2004 CHRYSLER VOYAGER sunroof

C312 - GRAY (HEADLINER SIDE)
CAV CIRCUIT
1 M27 20YL/LB
2 M22 20YL/OR
3 G23 20VT/DB (EXCEPT BASE/SUN-
ROOF)
3 G23 22VT/DB (PREMIUM/LUXURY
SUNROOF)
4 G25 20VT/TN (EXCEPT BASE/SUN-
ROOF)
4 G25 22VT/TN (PREMIUM/LUXURY SUN-
ROOF)
5 D25 20WT/VT (EXCEPT BASE)
6 A114 20GY/RD (EXCEPT BASE)
7 F503 20WT/PK (EXCEPT BASE)
7 F503 20BK/PK (PREMIUM/LUXURY)
8-
9 P112 20BK/OR (PREMIUM/LUXURY)
10 P114 20BK/LB (PREMIUM/LUXURY)
11 M24 20YL/WT
12 Z837 20BK/OR
13 Z13 20BK/WT (EXCEPT BASE)
14 Z113 20BK/DB (EXCEPT BASE)
14 Z113 20BK (PREMIUM/LUXURY)
15 Q3 20OR/TN (SUNROOF)
16 Q4 20OR/YL (SUNROOF)
17 Q5 20OR/LB (SUNROOF)
18 -
19 -
20 -
C313 (REAR CONSOLE) - BLACK (BODY SIDE)
CAV CIRCUIT
1 Z747 18BK/LB
2 F307 18LB/PK
3 F307 18LB/PK
C313 (REAR CONSOLE) - BLACK (REAR CON-
SOLE SIDE)
CAV CIRCUIT
1 Z747 16BK
1 Z747 16BK
2 F307 18OR
3 F307 16RD
8W - 80 - 44 8W-80 CONNECTOR PIN-OUTSRS

C326 - YELLOW (SEAT SIDE)
CAV CIRCUIT
1-
2-
3 R33 18LG/WT
4 R31 18LG/OR
C327 - YELLOW (SAFETY SEAT SIDE)
CAV CIRCUIT
1-
2-
3 R34 18LB/WT (EXCEPT EXPORT)
3 R34 18WT/BK (EXPORT)
4 R32 18LB/OR (EXCEPT EXPORT)
4 R32 18DG/WT (EXPORT)
C327 - YELLOW (SEAT SIDE)
CAV CIRCUIT
1-
2-
3 R34 18LB/WT
4 R32 18LB/OR
C328 (SUNROOF) - (BODY SIDE)
CAV CIRCUIT
1 Q3 20OR/TN
2 Q5 20OR/LB
3 Q4 20OR/YL
4 F302 18GY/PK
5 A115 12YL/RD
6 Z138 12BK/DB
7-
C328 (SUNROOF) - (SUNROOF SIDE)
CAV CIRCUIT
1 Q3 20OR/TN
2 Q5 20OR/LB
3 Q4 20OR/YL
4 F302 18GY/PK
5 A115 14YL/RD
6 Z138 14BK/DB
7-
8W - 80 - 52 8W-80 CONNECTOR PIN-OUTSRS

SUNROOF MODULE (EXCEPT EXPORT) - BLACK 12 WAY
CAV CIRCUIT FUNCTION
1 Q3 20OR/TN SUNROOF VENT
2 Q5 20OR/LB SUNROOF CLOSE
3 Q4 20OR/YL SUNROOF OPEN
4 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
5 A115 14YL/RD FUSED B(+)
6 Z138 14BK/DB GROUND
7- -
8- -
9- -
10 - -
11 - -
12 - -
SUNROOF SWITCH (EXCEPT EXPORT) - NATURAL 4 WAY
CAV CIRCUIT FUNCTION
1 Q3 20OR/TN SUNROOF VENT
2 Q4 20OR/YL SUNROOF OPEN
3 Z137 20BK/DB GROUND
4 Q5 20OR/LB SUNROOF CLOSE
THATCHAM ALARM MODULE (UNITED KINGDOM) - BLACK 16 WAY
CAV CIRCUIT FUNCTION
1 A645 20RD/VT REAR INTRUSION SENSOR SIGNAL
2 G460 20DG/VT FRONT INTRUSION SENSOR SIGNAL
3 G22 20YL VTSS INDICATOR SUPPLY
4 D23 20WT/BR FLASH PROGRAM ENABLE
5- -
6 D96 20WT/LB SIREN SIGNAL CONTROL
7 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 Z109 20BK/GY GROUND
9 G945 20VT/DG SENSOR GROUND
10 G946 20LG/VT SENSOR GROUND
11 G922 20GY VTSS INDICATOR DRIVER
12 - -
13 D25 20WT/VT PCI BUS
14 - -
15 L91 20WT/DB HAZARD SWITCH SENSE
16 A114 18GY/RD FUSED B(+) (I.O.D.)
8W - 80 - 132 8W-80 CONNECTOR PIN-OUTSRS

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
C313 (Rear Console) BK At Rear Console 34
C314 BK Left Side Liftgate 49
C315 (Power Liftgate) BK Right Side Liftgate 49
C316 (Power Sliding Door) BK Wire Track to Sliding Door N/S
C317 (Power Sliding Door) BK Right Sliding Door 32, 45
C318 (Trailer Tow) BK Left Quarter N/S
C320 DKGY Driver Power Seat on Seat Harness N/S
C321 DKGY Under Passenger Seat N/S
C322 (Memory) BK On Seat Harness to Body 32
C324 (Manual Sliding Door) BK Left Sliding Door N/S
C325 (Manual Sliding Door) BK Right Sliding Door 32
C326 YL At Driver Side Airbag N/S
C327 YL At Passenger Side Airbag N/S
C328 (Sunroof) Left Quarter Panel 47
C329 (Diesel) BK Near Fuel Tank N/S
C330 (Diesel) LTGY Near Throttle Body 15, 16
C331 (Diesel) BK/GY Left Rear Engine Compartment N/S
C332 (3 Zone ATC) BK/LTGN Near T/O for Right Rear Lamp
AssemblyN/S
C333 (Except Export DKGY Left Side Instrument Panel 21
Cabin Heater Assist C1 (Diesel) BK Top of Engine N/S
Cabin Heater Assist C2 (Diesel) BK Top of Engine N/S
Camshaft Position Sensor (Gas) BK Rear of Cylinder Head
Right Side of Engine11 , 1 7
Camshaft Position Sensor
(Diesel)BK Rear of Cylinder Head 15, 16
CD Changer Behind CD Changer N/S
Center High Mounted Stop Lamp BK At Lamp 49
Clockspring - C1 WT Steering Column 20, 21, 22, 23, 31
Clockspring - C2 YL Steering Column 20, 21, 22, 23, 31
Clockspring - C3 BK Steering Column N/S
Clockspring - C4 BK Steering Column N/S
Clutch Pedal Interlock Switch BK At Switch/Driver Side 42
Clutch Pedal Upstop Switch
(Diesel)RD At Switch/Driver Side 42
Controller Anti-Lock Brake BK Right Side of Engine Compartment 11, 16, 17, 18
Crank Case Ventilation Heater
(Diesel)BK Top of Cylinder Head 15
Crankshaft Position Sensor
(Diesel)BK Rear of Engine 16
Crankshaft Position Sensor (Gas) BK Rear of Engine 13, 17
Data Link Connector WT Lower Instrument Panel Near
Steering Column41, 42
Dosing Pump (Diesel) BK Top of Engine N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-3
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Sentry Key Remote Entry Module
(Skreem)BK At Steering Column 20, 21, 22, 23, 31
Siren (United Kingdom) BK Left Front Body N/S
Speed Control Servo (Gas) BK Near Controller Antilock Brake 11, 17, 18
Sunroof Module (Except Export) BK At Sunroof N/S
Sunroof Switch (Except Export) Nat Near Overhead Console N/S
Thatcham Alarm Module C1
(United Kingdom)BK Top Right Side of Instrument Panel
Near SpeakerN/S
Throttle Position Sensor (Gas) GY On Throttle Body 10, 11, 17
Traction Control Switch BK Rear of Swtich 21, 22, 31
Trailer Tow Connector (Except
Export)BK Left Quarter Panel N/S
Transmission Range Sensor DKGY Top of Transmission 14, 19
Transmission Solenoid/Pressure
Switch AssemblyBK Side of Transmission 14, 18 19
Vehicle Speed Sensor (MTX) BK Rear of Transmission 16
Washer Fluid Level Switch BK Bottom of Reservoir 3
Washer Pump Motor BK Right Fender Well 3
Water in Fuel Sensor (Diesel) BK Left Rear Engine Compartment N/S
Wiper Module DKGY Left Side Cowl 6
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Body Ground Near Powertrain Control Module N/S
G101 Above Starter 13, 18
G102 Left Headlamp Area 1
G103 Above Starter 15
G200 Right Side of Instrument Panel 20, 24, 29
G201 Right Side of Instrument Panel 20, 24, 29
G202 Near Radio N/S
G300 Left B Pillar 32
G301 Right B Pillar 33, 39
G302 Left Rear Quarter 47
G303 Liftgate Ground 49
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
DESCRIPTION - VEHICLE IDENTIFICATION....1
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 1
DIAGNOSIS AND TESTING - WIND NOISE . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR........................3
STANDARD PROCEDURE - HEAT STAKING . 10
SPECIFICATIONS
TORQUE............................11
BODY LUBRICATION...................12
SPECIAL TOOLS
BODY..............................13DOOR - FRONT.........................14
DOORS - SLIDING.......................24
DECKLID/HATCH/LIFTGATE/TAILGATE.......40
EXTERIOR.............................45
HOOD.................................60
INSTRUMENT PANEL.....................63
INTERIOR..............................73
PAINT.................................84
SEATS................................86
STATIONARY GLASS....................108
WEATHERSTRIP/SEALS..................113
SUNROOF.............................116
BODY STRUCTURE.....................124
BODY
DESCRIPTION - VEHICLE IDENTIFICATION
Throughout this group, references to the
DaimlerChrysler Corporation vehicle family identifi-
cation code are used when describing a procedure
that is unique to that vehicle. Refer to Introduction
Group of this manual for detailed information on
vehicle identification. If a procedure is common to all
vehicles covered in this manual, no reference will be
made to a vehicle family code.
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE A OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL ± BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE THAT
IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use when
welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning solvents
on painted or upholstered surfaces. Damage to fin-
ish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
RSBODY23-1

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Lifgate stabilizer wedge striker to D-pillar bolts 3 Ð 30
Luggage rack crossbar fasteners 4 Ð 35
Lumbar support handle screw 1 Ð 9
Pivot bolt to the body half of hood hinge 28 21 Ð
Prop assembly to lifgate bolts 28 21 Ð
Rear door glass to regulator bolt 11 8 Ð
Rear door hinge to B-pillar bolt 28 20 Ð
Rear door hinge to door bolt 28 20 Ð
Rear door latch striker 28 20 Ð
Rear latch to sliding door end frame 28 20 Ð
Rear seat back to seat cushion bolt 27 19 Ð
Recliner to seat back frame 12 9 Ð
Seatback frame upper rail 8 Ð 71
Seatback hinge bolt 48 35 Ð
Seatback hinge cover screws 2.3 Ð 20
Shoulder belt turning loop onto height adjuster 39 29 Ð
Side view mirror bolts 10 Ð 85
Sliding door center hinge adjusting bolt 15 Ð 130
Sliding door glass nuts 3.4 Ð 30
Sliding door latch striker 28 21 Ð
Sliding door to roller arm bracket 12 9 Ð
Storage bin track guide to seat riser 3.5 Ð 31
Sunroof opening panel to lifter arm screws 5 44
Sunroof opening panel motor screws 4 35
Sunroof trough bracket to roof bolts 6 53
Sunroof trough to trough bracket bolts 6 53
Sunroof trough bracket bolts 6 53
Support cylinders to liftgate 28 21 Ð
BODY LUBRICATION
LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be
inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protection
against rust and wear. When performing other under
hood services, the hood latch release mechanism and
safety catch should be inspected, cleaned, and lubri-
cated. During the winter season, external door lock
cylinders should be lubricated to assure proper oper-
ation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating acomponent, any excess oil or grease should be
removed.LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
(1) Apply a small amount of lubricant directly into
the lock cylinder.
(2) Apply a small amount of lubricant to the key.
(3) Insert key into lock cylinder and cycle the
mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the
cylinder.
23 - 12 BODYRS
BODY (Continued)

SUNROOF
TABLE OF CONTENTS
page page
SUNROOF
DESCRIPTION........................116
DIAGNOSIS AND TESTING - SUNROOF.....116
DRAIN TUBE
REMOVAL............................119
INSTALLATION........................120
GLASS PANEL
REMOVAL............................120
INSTALLATION........................120
ADJUSTMENTS
SUNROOF GLASS PANEL ADJUSTMENT . . 120
SUNROOF ASSEMBLY
REMOVAL............................120
INSTALLATION........................120
SUNSHADE
REMOVAL............................120INSTALLATION........................121
WIND DEFLECTOR
REMOVAL............................121
INSTALLATION........................121
WATER CHANNEL
REMOVAL............................121
INSTALLATION........................121
SUNROOF MOTOR
REMOVAL............................121
INSTALLATION........................121
ADJUSTMENTS
ADJUSTMENT.......................122
SUNROOF SWITCH
REMOVAL............................123
INSTALLATION........................123
SUNROOF
DESCRIPTION
WARNING: Keep fingers and other body parts out
of sunroof opening at all times.
The sun roof features consists of: (Fig. 1)
²Sun roof glass
²Sun roof sun shade
The sunroof power sliding glass panel and sun-
shade can be positioned anywhere along its travel,
rearward of glass panel front edge.
The sunroof is electrically operated from a switch
located in the overhead console. To operate the sun-
roof the ignition switch must be in the Accessory or
On/Run position. Both switchs are a rocker style
design that open or close the sunroof. When pressing
and releasing the open button once, the sunroof will
express open to the comfort stop and the wind deflec-
tor will raise. If the button is pressed a second time,
the sunroof will continue to open to full travel unless
the button is released, at which time it will stop in
that position. Pressing and holding the close button
will close the sunroof. If the close button is released
before the glass fully closes, the sunroof will stop in
that position. The vent switch operates in a similar
manor. The sunroof will also operate for up to fifteenminutes after the ignition key is turned off for cus-
tomer comfort and convenance while parking.
DIAGNOSIS AND TESTING - SUNROOF
Refer to Sunroof Diagnostic Chart for possible
causes. Before beginning sunroof diagnostics verify
that all other power accessories are in proper operat-
ing condition. If not, a common electrical problem
may exist. Refer to Wiring Diagrams, in this publica-
tion for circuit, splice and component descriptions.
Check the condition of the circuit protection (20 amp
circuit breaker in the Junction Block). Inspect all
wiring connector pins for proper engagement and
continuity. Check for battery voltage at the power
sunroof controller, refer to Wiring Diagrams, for cir-
cuit information. If battery voltage of more than 10
volts is detected at the controller, proceed with the
following tests (the controller will not operate at less
than 10 volts).
Before beginning diagnosis for wind noise or water
leaks, verify that the problem was not caused by
releasing the control switch before the sunroof was
fully closed. The sunroof module has a water-man-
agement system. If however, the sunroof glass is in a
partial closed position, high pressure water may be
forced beyond the water management system bound-
aries and onto the headlining.
23 - 116 SUNROOFRS