2004 CHRYSLER VOYAGER Power system

(4) Place front door trim panel in position on door.
(5) Install trim panel into inner belt molding at
top of door.
(6) Install clips to attach door trim to door frame
around perimeter of panel.
(7) If equipped, install screw to attach door trim to
door panel behind inside latch release handle.
(8) If equipped, connect power switch into wire
connector.
(9) Place power accessary switch in position on
door trim.
(10) Connect wire connector into memory seat/mir-
ror switch and install switch into trim panel.
(11) Install screws to attach accessary switch
panel to door trim.
(12) Install screw cover into switch panel.
(13) If equipped, install window crank.
(14) If equipped, install screws to attach trim
panel to door inside map pocket.
(15) If equipped, install screw to attach door pull
cup to inner door panel.
(16) If equipped, install screws to attach door
assist handle to inner door panel.
(17) Connect wire connector into courtesy lamp.
(18) Install lamp in door trim.
(19) Install switch bezel.
WATERSHIELD
REMOVAL
(1) Remove door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(2) Remove the front door speaker. (Refer to 8 -
ELECTRICAL/AUDIO/SPEAKER - REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
INSTALLATION
(1) Insure that enough adhesive remains to
securely retain the water dam. Replace as necessary.
(2) Place the shield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(3) Install the front door speaker. (Refer to 8 -
ELECTRICAL/AUDIO/SPEAKER - INSTALLATION)
(4) Install door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
WINDOW CRANK
REMOVAL
(1) Using a window crank removal tool, disengage
clip attaching window crank to regulator shaft (Fig.
13).NOTE: Wrap a shop towel around the window crank
to catch the clip when it springs out.
(2) Pull window crank from regulator shaft.
INSTALLATION
(1) Place the clip on to the window crank handle.
(2) Position window crank to regulator shaft.
(3) Push window crank onto regulator shaft to
engage retaining clip.
EXTERIOR HANDLE
REMOVAL
(1) Roll door glass up.
(2) Remove the watershield as necessary to gain
access to the outside door handle. (Refer to 23 -
BODY/DOOR - FRONT/WATERSHIELD -
REMOVAL)
(3) Through access hole at rear of inner door
panel, disconnect Vehicle Theft Security System
(VTSS) switch connector from door harness, if
equipped.
(4) Disengage push in fasteners attaching VTSS
switch harness to inner door reinforcement bar, if
equipped.
(5) Disengage clip holding door latch linkage to
door latch (Fig. 11).
(6) Remove latch linkage from latch.
(7) Disengage clip holding door lock linkage to
door latch.
(8) Remove lock linkage from latch.
(9) Remove nuts holding outside door handle to
door outer panel.
(10) Remove outside door handle from vehicle.
Fig. 13 WINDOW CRANK - TYPICAL
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
RSDOOR - FRONT23-21
TRIM PANEL (Continued)

DOORS - SLIDING
TABLE OF CONTENTS
page page
CENTER HINGE
REMOVAL.............................24
INSTALLATION.........................24
SLIDING DOOR STOP BUMPER BEZEL
REMOVAL.............................25
INSTALLATION.........................25
STOP BUMPER
REMOVAL.............................25
INSTALLATION.........................25
HOLD OPEN LATCH
REMOVAL.............................25
INSTALLATION.........................25
HOLD OPEN LATCH STRIKER
REMOVAL.............................26
INSTALLATION.........................26
LATCH / LOCK ASSEMBLY
REMOVAL.............................26
INSTALLATION.........................27
INSIDE HANDLE ACTUATOR
REMOVAL.............................27
INSTALLATION.........................27
CENTER STRIKER
REMOVAL.............................28
INSTALLATION.........................28
LOWER HINGE
REMOVAL.............................28
INSTALLATION.........................28
REAR LATCH STRIKER
REMOVAL.............................29
INSTALLATION.........................29
SLIDING DOOR
REMOVAL.............................29
INSTALLATION.........................30ADJUSTMENTS
SLIDING DOOR ADJUSTMENTS..........30
STABILIZER
REMOVAL.............................33
INSTALLATION.........................33
STABILIZER SOCKET
REMOVAL.............................33
INSTALLATION.........................33
TRIM PANEL
REMOVAL.............................33
INSTALLATION.........................34
INSIDE LATCH HANDLE
REMOVAL.............................34
INSTALLATION.........................34
BELLCRANK
REMOVAL.............................35
INSTALLATION.........................35
OUTSIDE HANDLE
REMOVAL.............................35
INSTALLATION.........................35
UPPER HINGE
REMOVAL.............................36
INSTALLATION.........................36
OUTSIDE HANDLE CABLE
REMOVAL.............................37
INSTALLATION.........................37
INSIDE HANDLE CABLE
REMOVAL.............................37
INSTALLATION.........................38
HOLD OPEN LATCH CABLE
REMOVAL.............................38
INSTALLATION.........................38
CENTER HINGE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Open sliding door to the mid point of its travel.
(2) Support sliding door on a suitable lifting
device.
(3) Mark outline of center hinge of inner door
panel to aid installation.(4) Remove bolts attaching center hinge to sliding
door.
(5) Remove center hinge from sliding door.
(6) Roll center hinge to rear of roller channel.
(7) Remove center hinge from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
23 - 24 DOORS - SLIDINGRS

HOLD OPEN LATCH STRIKER
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Open sliding door, do not latch open.
(2) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(3) Remove two bolts attaching sliding door hold
open latch striker to door sill (Fig. 3).
(4) Remove hold open latch striker from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Place hold open latch striker in position on
vehicle.
(2) Install two bolts attaching sliding door hold
open latch striker to door sill.
(3) Install sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(4) Verify sliding door operation.
LATCH / LOCK ASSEMBLY
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(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.
(4) Disengage external cable from latch/lock
assembly (Fig. 4).
(5) Remove foam block.
(6) Remove inside door handle assembly (Refer to
23 - BODY/DOORS - SLIDING/INSIDE LATCH
HANDLE - REMOVAL).
(7) Disengage inside cable from latch/lock assem-
bly.
(8) Disengage link from bellcrank.
(9) Disengage hold open latch cable from lower
hinge.
(10) Remove bolts attaching latch/lock control to
sliding door (Fig. 5).
(11) If equipped, lower latch and disconnect wire
connector from power door lock motor.
(12) Remove latch/lock from door.
Fig. 3 SLIDING DOOR HOLD OPEN LATCH STRIKER
1 - POWER DOOR LOWER TRACK
2 - POWER DOOR HOLDING STRIKER
3 - MANUAL DOOR HOLDING STRIKER
4 - MANUAL DOOR LOWER TRACK
Fig. 4 SLIDING DOOR LATCH/LOCK ASSEMBLY
1 - SLIDING DOOR
2 - LATCH LOCK ASSEMBLY
23 - 26 DOORS - SLIDINGRS

INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Position latch/lock locking lever in unlocked
position.
(2) Place latch/lock in position on door (Fig. 5).
(3) If equipped, engage wire connector into power
door lock motor (Fig. 4).
CAUTION: REPLACE BOLTS IF INSTALLING NEW
LATCH.
(4) Insert bolt into slots in sliding door inner
panel.
(5) Tighten bolts attaching latch/lock assembly to
sliding door.
(6) Engage inside cable into latch/lock assembly.
(7) Install inside door handle assembly (Refer to
23 - BODY/DOORS - SLIDING/INSIDE LATCH
HANDLE - INSTALLATION).
(8) Install foam block.
(9) Engage external cable to latch/lock assembly.
(10) Engage link rod to bellcrank.
(11) Engage hold open latch cable from lower
hinge.
(12) Engage clip to hold bellcrank link to latch/lock
control.
(13) Verify sliding door operation.(14) Install latch/lock cover.
(15) Insure that enough adhesive remains to
securely retain the watershield. Replace as necessary.
(16) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(17) Install sliding door stop bumper.(Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(18) Install sliding door trim panel.(Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove latch/lock assembly. (Refer to 23 -
BODY/DOORS - SLIDING/LATCH/LOCK CONTROL
- REMOVAL).
(2) Remove lock actuator three attaching screws
(Fig. 6).
(3) Remove lock actuator.
INSTALLATION
(1) Place lock actuator into position on latch/lock
assembly.
(2) Insall attaching screws (Fig. 6).
(3) Install latch/lock assembly. (Refer to 23 -
BODY/DOORS - SLIDING/LATCH / LOCK CON-
TROL - INSTALLATION).
Fig. 5 REMOVING SLIDING DOOR LATCH/LOCK
ASSEMBLY
1 - WIRE HARNESS
2 - LATCH/LOCK ASSEMBLY
3 - BELLCRANK LINK ROD
4 - LINK AND SLEEVE ASSEMBLY
Fig. 6 LOCK ACTUATOR
1 - INSIDE HANDLE ACTUATOR
2 - LATCH/LOCK ASSEMBLY
3 - THREE ATTACHING SCREWS
RSDOORS - SLIDING23-27
LATCH / LOCK ASSEMBLY (Continued)

CENTER STRIKER
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove bolts attaching stop bumper. Remove
stop bumper from door.
(3) Remove screws attaching center striker assem-
bly to door end frame (Fig. 7).
(4) Remove center striker assembly from door
through access hole.
INSTALLATION
(1) Place center striker in position on door through
access hole (Fig. 7).
(2) Install screws to attach center striker to door
end frame.
(3) Install bolts attaching stop bumper.
(4) Install sliding door trim panel (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION).
LOWER HINGE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Open sliding door.
(2) Mark outline of roller arm on sliding door to
aid installation (Fig. 8).(3) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(4) Remove screws attaching open latch to lower
roller arm.
(5) Remove open latch from lower arm.
(6) Support sliding door on a suitable lifting device
with a padded upper surface. The door must be
moveable with lifting device in place.
(7) Remove hold open latch striker.
(8) Remove bolts attaching lower roller arm to
sliding door.
(9) Remove roller arm from sliding door.
(10) Disengage roller arm from lower channel.
(11) Remove roller arm from vehicle.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Place roller arm into position (Fig. 8).
(2) Engage roller arm to lower channel.
(3) Install roller arm to sliding door.
(4) Install bolts attaching lower roller arm to slid-
ing door.
(5) Install hold open latch striker.
(6) Install screws attaching open latch to lower
roller arm.
(7) Install sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(8) Check sliding door for proper operation.
Fig. 7 SLIDING DOOR CENTER STRIKER
ASSEMBLY
1 - STRIKER BOLT ASSEMBLY
2 - SLIDING DOORFig. 8 SLIDING DOOR LOWER ROLLER ARM
1 - POWER LOWER ROLLER ARM
2 - MANUAL LOWER ROLLER ARM
23 - 28 DOORS - SLIDINGRS

REAR LATCH STRIKER
REMOVAL
(1) Open sliding door.
(2) Mark outline of striker on C-pillar door jamb
face to aid installation.
(3) Remove screws attaching striker to C-pillar
(Fig. 9).
(4) Remove striker from vehicle.
INSTALLATION
(1) Place striker in position on vehicle.
(2) Align striker to outline marks on C-pillar.
(3) Install screws attaching striker to C-pillar.
Tighten screws to 28 N´m (21 ft. lbs.) torque.
(4) Verify sliding door alignment and operation.
SLIDING DOOR
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Apply masking tape to outside surface of quar-
ter panel below the center roller channel, rearward of
the door opening.
(2) Release sliding door latch and open door.
(3) Apply masking tape to door jamb area, rear-
ward of the upper roller channel.
(4) Remove screw attaching upper stop bumper to
upper roller arm (Fig. 10).
(5) Remove upper stop from upper roller arm.(6) Remove center stop from sliding door. (Refer to
23 - BODY/DOORS - SLIDING/STOP BUMPER -
REMOVAL)
(7) Remove sliding door sill plate. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
REMOVAL)
(8) Remove hold open latch striker (Refer to 23 -
BODY/DOORS - SLIDING/HOLD OPEN LATCH
STRIKER - REMOVAL).
(9) Open quarter glass.
(10) Remove center roller channel end cover (Fig.
11).
(11) Support sliding door on a suitable lifting
device with a padded upper surface. The door must
be moveable with lifting device in place.
CAUTION: Do not allow the center hinge roller to
contact the quarter glass. Glass can break.
(12) Slide door rearward until the upper sliding
door hinge roller disengages from the upper channel
(Fig. 12).
(13) Continue moving the door rearward until the
lower rollers exit the lower track.
(14) Continue moving door rearward till center
hinge roller exits the channel (Fig. 13)
(15) Remove sliding door from vehicle.
Fig. 9 SLIDING DOOR LATCH STRIKER
1 - LATCH STRIKER
2 - SLIDING DOOR
Fig. 10 SLIDING DOOR UPPER STOP
1 - UPPER STOP PLATE
2 - SLIDING DOOR
3 - UPPER SLIDING DOOR HINGE
RSDOORS - SLIDING23-29

INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Place sliding door in position on lifting device.
(2) Engage center hinge roller into channel and
move door forward (Fig. 13).
(3) Position door rearward of the sliding door open-
ing.
CAUTION: Do not allow the center hinge roller to
contact the quarter glass. Glass can break.(4) Engage the center hinge roller into the channel
(Fig. 13).
(5) Roll door forward until lower roller engage into
rear of the track.
(6) Engage the upper sliding door hinge into the
upper channels (Fig. 12).
(7) Install hold open latch striker(Refer to 23 -
BODY/DOORS - SLIDING/HOLD OPEN LATCH
STRIKER - INSTALLATION).
(8) Install sliding door sill plate.
(9) Install center roller channel end cover (Fig. 11).
(10) Install center stop on sliding door. (Refer to 23
- BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(11) Place upper roller stop bumper in position on
upper roller arm.
(12) Install screw attaching upper roller arm stop
bumper to upper roller arm (Fig. 10).
(13) Remove masking tape from body surfaces.
(14) Verify door operation and fit. Adjust as neces-
sary. (Refer to 23 - BODY/DOORS - SLIDING/SLID-
ING DOOR - ADJUSTMENTS)
ADJUSTMENTS
SLIDING DOOR ADJUSTMENTS
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
PRELIMINARY CHECKS
(1) Close the sliding door, visually checking C-post
striker alignment entry into latch. Striker at this
Fig. 11 CENTER CHANNEL END COVER
1 - CENTER CHANNEL
2 - CENTER CHANNEL END COVER
3 - PLASTIC NUT
Fig. 12 SLIDING DOOR UPPER ROLLER
1 - SLIDING DOOR
2 - UPPER HINGE
3 - UPPER CHANNEL
Fig. 13 SLIDING DOOR CENTER ROLLER
1 - SLIDING DOOR
2 - QUARTER GLASS
3 - CENTER HINGE ROLLERS
4 - CENTER HINGE
23 - 30 DOORS - SLIDINGRS
SLIDING DOOR (Continued)

(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)