOR
1 - Sun Roof
2 - Retaing Clip
3 - Sun Roof Assembly Trim
RSSUNROOF23 - 121
SUNSHADE (Continued)

(5) Install the sunroof motor and verify proper
sunroof operation (Refer to 23 - BODY/SUNROOF/
DRIVE MOTOR - INSTALLATION).
(6) Install the sunroof glass, leaving the retaining
bolts loose.
(7) Install the sunroof assembly into the vehicle
(Refer to 23 - BODY/SUNROOF/MODULE ASSEM-
BLY - INSTALLATION).
(8) Flush the sunroof glass into the vehicle roof
opening and check sunroof glass alignment (Refer to
23 - BODY/SUNROOF/GLASS PANEL - ADJUST-
MENTS).
SUNROOF SWITCH
REMOVAL
(1) Disconnect the negative battery cable.
(2) Separate the overhead console from the head-
liner, by carefully pulling down on the front portion,
toward the windshield, to release the retaining clips
(Fig. 6).
(3) Release the sunroof switch retaining tab, dis-
connect the electrical connector and remove the
switch from the console (Fig. 6).
INSTALLATION
(1) Position the switch against the overhead con-
sole and push the switch to seat properly in retaining
clip.(2) Install the overhead console.
(3) Connect the negative battery cable.
Fig. 6 OVERHEAD CONSOLE
1 - OVERHEAD CONSOLE
2 - POWER SUNROOF SWITCH
3 - SUNROOF SWITCH RETAINING CLIP (PART OF CONSOLE)
4 - OVERHEAD CONSOLE RETAINING CLIPS
RSSUNROOF23 - 123
SUNROOF MOTOR (Continued)

SEALER LOCATIONS
SPECIFICATIONS - BODY SEALING LOCATIONS
INDEX
DESCRIPTION FIGURE
METHODS OF APPLYING AUTO BODY SEALANT 5
LOWER WINDSHIELD OPENING - RIGHT AND LEFT SIDES 6
COWL SIDE - LEFT AND RIGHT SIDES 7
SIDE QUARTER WINDSHIELD OPENING - LEFT AND RIGHT SIDES 8
UPPER WINDSHIELD A-PILLAR - LEFT AND RIGHT SIDES 9
ROOF TRACK C-PILLAR - LEFT AND RIGHT SIDES 10
SLIDING DOOR UPPER FLANGE SEAMS - LEFT AND RIGHT SIDES 11
QUARTER PANEL EXTERIOR AREA - LEFT AND RIGHT SIDES 12
LOWER REAR EXTERIOR CORNER PANELS - LEFT AND RIGHT SIDES 13
LOWER SILL LIFT GATE OPENING - LEFT AND RIGHT SIDES 14
C-PILLAR CAN - LEFT AND RIGHT SIDES 15
SHOCK TOWER AREA - LEFT AND RIGHT SIDES 16
OUTER SHOCK TOWER AREA - LEFT AND RIGHT SIDES 17
CROSS MEMBER SUPPORT - LEFT AND RIGHT SIDES 18
A & B-PILLAR FLOOR PAN RISERS - LEFT AND RIGHT SIDES 19
REAR WHEEL HOUSE FLOOR PAN - LEFT AND RIGHT SIDES 20
REAR WHEELHOUSE TO FLOOR PAN - LEFT AND RIGHT SIDES 21
UPPER SLIDING DOOR FLANGE - LEFT AND RIGHT SIDES 22
UPPER LIFTGATE HINGE AREA - LEFT AND RIGHT SIDES 23
REAR BRACKET SUPPORT REAR HANGER - LEFT AND RIGHT SIDES 24
LIFTGATE PANEL OPENING - UNDERSIDE 25
D-PILLAR INSIDE SEAM - LEFT AND RIGHT SIDES 26
REAR TAIL LAMP AREA SEAMS - LEFT AND RIGHT SIDES 27
UPPER LIFTGATE PANEL SILL - LEFT AND RIGHT SIDES 28
FRONT WHEELHOUSE & SHOCK TOWER - LEFT AND RIGHT SIDES 29
REAR QUARTER WHEELHOUSE LIP & SEAT ANCHOR BOLT - LEFT AND RIGHT
SIDES30
TAIL LAMP CAN - LEFT AND RIGHT SIDES 31
B-PILLAR AND SILL AREAS - LEFT AND RIGHT SIDES 32
FRONT FLOOR PAN & RISER 33
FLOOR PAN SEAMS - LEFT AND RIGHT SIDES 34
FLOOR PAN & REAR WHEELHOUSE AREA - LEFT AND RIGHT SIDES 35
FLOOR PAN SILL & D-PILLAR SEAMS - LEFT AND RIGHT SIDES 36
LEFT SIDE SEAT ANCHOR REINFORCEMENT - SHORT WHEEL BASE ONLY 37
UNDERBODY - LEFT AND RIGHT SIDES 38
ROOF TOP JOINT & UPPER FRONT SLIDING DOOR - LEFT AND RIGHT SIDES 39
ROOF TOP JOINT & UPPER REAR SLIDING DOOR - LEFT AND RIGHT SIDES 40
23 - 130 BODY STRUCTURERS

Fig. 16 SHOCK TOWER AREA - LEFT AND RIGHT SIDES
Fig. 17 OUTER SHOCK TOWER AREA - LEFT AND RIGHT SIDES
23 - 138 BODY STRUCTURERS
SEALER LOCATIONS (Continued)

Fig. 28 UPPER LIFTGATE PANEL SILL - LEFT AND RIGHT SIDES
Fig. 29 FRONT WHEELHOUSE & SHOCK TOWER - LEFT AND RIGHT SIDES
23 - 144 BODY STRUCTURERS
SEALER LOCATIONS (Continued)

WELD LOCATIONS
SPECIFICATIONS - WELD LOCATIONS
INDEX
DESCRIPTION FIGURE
FRONT FENDER SHIELD - RIGHT 64
FRONT FENDER SHIELD - LEFT 65
STRUT TOWER AND REINFORCEMENTS - RIGHT 66
SUSPENSION RETAINERS AND REINFORCEMENTS - RIGHT 67
STRUT TOWER AND REINFORCEMENTS - LEFT 68
SUSPENSION RETAINERS AND REINFORCEMENTS - LEFT 69
FLOOR PAN REINFORCEMENTS - SIDE RAILS 70
REAR SUSPENSION BRACKETS 71
FLOOR PAN CROSS MEMBERS 72
SEAT REINFORCEMENTS - LONG WHEEL BASE ONLY 73
STRIKER REINFORCEMENTS - LONG WHEEL BASE ONLY 74
FUEL TANK MOUNTING/REAR SEAT AND SUSPENSION 75
REAR SUSPENSION HANGER BRACKETS - LONG WHEEL BASE 76
FRONT SEAT CROSS MEMBER 77
FLOOR PAN SIDE RAIL REINFORCEMENT 78
SILL BULKHEAD REINFORCEMENTS 79
FLOOR PAN CROSS MEMBER REINFORCEMENTS 80
FRONT SEAT CROSS MEMBER 81
SEAT REINFORCEMENT CROSS MEMBERS - SHORT WHEEL BASE 82
CENTER CONSOLE REINFORCEMENT - SHORT WHEEL BASE 83
REAR SUSPENSION HANGER BRACKETS - SHORT WHEEL BASE 84
LOWER LIFTGATE PANEL LATCH REINFORCEMENT 85
ENGINE MOUNTING PLATE AND TOW BRACKET 86
HEADLAMP MOUNTING PLATE 87
LOWER RADIATOR CROSS MEMBER BRACKETS 88
CROSS MEMBER EXTENSIONS 89
JACK MOUNTING BRACKET - LONG WHEEL BASE SHOWN, SHORT SIMILAR 90
FRONT SEAT CROSS MEMBER - LONG WHEELBASE ONLY 91
FRONT SEAT CROSS MEMBER - ALL WHEEL DRIVE ONLY 92
FUEL TANK SUPPORT CROSS MEMBERS - LONG WHEEL BASE ONLY 93
REAR SUPPORT AND TIRE STOWAGE CROSS MEMBERS - LONG WHEEL BASE
ONLY94
INNER SIDE SILLS - LONG WHEEL BASE ONLY 95
WHEELHOUSES, SIDE SILLS, SUSPENSION BRACKETS - LONG WHEEL BASE ONLY 96
REAR SEAT REINFORCEMENTS - SHORT WHEEL BASE ONLY 97
FUEL TANK SUPPORT AND TIRE STOWAGE - SHORT WHEEL BASE ONLY 98
INNER SIDE SILLS - SHORT WHEEL BASE ONLY 99
23 - 166 BODY STRUCTURERS

DESCRIPTION FIGURE
REAR SEAT REINFORCEMENTS - SHORT WHEEL BASE ONLY 100
CENTER CONSOLE REINFORCEMENT - SHORT WHEEL BASE ONLY 101
WHEELHOUSES - SHORT WHEEL BASE ONLY 102
FRONT SEAT CROSS MEMBER - SHORT WHEELBASE, ALL WHEEL DRIVE ONLY 103
FLOOR PAN SIDE RAIL - LONG WHEEL BASE ONLY 104
INNER BODY SIDE SILL REINFORCEMENTS 105
TOE BOARD CROSS MEMBER 106
FRONT SIDE RAIL - SHORT WHEEL BASE ONLY 107
DASH PANEL REINFORCEMENT 108
LOWER COWL PLENUM 109
UPPER COWL PLENUM SUPPORT 110
UPPER DASH PANEL 111
COWL SIDE PANELS 112
INSTRUMENT PANEL ATTACHMENT TAPPING PLATES 113
INSTRUMENT PANEL, DASH PANEL, ACM MODULE AND ACCELERATOR PEDAL 114
STRUT TOWER BRACKET AND COWL PLENUM 115
FRONT SIDE RAILS TO LOWER DASH PANEL 116
INNER BODY SIDE SILL TO LOWER DASH PANEL 117
FRONT HINGE TAPPING PLATE 118
FRONT HINGE PILLAR 119
INNER WINDSHIELD FRAME 120
WINDSHIELD FRAME 121
FENDER BRACKET 122
INNER B-PILLAR 123
STRIKER LATCH AND TAPPING PLATES 124
RIGHT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY 125
RIGHT REAR INNER QUARTER PANEL/OUTER WHEELHOUSE - LONG WHEEL BASE
ONLY126
RIGHT REAR BODY SIDE APERTURE - LONG WHEEL BASE ONLY 127
STRIKER LATCH REINFORCEMENT - LONG WHEEL BASE ONLY 128
BELT TAPPING PLATE - LONG WHEEL BASE ONLY 129
C-PILLAR REINFORCEMENT - LONG WHEEL BASE ONLY 130
OUTER WHEELHOUSE - LONG WHEEL BASE ONLY 131
C AND D-PILLAR INNER REINFORCEMENTS - LONG WHEEL BASE ONLY 132
LEFT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY 133
OUTER WHEELHOUSE EXTENSION - LONG WHEEL BASE ONLY 134
TAIL LAMP - LONG WHEEL BASE ONLY 135
SLIDING DOOR LATCH - LONG WHEEL BASE ONLY 136
ROOF BOW EXTENSION - LONG WHEEL BASE ONLY 137
RIGHT REAR INNER QUARTER PANEL - SHORT WHEEL BASE ONLY 138
LATCH REINFORCEMENT AND OUTER WHEELHOUSE - SHORT WHEEL BASE ONLY 139
D-PILLAR REINFORCEMENT - SHORT WHEEL BASE ONLY 140
RSBODY STRUCTURE23 - 167
WELD LOCATIONS (Continued)

DESCRIPTION FIGURE
LOWER COWL PLENUM, SUPPORT AND DASH PANEL - RIGHT HAND DRIVE 182
STEERING COLUMN REINFORCEMENT, BELT REINFORCEMENT AND DASH PANEL -
RIGHT HAND DRIVE183
INSTRUMENT PANEL TAPPING PLATE AND COWL SIDE PANEL - RIGHT HAND DRIVE 184
DASH PANEL AND BELT REINFORCEMENT - RIGHT HAND DRIVE 185
UPPER SUPPORT, UPPER REINFORCEMENT AND UPPER COWL PLENUM - RIGHT
HAND DRIVE186
UPPER SUPPORT, BRAKE PEDAL BRACKET REINFORCEMENT AND DASH PANEL -
RIGHT HAND DRIVE187
REINFORCEMENT, MOUNTING BRACKETS AND DASH PANEL - RIGHT HAND DRIVE 188
STRUT TOWER, COWL SIDE PANEL - RIGHT HAND DRIVE 189
REINFORCEMENTS, SIDE RAILS, COWL SIDE PANELS AND DASH PANEL - RIGHT
HAND DRIVE190
UPPER COWL PLENUM, GUSSETS, SIDE SHIELDS AND BODY SIDE APERTURE -
RIGHT HAND DRIVE191
SIDE GLASS ANTENNA TAPPING PLATE AND INNER BODY SIDE APERTURE - RIGHT
HAND DRIVE192
RSBODY STRUCTURE23 - 169
WELD LOCATIONS (Continued)