2004 CHRYSLER VOYAGER Service Manual

auxiliary battery cruise control water pump height adjustment CD changer center console

Page 2145 of 2585

CHRYSLER VOYAGER 2004 Service Manual (3) Remove screw from pull cup.
(4) Disengage push-in fasteners holding trim to
door panel around perimeter and upper edge of door
(Fig. 20).
(5) Remove sliding door trim panel from vehicle.
INSTALLAT

(3) Remove screw from pull cup.
(4) Disengage push-in fasteners holding trim to
door panel around perimeter and upper edge of door
(Fig. 20).
(5) Remove sliding door trim panel from vehicle.
INSTALLATION
(1) Place sliding door trim panel in position on
vehicle.
(2) Align locating pins on backside of trim panel to
mating holes in the inner door panel.
(3) Engage push-in fasteners to hold trim to door
panel around perimeter and upper edge of door (Fig.
20).
(4) Install pull cup screw.
(5) If necessary, install screw from inside ash
receiver bezel on left sliding door trim panel.
(6) Install sliding door upper frame molding.
INSIDE LATCH HANDLE
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove screws attaching bottom of inside latch
handle to sliding door (Fig. 21).(3) Remove two screw attaching top of inside latch
handle to sliding door.
(4) Remove latch handle from sliding door.
(5) Disengage cable end from clip on release han-
dle mechanism.
(6) Disengage cable end from release handle mech-
anism.
(7) Remove push pin fastener attaching cable end
to release handle.
(8) Disengage cable casing end from release handle
(Fig. 22).
(9) Disengage cable end from latch handle.
(10) Remove handle from vehicle.
INSTALLATION
(1) Place inside latch handle in position on vehicle.
(2) Engage cable end into latch handle.
(3) Engage cable casing end into release handle.
(4) Install push pin fastener to hold cable into
release handle.
(5) Engage cable end into release handle mecha-
nism.
(6) Engage clip to hold cable end into release han-
dle mechanism.
(7) Place latch handle in position on sliding door.
(8) Install screw to hold top of inside release han-
dle to sliding door.
(9) Install screws to hold bottom of inside latch
handle to sliding door.
(10) Verify sliding door operation. Adjust as neces-
sary. (Refer to 23 - BODY/DOORS - SLIDING/SLID-
ING DOOR - ADJUSTMENTS)
Fig. 20 SLIDING DOOR TRIM PANEL
1 - PUSH-IN FASTENERS
2 - SLIDING DOOR UPPER FRAME MOLDING
3 - SLIDING DOOR TRIM PANEL
4 - PUSH-IN FASTENERS
5 - PUSH-IN FASTENERS
6 - SLIDING DOOR
Fig. 21 SLIDING DOOR INSIDE HANDLE
1 - INSIDE ASSIST HANDLE
2 - INSIDE RELEASE HANDLE CABLE
3 - ATTACHING SCREWS
23 - 34 DOORS - SLIDINGRS
TRIM PANEL (Continued)

Page 2146 of 2585

CHRYSLER VOYAGER 2004 Service Manual (11) Install sliding door trim panel.(Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
BELLCRANK
REMOVAL
(1) Remove stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - REMOVA

(11) Install sliding door trim panel.(Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
BELLCRANK
REMOVAL
(1) Remove stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - REMOVAL).
(2) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel as necessary to gain
access to latch bellcrank.
(4) Disengage lock link (Fig. 23).
(5) Disengage link and sleeve
(6) Remove bellcrank by rotating bellcrank to
release it from door.
(7) Remove bellcrank from vehicle.
INSTALLATION
(1) Position bellcrank on vehicle.
(2) Rotate bellcrank into position.
(3) Place lock link into position and engage clip
(Fig. 23).
(4) Place link and sleeve into position and engage
clip.
(5) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(6) Install sliding door trim panel (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION).(7) Install stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - INSTALLA-
TION).
OUTSIDE HANDLE
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel as necessary to access
outside release handle fasteners.
(4) Disengage clip attaching outside door handle
linkage to door cable.
(5) Remove linkage from outside door handle.
(6) Remove three nuts attaching outside door han-
dle to outer door panel (Fig. 24).
(7) Remove outside door handle from vehicle.
INSTALLATION
(1) Position outside door handle on vehicle.
(2) Install nuts attaching outside door handle to
outer door panel.
(3) Engage clip attaching linkage to outside door
handle.
(4) Engage rigging cam to latch/lock control mech-
anism.
(5) Move clip on latch/lock control to bottom of slot
and engage linkage to latch/lock control.
Fig. 22 RELEASE HANDLE CABLE
1 - ASSIST HANDLE MECHANISM
2 - SLIDING DOOR INSIDE ASSIST HANDLE
3 - RELEASE HANDLE CABLE
Fig. 23 BELLCRANK
1 - OUTSIDE HANDLE
2 - OUTSIDE HANDLE BRACKET ATTACHING NUT
3 - LOCK KNOB
4 - LATCH LINK
5 - LOCKING LINK
6 - DOOR LOCKING LEVER (BELLCRANK)
RSDOORS - SLIDING23-35
INSIDE LATCH HANDLE (Continued)

Page 2147 of 2585

CHRYSLER VOYAGER 2004 Service Manual (6) Verify sliding door operation. Adjust as neces-
sary.
(7) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(8) Install sliding

Page 2148 of 2585

CHRYSLER VOYAGER 2004 Service Manual (9) Verify sliding door alignment and operation.
Adjust as necessary. (Refer to 23 - BODY/DOORS -
SLIDING/SLIDING DOOR - ADJUSTMENTS)
OUTSIDE HANDLE CABLE
REMOVAL
NOTE: For power sliding door procedur

(9) Verify sliding door alignment and operation.
Adjust as necessary. (Refer to 23 - BODY/DOORS -
SLIDING/SLIDING DOOR - ADJUSTMENTS)
OUTSIDE HANDLE CABLE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - REMOVAL).
(3) Remove the appropriate side door trim panel.
(Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - REMOVAL)
(4) Peel watershield away from adhesive around
perimeter of inner door panel.
CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
(5) Trace the outside handle cable along its routing
path and disconnect from its retaining clips.
(6) Disconnect the outside handle cable from the
latch assembly. Gently pry cable sleeve retainer out
of the latch mounting bracket and then unhook
swedged cable end from the latch link.
(7) Disconnect the outside handle cable from the
handle assembly. Gently pry cable sleeve retainer out
of the handle bracket and then unhook swedged
cable end from the handle link.
(8) Remove the outside handle cable from the side
door.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Match the replacement cable up against the old
cable to verify the correct part.
(2) Position the outside handle cable on the side
door.
(3) Connect the outside handle cable on the handle
assembly. Hook the swedged cable end on the handle
link and gently push the cable sleeve retainer in the
handle bracket.NOTE: The outside handle cable is marked with red
tape. It must be attached to the latch at the lowest
point. This is marked with a ªRº on the latch.
(4) Connect the outside handle cable on the latch
assembly. Hook the swedged cable end on the latch
link and gently push the cable sleeve retainer in the
latch bracket.
(5) Trace the outside handle cable along its routing
path and install on its retaining clips and position
foam insulators. Use previously made schematic as a
guide or remove the opposite side door trim panel
and use that door as a guide.
CAUTION: Be certain replacement cable is routed
and retained correctly and foam insulators are
properly positioned.
(6) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(7) Install the appropriate side door trim panel on
the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - INSTALLATION)
(8) Install stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - INSTALLA-
TION).
(9) Connect the negative battery cable.
INSIDE HANDLE CABLE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate side door trim panel
from the vehicle. (Refer to 23 - BODY/DOORS -
SLIDING/TRIM PANEL - REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
(4) Remove the inside handle assembly from the
side door. (Refer to 23 - BODY/DOORS - SLIDING/
INSIDE LATCH HANDLE - REMOVAL)
(5) Disconnect the inside handle cable from the
handle assembly. Gently pry cable sleeve retainer out
of the handle bracket and then unhook swedged
cable end from the handle link.
(6) Open the side door and remove the latch
assembly. Refer to the Power Side Doors section for
the procedure.
RSDOORS - SLIDING23-37
UPPER HINGE (Continued)

Page 2149 of 2585

CHRYSLER VOYAGER 2004 Service Manual CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
(7) Trac

CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
(7) Trace the inside handle cable along its routing
path and disconnect from its retaining clips.
(8) Disconnect the inside handle cable from the
latch assembly. Gently pry cable sleeve retainer out
of the latch mounting bracket and then unhook
swedged cable end from the latch link.
(9) Remove the inside handle cable from the side
door.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Match the replacement cable up against the old
cable to verify the correct part.
(2) Position the inside handle cable on the side
door.
(3) Connect the inside handle cable on the handle
assembly. Hook the swedged cable end on the handle
link and gently push the cable sleeve retainer in the
handle bracket.
(4) Install the inside handle assembly on the side
door. (Refer to 23 - BODY/DOORS - SLIDING/IN-
SIDE LATCH HANDLE - INSTALLATION)
NOTE: The inside handle cable is marked with blue
tape and must be attached to the latch at the center
(just above the lower cable). This position is
marked with a ªBº on the latch.
(5) Connect the inside handle cable on the latch
assembly. Hook the swedged cable end on the latch
link and gently push the cable sleeve retainer in the
latch bracket.
(6) Trace the inside handle cable along its routing
path and install on its retaining clips and position
foam insulators. Use previously made schematic as a
guide or remove the opposite side door trim panel
and use that door as a guide.
CAUTION: Be certain replacement cable is routed
and retained correctly and foam insulators are
properly positioned.
(7) Install the latch assembly. Refer to the Power
Side Doors section for the procedure.
(8) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.(9) Install the appropriate side door trim panel on
the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - INSTALLATION)
(10) Connect the negative battery cable.
HOLD OPEN LATCH CABLE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate side door trim panel
from the vehicle. (Refer to 23 - BODY/DOORS -
SLIDING/TRIM PANEL - REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
(4) Open the side door and remove the latch
assembly. (Refer to 8 - ELECTRICAL/POWER
DOORS/LATCH - REMOVAL)
CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
(5) Trace the hold open latch cable along its rout-
ing path and disconnect from its retaining clips.
(6) Disconnect the hold open latch cable from the
latch assembly. Gently pry cable sleeve retainer out
of the latch mounting bracket and then unhook
swedged cable end from the latch link.
(7) Remove the hold open latch from the side door.
(Refer to 23 - BODY/DOORS - SLIDING/HOLD
OPEN LATCH - REMOVAL)
(8) Disconnect the hold open latch cable from the
hold open latch. Gently pry cable sleeve retainer out
of the handle bracket and then unhook swedged
cable end from the latch link.
(9) Remove the hold open latch cable from the side
door.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Match the replacement cable up against the old
cable to verify the correct part.
(2) Position the hold open latch cable on the side
door.
23 - 38 DOORS - SLIDINGRS
INSIDE HANDLE CABLE (Continued)

Page 2150 of 2585

CHRYSLER VOYAGER 2004 Service Manual NOTE: The hold open latch cable is marked with
white tape. It must be attached to the upper most
cable attachment at the latch. This position is
marked with a ªWº on the latch.
(3) Connect the hold

Page 2151 of 2585

CHRYSLER VOYAGER 2004 Service Manual DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL.............................40
INSTALLATION.........................40
HINGE
REMOVAL.............................40

DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL.............................40
INSTALLATION.........................40
HINGE
REMOVAL.............................40
INSTALLATION.........................40
LATCH
REMOVAL.............................41
INSTALLATION.........................41
LATCH STRIKER
REMOVAL.............................41
INSTALLATION.........................41
LIFTGATE
REMOVAL.............................42
INSTALLATION.........................42
LIFTGATE SPOILER
REMOVAL.............................42INSTALLATION.........................42
LOCK CYLINDER
REMOVAL.............................42
INSTALLATION.........................42
SUPPORT CYLINDER
REMOVAL.............................43
INSTALLATION.........................43
TRIM PANEL
REMOVAL.............................43
INSTALLATION.........................44
SLAM BUMPER
REMOVAL
REMOVAL...........................44
REMOVAL - LIFTGATE SIDE.............44
INSTALLATION
INSTALLATION.......................44
INSTALLATION - LIFTGATE SIDE.........44
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.
23 - 40 DECKLID/HATCH/LIFTGATE/TAILGATERS

Page 2152 of 2585

CHRYSLER VOYAGER 2004 Service Manual (8) Verify liftgate alignment. Refer to Liftgate
Remove and Installation for proper gap measure-
ments.
LATCH
REMOVAL
(1) Remove liftgate trim panel.
(2) Disengage outside handle link from clip on
lat

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