2004 CHRYSLER VOYAGER roof

point must not affect alignment. Striker should go
straight into the latching mechanism.
(2) On vehicles with left sliding doors, check the
fuel door blocker striker entry into latch. Striker at
this point must not affect alignment.
(3) Check C-post and B-post for door to aperture
gaps and door to door gaps. All gaps should be 5 mm
  1 mm.
(4) Check door for height using character lines as
a reference. Also check roof contour as a controlling
factor.
Using the procedures noted below, adjust the side
door in the order the individual steps are called out.
DOOR FLUSHNESS ADJUSTMENT
(1) Check sliding door flushness at the C-pillar
striker.
(2) If the sliding door is under or over flush,
remove striker assembly and move thread plate over
keeping one bolt in plate so it will not fall between
inner and outer panels.
(3) Adjust the C-pillar striker in or out until the
door is flush. Then, the on size hole can be elongated
in the direction required. This can be done by grind-
ing or filing the sheet metal and then painting raw
edge to prevent rusting.
(4) Check upper B-pillar flushness to A-pillar
cover.
(5) The sliding door upper hinge can only be
moved outboard by addinga1mmshim behind the
hinge mounting area once the too attachment bolts
are removed and reinstalled.
(6) Check flushness at upper C-pillar.
(7) If upper C-pillar flushness is out of specifica-
tion use a heavy rubber mallet on the door assembly
until door is in specifications.
DOOR GAP ADJUSTMENT - UP/DOWN
(1) Visually inspect the sliding door for fitting low
at the top of the door by checking the alignment of
the top contour of the door to the quarter panel.
(2) Fully open the sliding door.
(3) Verify that all center hinge bolts are tight.
(4) Adjust the rear of the sliding door up by turn-
ing the center hinge bolt clockwise (Fig. 14).
(5) Close the door and check the sliding door align-
ment.
(6) Adjust the front of the sliding door up by
adjusting lower hinge bolts.
(7) Open door half way and remove lower hinge
bolt access plug.
(8) Loosen bolts as necessary to move the front of
door up or down.
(9) Check the upper hinge for possible bind, adjust
as necessary.(10) Close the door and check the sliding door
alignment.
(11) Fully open door and apply thread lock nut
onto the center hinge bolt. Tighten nut until till it
butts up against the welded nut on the center hinge.
Tighten nut to 15 N´m (130 in. lbs.). It may be nec-
essary to hold the center hinge bolt to prevent it
from turning while tightening nut.
(12) Verify alignment, adjust as necessary.
DOOR GAP ADJUSTMENT - FORE/AFT
(1) Check height of sliding door at the B-post and
C-post to determine which area is contributing the
greatest to the incorrect gaps.
(2) If the sliding door is high at the C-post.
(a) Open the door to mid-point of travel.
(b) Mark outline of center hinge on sliding door
to assist in making adjustments.
(c) Loosen center hinge bolts (Fig. 14).
(d) Move hinge fore or aft to position the sliding
door into the correct location.
(e) Tighten center hinge bolts.
(f) Verify alignment, adjust as necessary.
(3) If the sliding door is low at the B-post;
(a) Remove access plug in the sliding door trim
panel.
(b) Open the door to mid-point of travel.
(c) Mark outline of lower roller arm bracket on
sliding door to assist in making adjustments.
(d) Loosen lower roller arm bracket bolts (Fig.
15).
(e) Move hinge upward to raise the door.
(f) Tighten lower roller arm bracket bolts.
(g) Verify alignment, adjust as necessary.
Fig. 14 SLIDING DOOR CENTER HINGE
1 - ADJUSTING BOLT
2 - WELD NUT
RSDOORS - SLIDING23-31
SLIDING DOOR (Continued)

(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 door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(9) Install sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
UPPER HINGE
REMOVAL
(1) Open sliding door, do not latch open.
(2) Remove screw attaching upper stop bracket to
upper roller bracket (Fig. 25).
(3) Remove stop bracket from vehicle.
(4) Place a padded block between the open sliding
door and the roof rail.
(5) Mark outline of upper hinge bracket on sliding
door.
(6) Remove bolts attaching upper roller to sliding
door (Fig. 26).
(7) Remove upper hinge from door.
(8) Slide roller out of rear end of roof upper chan-
nel.
(9) Remove upper hinge from vehicle.
INSTALLATION
(1) Place upper hinge in position on vehicle (Fig.
26).
(2) Slide roller into rear end of roof upper channel.
(3) Place upper hinge in position on door.
(4) Align outline marks on sliding door to upper
roller bracket
(5) Install bolts attaching upper hinge to sliding
door.
(6) Remove padded block from between sliding
door and roof rail.
(7) Place stop bracket in position on vehicle.
(8) Install screw attaching upper stop bracket to
upper roller bracket (Fig. 25).
Fig. 24 SLIDING DOOR OUTSIDE LATCH RELEASE
HANDLE
1 - OUTSIDE HANDLE
2 - OUTSIDE HANDLE BRACKET ATTACHING NUT
3 - LOCK KNOB
4 - LATCH LINK
5 - LOCKING LINK
6 - DOOR LOCKING LEVER (BELLCRANK)
Fig. 25 SLIDING DOOR UPPER STOP
1 - UPPER STOP PLATE
2 - SLIDING DOOR
3 - UPPER SLIDING DOOR HINGE
Fig. 26 SLIDING DOOR UPPER HINGE
1 - SLIDING DOOR UPPER HINGE
2 - SLIDING DOOR
23 - 36 DOORS - SLIDINGRS
OUTSIDE HANDLE (Continued)

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

(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
latch.
(3) Disconnect wire connector from liftgate latch
(Fig. 2).
(4) Remove screws attaching latch to liftgate.
(5) Remove latch from vehicle.
INSTALLATION
(1) Engage link and place latch in position on vehi-
cle.
(2) Install screws attaching latch to liftgate.
Tighten to 10 N´m (95 lb.in.) torque.
(3) Connect wire connector to liftgate latch.
(4) Verify liftgate fit and operation. Adjust as nec-
essary.
(5) Install liftgate trim panel.
LATCH STRIKER
REMOVAL
(1) Open liftgate.
(2) Mark outline of striker on sill to aid installa-
tion.
(3) Remove screws attaching striker to sill (Fig. 3).
(4) Remove striker from vehicle.
INSTALLATION
(1) Place striker in position on vehicle.
(2) Align striker to outline mark on sill.
(3) Install screws attaching striker to sill. Tighten
screws to 28 N´m (21 ft. lbs.) torque.
(4) Verify liftgate alignment and operation.
Fig. 1 LIFTGATE HINGE
1 - LIFTGATE
2 - HINGE
3 - REAR ROOF HEADER
Fig. 2 LIFTGATE LATCH
1 - ELECTRICAL CONNECTOR
2 - LIFTGATE LATCH
3 - SCREW
4 - LIFTGATE
5 - LIFTGATE LOCK CYLINDER
Fig. 3 LIFTGATE LATCH STRIKER
1 - LIFTGATE SILL
2 - LIFTGATE STRIKER
RSDECKLID/HATCH/LIFTGATE/TAILGATE23-41
HINGE (Continued)

LIFTGATE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Remove screws attaching liftgate wire connec-
tor to rear header.
(3) Disconnect liftgate wire harness from body
wire harness.
(4) Remove liftgate upper frame molding.
(5) Disconnect rear window washer hose from
spray nozzle.
(6) Support liftgate on a suitable lifting device.
(7) Remove screws attaching support cylinders to
liftgate.
(8) Remove bolts attaching liftgate hinge to roof
header (Fig. 4).
(9) With assistance, remove liftgate from vehicle.
INSTALLATION
(1) With assistance, place liftgate in position on
vehicle.
(2) Install bolts attaching liftgate hinge to roof
header. Tighten bolts to 33 N´m (24 ft. lbs.) torque.
(3) Install screws attaching support cylinders to
liftgate. Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(4) Remove lifting device from under liftgate.
(5) Connect liftgate wire harness into body wire
harness.
(6) Install screws attaching wire connector to rear
header.
(7) Connect rear window washer hose onto spray
nozzle.
(8) Install liftgate upper frame molding.
(9) Verify liftgate alignment. The liftgate should
have a gap to adjacent panels and fit flush across the
gaps. The gap is;²7 mm (0.280 in.) to the fascia,
²6 mm (0.240 in.) to the roof,
²4 mm (0.160 in.) to the aperture.
LIFTGATE SPOILER
REMOVAL
(1) Remove nuts (Fig. 5).
(2) Remove spoiler from vehicle.
INSTALLATION
(1) Place liftgate spoiler in position and install
nuts.
(2) Tighten nuts to 9 N´m (80 in. lbs.) torque.
LOCK CYLINDER
REMOVAL
(1) Remove the liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the electrical connector.
(3) Disconnect the latch rod.
(4) Rotate plastic lock cylinder nut one quarter
turn and remove nut and spring washer.
(5) Remove the lock cylinder from the liftgate.
INSTALLATION
(1) Install lock cylinder into liftgate.
(2) Install the plastic lock cylinder lock nut, spring
washer and rotate one quarter turn.
(3) Connect the electrical connector.
Fig. 4 LIFTGATE
1 - HINGE
2 - ROOF
3 - NET HOLE OR SLOT
Fig. 5 LIFTGATE SPOILER
1 - RETAINER SEALER WASHER
2 - LIFT GATE SPOILER
23 - 42 DECKLID/HATCH/LIFTGATE/TAILGATERS

EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL.............................45
INSTALLATION.........................46
COWL GRILLE
REMOVAL.............................50
INSTALLATION.........................51
EXTERIOR NAME PLATES - TAPE ATTACHED
REMOVAL.............................51
INSTALLATION.........................51
EXTERIOR NAME PLATES - ADHESIVE
ATTACHED
REMOVAL.............................51
INSTALLATION.........................51
FRONT FENDER
REMOVAL.............................52
INSTALLATION.........................52
FUEL FILL DOOR
REMOVAL.............................52
INSTALLATION.........................52
FUEL FILL DOOR BLOCKER LATCH
REMOVAL.............................53
INSTALLATION.........................53
FUEL FILL DOOR BLOCKER LATCH STRIKER
REMOVAL.............................53
INSTALLATION.........................53
FUEL FILL DOOR BLOCKER LOCKOUT LINK
REMOVAL.............................53INSTALLATION.........................54
GRILLE OPENING REINFORCEMENT
REMOVAL.............................54
INSTALLATION.........................54
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL.............................55
INSTALLATION.........................55
LUGGAGE RACK RISER
REMOVAL.............................55
INSTALLATION.........................56
LUGGAGE RACK CROSSBAR
REMOVAL.............................56
INSTALLATION.........................57
REAR QUARTER PANEL/FENDER AIR
EXHAUSTER
DESCRIPTION.........................57
REMOVAL.............................57
INSTALLATION.........................58
ROOF JOINT MOLDING
REMOVAL.............................58
INSTALLATION.........................58
SIDE VIEW MIRROR
REMOVAL.............................59
INSTALLATION.........................59
SIDE VIEW MIRROR GLASS
REMOVAL.............................59
INSTALLATION.........................59
BODY SIDE MOLDINGS
REMOVAL
Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig.
5)for proper location of fasteners holding the molding
to the wheelhouse lip and rocker panels.
(1) Warm the affected stick on molding and body
metal to approximately 38É C (100É F) using a suit-
able heat lamp or heat gun.
(2) If equipped, remove pop rivets holding molding
edge to wheelhouse lip.(3) Pull stick on molding from painted surface.
(4) Remove adhesive tape residue from painted
surface of vehicle. Use a 3M Scotch-BriteŸ Molding
Adhesive and Stripe Removal Disc, or equivalent, to
clean adhesive residue from painted surfaces. These
products are available from automotive paint suppli-
ers. Refer to instructions supplied with the specific
product for proper usage.
RSEXTERIOR23-45

INSTALLATION
SHORT WHEELBASE
(1) Position the air exhauster to the hole in the
lower aperture panel (Fig. 19).
(2) Using hand pressure, press the air exhauster
into the opening in the lower aperture panel until
the snap features are fully engaged.
(3) Reinstall the rear fascia onto the body. (Refer
to 13 - FRAMES & BUMPERS/BUMPERS/REAR
FASCIA - INSTALLATION).
LONG WHEELBASE
NOTE: Models with the optional rear heater and air
conditioner do not have an air exhauster on the
right side of the vehicle, but have a plastic plug
installed in the right lower aperture panel. This plug
is installed using the same procedure used to
install the air exhauster onto the short wheelbase
model. Refer to SHORT WHEELBASE.
(1) Position the air exhauster to the hole in the
lower aperture panel (Fig. 20).
(2) Using hand pressure, press the air exhauster
into the opening in the lower aperture panel until
the snap features are fully engaged.
(3) Reinstall the quarter trim panel onto the inside
of the left or right quarter inner panel. (Refer to 23 -
BODY/INTERIOR/RIGHT QUARTER TRIM PANEL
- INSTALLATION) or (Refer to 23 - BODY/INTERI-
OR/LEFT QUARTER TRIM PANEL - INSTALLA-
TION).
ROOF JOINT MOLDING
REMOVAL
The RAP molding is set with body side molding
tape. The temperature in the work area and the vehi-
cle should be at least 21É C (70É F) to avoid damag-
ing the RAP moldings.
(1) Warm the affected stick-on molding and body
metal to approximately 38É C (100É F) using a suit-
able heat lamp or heat gun.
(2) Pull stick-on molding from painted surface.
(3) Remove adhesive tape residue from painted
surface of vehicle. Use a 3M Scotch-BriteŸ Molding
Adhesive and Stripe Removal Discs, or equivalent, to
clean adhesive residue from painted surfaces. The
adhesive removal discs are available from automotive
paint suppliers. Refer to instructions supplied with
the discs for proper usage.
INSTALLATION
The RAP molding is set with body side molding
tape. The temperature in the work area and the vehi-
cle should be at least 21É C (70É F) to avoid damag-
ing the RAP moldings.
(1) If molding is to be reused;
(a) Remove tape residue from molding.
(b) Clean back of molding with MopartSuper
Kleen solvent, or equivalent.
(c) Wipe molding dry with lint free cloth.
(d) Apply new body side molding (two sided
adhesive) tape to back of molding.
(2) Clean body surface with MopartSuper Kleen
solvent, or equivalent. Wipe surface dry with lint free
cloth.
(3) Remove protective cover from tape on back of
molding.
(4) Apply molding to body from front of vehicle to
rear.
(5) Using a roller tool, roll molding onto body
panel with enough force to assure adhesion and not
bend roof panels.
23 - 58 EXTERIORRS
REAR QUARTER PANEL/FENDER AIR EXHAUSTER (Continued)

A-PILLAR LOWER EXTENSION
TRIM
REMOVAL
(1) Remove instrument panel side cover.
(2) Remove A-pillar extension trim from vehicle by
disengaging hidden clips (Fig. 1).
INSTALLATION
(1) Place A-pillar extension trim in position on
vehicle (Fig. 1).
(2) Install instrument panel side cover.
A-PILLAR TRIM
REMOVAL
(1) Remove the assist handle if equipped. (Refer to
23 - BODY/INTERIOR/ASSIST HANDLE -
REMOVAL)
(2) Disengage hidden clips holding A-pillar trim
panel to A-pillar (Fig. 2).
(3) Remove A-pillar trim from vehicle.
INSTALLATION
(1) Position foot on A-pillar trim panel into instru-
ment panel top cover channel.
(2) Position A-pillar trim in vehicle.
(3) Align locator pins.
(4) Engage hidden clips.(5) Install the assist handle, if equipped. (Refer to
23 - BODY/INTERIOR/ASSIST HANDLE - INSTAL-
LATION)
ASSIST HANDLE
REMOVAL
(1) Using a trim stick (C-4755), remove screw
access covers from grab-handle.
(2) Remove screws holding grab-handle to roof rail.
(3) Remove grab-handle from vehicle.
INSTALLATION
(1) Place grab-handle in position on vehicle.
(2) Install screws to hold grab-handle to roof rail.
(3) Install screw access covers into grab-handle.
B-PILLAR LOWER TRIM
REMOVAL
(1) Slide lower seat belt cover rearward to expose
anchor bolt.
(2) Remove bolt attaching lower seat belt anchor to
floor.
(3) Remove upper B-pillar trim cover.
(4) Remove access panel from B-pillar trim (Fig.
3).
(5) Disengage hidden clips attaching lower trim
cover to B-pillar.
Fig. 1 A-PILLAR LOWER EXTENSION TRIM
1 - FRONT LOWER EXTENSION TRIM
2 - FRONT EXTENSION TRIM TO INSTRUMENT PANEL
RETAINER
3 - CLIP
4 - COWL TRIM PANEL
Fig. 2 A-PILLAR TRIM
1 - A-PILLAR
2 - CLIPS
23 - 74 INTERIORRS