2004 CHRYSLER VOYAGER Service Manual

navigation change time trailer spare wheel tires bonnet

Page 2193 of 2585

CHRYSLER VOYAGER 2004 Service Manual INSTALLATION
(1) Position D-pillar trim on vehicle.
(2) Pass second row seat belt, if equipped, through
slot in trim panel on short wheel base vehicle.
(3) Connect speaker wire connector to speaker, i

INSTALLATION
(1) Position D-pillar trim on vehicle.
(2) Pass second row seat belt, if equipped, through
slot in trim panel on short wheel base vehicle.
(3) Connect speaker wire connector to speaker, if
equipped.
(4) Align locating pins on backside of trim panel to
mating holes in D-pillar.
(5) Engage hidden clips attaching trim to D-pillar.
(6) Install screws attaching trim panel to attach-
ing bracket on short wheel base vehicle.
(7) Install quarter trim bolster on short wheel base
vehicle.
(8) Install bolt to attach second row seat belt, if
equipped, anchor to quarter on short wheel base
vehicle. Tighten all seat belt bolts to 39 N´m (29 ft.
lbs.) torque.
(9) Install second row seat belt turning loop on
long wheel base vehicle.
(10) Install liftgate sill plate.
(11) Install rear header trim cover.
SLIDING DOOR SILL PLATE
REMOVAL
(1) Disengage hidden clips holding sill plate to
sliding door opening sill.
(2) Disengage hooks holding outside edge of sill
plate to door sill (Fig. 15).
(3) Remove sill plate from vehicle.
INSTALLATION
(1) Place sill plate in position on vehicle.
(2) Engage hooks to hold outside edge of sill plate
to door sill.
(3) Align guide pins to holes in door sill.
(4) Engage hidden clips to hold sill plate to sliding
door opening sill.(5) Engage interlock tabs at lower B-pillar and
quarter trim panel.
SUN VISOR
REMOVAL
All vehicles with driver and passenger side air
bags must have a colored coded five Bullet point air
bag warning label applied to the sun visor, verify
label availability and ensure the label is installed.
(1) Disengage sun visor from center support.
(2) Remove screws attaching sun visor to roof
header (Fig. 16).
(3) Remove sun visor from roof.
(4) If equipped, disconnect illuminated vanity mir-
ror wire connector from body harness.
(5) Remove sun visor from vehicle.
INSTALLATION
All vehicles with driver and passenger side air
bags must have a colored coded five Bullet point air
bag warning label applied to the sun visor, verify
label availability and ensure the label is installed.
(1) Place sun visor in position on vehicle.
(2) Connect illuminated vanity mirror wire connec-
tor into body harness.
(3) Place sun visor in position on roof.
(4) Install screws to hold sun visor to roof header
(Fig. 16).
(5) Engage sun visor into center support.
Fig. 15 SLIDING DOOR SILL PLATE
1 - HOOKS
2 - SILL PLATE
3 - CLIPS
4 - SLIDING DOOR SILL
5 - CLIPS
Fig. 16 SUN VISOR
1 - HEADLINING
2 - SUN VISOR
23 - 82 INTERIORRS
RIGHT D-PILLAR TRIM PANEL (Continued)

Page 2194 of 2585

CHRYSLER VOYAGER 2004 Service Manual SUN VISOR SUPPORT
REMOVAL
(1) Disengage sun visor from support.
(2) Remove screw holding support to roof header
(Fig. 17).
(3) Remove sun visor support from vehicle.
INSTALLATION
(1) Place sun visor s

Page 2195 of 2585

CHRYSLER VOYAGER 2004 Service Manual PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - COLOR CODE CHARTS . . 84
BASE COAT/CLEARCOAT FINISH
DESCRIPTION.........................85
PAINT CODE
DESCRIPTION.........................85PAI

Page 2196 of 2585

CHRYSLER VOYAGER 2004 Service Manual BASE COAT/CLEARCOAT
FINISH
DESCRIPTION
On most vehicles a two-part paint application
(basecoat/clearcoat) is used. Color paint that is
applied to primer is called basecoat. The clearcoat
protects the

BASE COAT/CLEARCOAT
FINISH
DESCRIPTION
On most vehicles a two-part paint application
(basecoat/clearcoat) is used. Color paint that is
applied to primer is called basecoat. The clearcoat
protects the basecoat from ultraviolet light and pro-
vides a durable high-gloss finish.
CAUTION: Do not use abrasive chemicals or com-
pounds on painted surfaces. Damage to finish can
result.
Do not use harsh alkaline based cleaning solvents
on painted surfaces. Damage to finish or color can
result.
PAINT CODE
DESCRIPTION
Exterior vehicle body colors are identified on the
Body Code plate. (Refer to VEHICLE DATA/VEHI-
CLE INFORMATION/BODY CODE PLATE -
DESCRIPTION). The paint code is also identified on
the Vehicle Safety Certification Label which is
located on the drivers door shut face. The first digit
of the paint code listed on the vehicle indicates the
sequence of application, i.e.: P = primary coat, Q =
secondary coat. The codes listed in the Color Code
Chart are used for manufacturing purposes.
PAINTED TOUCH-UP
DESCRIPTION
When a painted metal surface has been scratched
or chipped, it should be touched up as soon as possi-
ble to avoid corrosion. For best results, use Mopart
Scratch Filler/Primer, Touch Up Paints and Clear Top
Coat. (Refer to VEHICLE DATA/VEHICLE INFOR-
MATION/BODY CODE PLATE - DESCRIPTION).
WARNING: USE AN OSHA APPROVED RESPIRATOR
AND SAFETY GLASSES WHEN SPRAYING PAINT
OR SOLVENTS IN A CONFINED AREA. PERSONAL
INJURY CAN RESULT.
TOUCH UP PROCEDURE
(1) Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with MopartTar/Road Oil
Remover, and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur-
face finish. The applicator brush should be wet
enough to puddle-fill the scratch or chip without run-
ning. Do not stroke brush applicator on body surface.
Allow the filler/primer to dry hard.
(4) Cover the filler/primer with color touch up
paint. Do not overlap touch up color onto the original
color coat around the scratch or chip. Butt the new
color to the original color, if possible. Do not stroke
applicator brush on body surface. Allow touch up
paint to dry hard.
(5) On vehicles without clearcoat, the touch up
color can be lightly finesse sanded (1500 grit) and
polished with rubbing compound.
(6) On vehicles with clearcoat, apply clear top coat
to touch up paint with the same technique as
described in Step 4. Allow clear top coat to dry hard.
If desired, Step 5 can be performed on clear top coat.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL ± BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN RESULT.
FINESSE SANDING/BUFFING &
POLISHING
DESCRIPTION
Minor acid etching, orange peel, or smudging in
clearcoat or single-stage finishes can be reduced with
light finesse sanding, hand buffing, and polishing.If
the finish has been finesse sanded in the past,
it cannot be repeated. Finesse sanding opera-
tion should be performed by a trained automo-
tive paint technician.
CAUTION: Do not remove clearcoat finish, if
equipped. Basecoat paint must retain clearcoat for
durability.
RSPAINT23-85

Page 2197 of 2585

CHRYSLER VOYAGER 2004 Service Manual SEATS
TABLE OF CONTENTS
page page
CHILD SEAT MODULE, BENCH SEAT
REMOVAL.............................87
INSTALLATION
INSTALLATION.......................88
SYNCHRONIZING CABLE ADJUSTMENT . . . 88
QUAD C

SEATS
TABLE OF CONTENTS
page page
CHILD SEAT MODULE, BENCH SEAT
REMOVAL.............................87
INSTALLATION
INSTALLATION.......................88
SYNCHRONIZING CABLE ADJUSTMENT . . . 88
QUAD CHILD SEAT
REMOVAL.............................89
INSTALLATION.........................89
HEADREST
REMOVAL.............................89
INSTALLATION.........................89
HEADREST SLEEVE
REMOVAL.............................90
INSTALLATION.........................90
RECLINER HANDLE
REMOVAL.............................90
INSTALLATION.........................90
ARMREST
REMOVAL.............................91
INSTALLATION.........................91
FRONT SEAT
REMOVAL.............................91
INSTALLATION.........................91
FRONT SEAT BACK
REMOVAL.............................92
INSTALLATION.........................92
FRONT SEATBACK ASSIST STRAP
REMOVAL.............................92
INSTALLATION.........................92
FRONT SEATBACK PANEL
REMOVAL.............................92
INSTALLATION.........................93
FRONT SEATBACK COVER
REMOVAL.............................93
INSTALLATION.........................93
FRONT/QUAD SEAT CUSHION
REMOVAL.............................93
INSTALLATION.........................93
FRONT SEAT CUSHION SIDE COVER
REMOVAL.............................94
INSTALLATION.........................94
FRONT SEAT RISER - MANUAL TRACK
REMOVAL.............................94
INSTALLATION.........................95
FRONT SEAT TRACK POWER ADJUSTER
REMOVAL.............................95
INSTALLATION.........................95
FRONT SEAT TRACK MANUAL ADJUSTER
REMOVAL.............................95INSTALLATION.........................95
FRONT SEAT TRACK - REAR COVER
REMOVAL.............................96
INSTALLATION.........................96
QUAD BUCKET SEAT SIDE SHIELD/
CUPHOLDER
REMOVAL.............................96
INSTALLATION.........................96
QUAD BUCKET SEAT SIDE SHIELD - NO
CUPHOLDER
REMOVAL.............................97
INSTALLATION.........................97
QUAD BUCKET SEAT RISER
REMOVAL.............................98
INSTALLATION.........................98
BUCKET SEAT BACK - QUAD BUCKET
REMOVAL.............................98
INSTALLATION.........................99
BENCH SEATBACK PANEL
REMOVAL.............................99
INSTALLATION.........................99
SEAT CUSHION COVER - QUAD BUCKET,
50/50 SPLIT, BENCH
REMOVAL............................100
INSTALLATION........................100
BENCH SEAT RISER - 50/50 SPLIT
REMOVAL............................100
INSTALLATION........................100
BENCH SEAT RISER - SECOND ROW
REMOVAL............................101
INSTALLATION........................101
BENCH SEAT RISER - THIRD ROW
REMOVAL............................101
INSTALLATION........................101
SEAT BACK HINGE COVERS - QUAD BUCKET,
50/50 SPLIT, BENCH
REMOVAL............................101
INSTALLATION........................101
BENCH SEAT BACK HINGE
REMOVAL............................102
INSTALLATION
INSTALLATION......................102
SYNCHRONIZING CABLE ADJUSTMENT . . 102
BENCH SEAT BACK
REMOVAL............................103
INSTALLATION........................103
BENCH SEAT BACK COVER
REMOVAL............................103
INSTALLATION........................103
23 - 86 SEATSRS

Page 2198 of 2585

CHRYSLER VOYAGER 2004 Service Manual BENCH SEAT TRACK
REMOVAL............................104
INSTALLATION........................104
PLASTIC GROCERY BAG RETAINER
REMOVAL............................104
INSTALLATION........................

Page 2199 of 2585

CHRYSLER VOYAGER 2004 Service Manual INSTALLATION
INSTALLATION
(1) Place child restraint seat module in position on
seat back (Fig. 4).
(2) Position seat back hinge interlock lever over
the top of the outboard child restraint seat hinge

Page 2200 of 2585

CHRYSLER VOYAGER 2004 Service Manual QUAD CHILD SEAT
REMOVAL
(1) Remove the seat. Refer to Owners Manual for
proper procedures.
(2) Remove seat back cover (Fig. 7).
(3) Remove fasteners attaching quad child seat to
the seat (Fig. 8).
(4

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