2004 CHRYSLER VOYAGER wheel

(5) Install wheel and tire assembly on vehicle.
(Refer to 22 - TIRES/WHEELS - INSTALLATION) (6) Retrain tire pressure sensors. (Refer to 22 -
TIRES/WHEELS/TIRE PRESSURE MONITORING/
SENSOR - STANDARD PROCEDURE)
Fig. 4 Mounting Tire Using Rotating Tool Machine
1 - VALVE STEM
2 - MOUNTING END OF TOOL
3 - BEAD BREAKER (KEEP CLEAR OF SENSOR)
22s - 4 TIRE PRESSURE MONITORINGRS
SENSOR - TPM (Continued)

TIRES
TABLE OF CONTENTS
page page
TIRES DESCRIPTION DESCRIPTION - TIRE ...................5
DESCRIPTION - RADIAL-PLY TIRES ........6
DESCRIPTION - REPLACEMENT TIRES .....6
DESCRIPTION - SPARE TIRE (TEMPORARY) ........................6
DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - TIRE NOISE ....6
DIAGNOSIS AND TESTING - TIRE/VEHICLE LEAD ................................6
DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS ...........................8 DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS ..........................8
STANDARD PROCEDURE STANDARD PROCEDURE - TIRE INFLATIONPRESSURES ..........................8
STANDARD PROCEDURE - TIRE PRESSURE FOR HIGH SPEED
OPERATION ..........................9
STANDARD PROCEDURE - TIRE LEAK REPAIRING ...........................9
CLEANING - TIRES .....................10
TIRES
DESCRIPTION
DESCRIPTION - TIRE
Tires are designed and engineered for each specific
vehicle. They provide the best overall performance
for normal operation. The ride and handling charac-
teristics match the vehicle's requirements. With
proper care they will give excellent reliability, trac-
tion, skid resistance, and tread life. Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain, in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are: ² Rapid acceleration
² Severe application of brakes
² High-speed driving
² Taking turns at excessive speeds
² Striking curbs and other obstacles
² Operating vehicle with over or under inflated
tire pressures Radial ply tires are more prone to irregular tread
wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation. This will
help to achieve a greater tread-life potential.
TIRE IDENTIFICATION
Tire type, size, load index and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the Tire Identification
chart to decipher the code. For example purposes, the tire size P225/60 R 16 97 T is used in the chart. An
All Season type tire will also have eithe
rM+S,M&
SorM-S (indicating mud and snow traction)
imprinted on the side wall. An Extra or Light Load
marking ªXLº or ªLLº may also be listed on the side-
wall. The absence of an ªXLº or ªLLº marking infers
a standard load tire.
TIRE IDENTIFICATION
P TIRE TYPE (Not
present on all tires) P - Passenger
T - Temporary
C - Commercial
LT - Light Truck
225 SECTIONAL WIDTH SHOWN IN
MILLIMETERS
60 ASPECT RATIO SECTIONAL HEIGHT
÷ SECTIONAL WIDTH
(Refer to Aspect Ratio
Figure 1 )
R CONSTRUCTION
TYPE R - RADIAL
B - BIAS BELTED
D - DIAGONAL (BIAS)
16 WHEEL DIAMETER SHOWN IN INCHES
97 LOAD INDEX *
T SPEED RATING *
* NOTE: Consult the tire manufacturer regarding
any questions on tire specifications or capabilities.
RS TIRES22s-5

TIRE CHAINS
Refer to the owners manual supplied with the vehi-
cle to determine whether the use of tire chains is per-
mitted on this vehicle.
DESCRIPTION - RADIAL-PLY TIRES
Radial-ply tires improve handling, tread life, ride
quality and decrease rolling resistance. Radial-ply tires must always be used in sets of four
and under no circumstances should they be used on
the front only. It is recommended that tires from dif-
ferent manufacturers NOT be mixed. They may be
mixed with a temporary spare tire when necessary. A
maximum speed of 80 km/h (50 mph) is recom-
mended while a temporary spare is in use. Radial-ply tires have the same load-carrying capac-
ity as other types of tires of the same size. They also
use the same recommended inflation pressures.
DESCRIPTION - REPLACEMENT TIRES
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
WARNING: IN ORDER TO MAINTAIN THE SPEED
CAPABILITY OF THE VEHICLE, REPLACEMENT
TIRES MUST HAVE SPEED RATINGS EQUAL TO OR
HIGHER THAN THOSE FITTED TO THE VEHICLE AS
ORIGINAL EQUIPMENT. IF TIRES WITH LOWER
SPEED RATINGS ARE FITTED, THE VEHICLE'S
HANDLING MAY BE AFFECTED AND THE SPEED
CAPABILITY OF THE VEHICLE MAY BE LOWERED
TO THE MAXIMUM SPEED CAPABILITY OF THE
REPLACEMENT TIRES. TO AVOID AN ACCIDENT
RESULTING IN SEVERE OR FATAL INJURY, CON-
SULT THE TIRE MANUFACTURER IN REGARDS TO
MAXIMUM SPEED RATINGS. It is recommended that tires equivalent to the orig-
inal equipment tires be used when replacement is
needed. Failure to use equivalent replacement tires may
adversely affect the safety and handling of the vehi-
cle. The original equipment tires provide a proper com-
bination of many characteristics such as: ² Ride
² Noise
² Handling
² Durability
² Tread life
² Traction
² Rolling resistance
² Speed capability
The use of tires smaller than the minimum tire
size approved for the vehicle can result in tire over-
loading and failure. Use tires that have the approved load rating for
the vehicle and never overload them. Failure to equip
the vehicle with tires having adequate speed capabil-
ity can result in sudden tire failure and loss of vehi-
cle control. The use of oversize tires may cause interference
with vehicle components. Under extremes of suspen-
sion and steering travel, interference with vehicle
components may cause tire damage.
DESCRIPTION - SPARE TIRE (TEMPORARY)
The temporary (convenience) spare tire is designed
for emergency use only. The original tire should be
repaired and reinstalled, or replaced with a new, at
the first opportunity. The temporary (convenience) spare tire should be
inflated to the pressure listed on its sidewall. Do not
exceed speeds of 80 km/h (50 mph) when the tempo-
rary spare tire is in use on the vehicle. Refer to the
Owner's Manual for more details.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - TIRE NOISE
Unusual tire noise can be associated with tire and
wheel vibration or irregular tire wear. For vibration,
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING). For irregular tire wear, (Refer to 22 -
TIRES/WHEELS/TIRES - DIAGNOSIS AND TEST-
ING).
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD
Use the following Vehicle Lead Diagnosis And Cor-
rection Chart to diagnose and correct a vehicle lead
or drift problem.
Fig. 1 Tire Aspect Ratio
1 - SECTIONAL WIDTH
2 - SECTIONAL HEIGHT
22s - 6 TIRESRS
TIRES (Continued)

pressures may increase from 2 to 6 pounds per
square inch (psi) (14 to 41 kPa) during operation. Do
not reduce this normal pressure buildup.Improper inflation can cause:
² Uneven wear patterns
² Reduced tread life
² Reduced fuel economy
² Unsatisfactory ride
² The vehicle to drift.
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING. THE TIRE CAN FAIL
SUDDENLY, RESULTING IN LOSS OF VEHICLE
CONTROL. Under inflation causes rapid shoulder wear, tire
flexing, and can result in tire failure (Fig. 4).
Over inflation causes rapid center wear and loss of
the tire's ability to cushion shocks (Fig. 5).STANDARD PROCEDURE - TIRE PRESSURE
FOR HIGH SPEED OPERATION
DaimlerChrysler Corporation advocates driving at
safe speeds within posted speed limits. Where speed
limits allow the vehicle to be driven at high speeds,
correct tire inflation pressure is very important.
Vehicles loaded to maximum capacity should not be
driven at continuous speeds over 120 km/h (75 mph).
Never exceed the maximum speed capacity of the
tire. For information on tire identification and speed
ratings, (Refer to 22 - TIRES/WHEELS/TIRES -
DESCRIPTION).
STANDARD PROCEDURE - TIRE LEAK
REPAIRING
For proper repairing, a radial tire must be removed
from the wheel. Repairs should only be made if the
defect, or puncture, is in the tread area (Fig. 6). The
tire should be replaced if the puncture is located in
the sidewall. Deflate tire completely before attempting to dis-
mount the tire from the wheel. Use a lubricant
such as a mild soap solution when dismounting
or mounting tire. Use tools free of burrs or sharp
edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust
is removed from the rim bead and repaint if neces-
sary. Install wheel on vehicle, and progressively tighten
the 5 wheel nuts to a torque of 135 N´m (100 ft. lbs.).
Fig. 4 Under Inflation Wear
1 - THIN TIRE TREAD AREAS
Fig. 5 Over Inflation Wear
1 - THIN TIRE TREAD AREA
Fig. 6 Tire Repair Area
1 - REPAIRABLE AREA
RS TIRES22s-9
TIRES (Continued)

RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC
PARTS TYPES
CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
ASA ACRYLONITRILE STYRENE
ACRYLITELURAN S CONSOLES, GRILLES
ABS ACRYLONITRILE
BUTADIENE STYRENETERLURAN9A9PILLARS, CONSOLES,
GRILLES
ABS/PC ABS/PC ALLOY PULSE, PROLOY, BAYBLEND DOORS, INSTRUMENT
PANELS
ABS/PVC ABS/PV ALLOY PROLOY, PULSE, LUSTRAN,
CYCLOVINDOOR PANELS, GRILLES,
TRIM
BMC BULK MOLDING
COMPOUNDBMC FENDER EXTENSIONS
EMA EHTYLENE METHYL
ACRYLATE/IONOMERSURLYN, EMA, IONOMER BUMPER GUARDS, PADS
METTON METTON METTON GRILLES, KICK PANELS,
RUNNING BOARDS
MPPO MODIFIED
POLYPHENYLENE OXIDEMPPO SPOILER ASSEMBLY
PA POLYAMID ZYTEL, VYDYNE, PA,
MINLONFENDERS, QUARTER
PANELS
PET THERMOPLASTIC
POLYESTERRYNITE TRIM
PBT/PPO PBT/PPO ALLOY GERMAX CLADDINGS
PBTP POLYBUTYLENE
THEREPTHALATEPBT, PBTP, POCAN, VALOX WHEEL COVERS, FENDERS,
GRILLES
PBTP/EEBC POLYBUTYLENE
THEREPTHALATE/EEBC
ALLOYBEXLOY,9M9, PBTP/EEBC FASCIAS, ROCKER PANEL,
MOLDINGS
PC POLYCARBONATE LEXAN, MERLON, CALIBRE,
MAKROLON PCTAIL LIGHT LENSES, IP TRIM,
VALANCE PANELS
PC/ABS PC/ABS ALLOY GERMAX, BAY BLENDS,
PULSEDOORS, INSTRUMENT
PANELS
PPO POLYPHENYLENE OXIDE AZDEL, HOSTALEN,
MARLEX, PRFAX, NORYL,
GTX, PPOINTERIOR TRIM, DOOR
PANELS, SPLASH SHIELDS,
STEERING COLUMN
SHROUD
PPO/PA POLYPHENYLENE/
POLYAMIDPPO/PA, GTX 910 FENDERS, QUARTER
PANELS
PR/FV FIBERGLASS REINFORCED
PLASTICFIBERGLASS, FV, PR/FV BODY PANELS
PS POLYSTYRENE LUSTREX, STYRON, PS DOOR PANELS, DASH
PANELS
RTM RESIN TRANSFER
MOLDING COMPOUNDRTM BODY PANELS
SMC SHEET MOLDED
COMPOUNDSMC BODY PANELS
23 - 4 BODYRS
BODY (Continued)

CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
TMC TRANSFER MOLDING
COMPOUNDTMC GRILLES
UP UNSATURATED
POLYESTER
(THERMOSETTING)SMC, BMC, TMC, ZMC, IMC,
XSMC, UPGRILLE OPENING PANEL,
LIFTGATES, FLARESIDE
FENDERS, FENDER
EXTENSIONS
EEBC ETHER/ESTER BLOCKED
CO-POLYMEREEBC BUMPERS
EEBC/PBTP EEBC/POLYBUTYLENE
TEREPTHALATEEEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS
EMPP ETHYLENE MODIFIED
POLYPROPYLENEEMPP BUMPER COVERS
EPDM ETHYLENE/
PROPROPYLENE DIENE
MONOMEREPDM, NORDEL, VISTALON BUMPERS
EPM ETHYLENE/
PROPROPYLENE CO-
POLYMEREPM FENDERS
MPU FOAM POLYURETHANE MPU SPOILERS
PE POLYETHYLENE ALATHON, DYLAN,
LUPOLEN, MARLEX-
PP POLYPROPYLENE
(BLENDS)NORYL, AZDEL, MARLOX,
DYLON, PRAVEXINNER FENDER, SPOILERS,
KICK PANELS
PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES
PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS
PUR/PC PUR/PC ALLOY TEXIN BUMPERS
PVC POLYVINYL CHLORIDE APEX, GEON, VINYLITE BODY MOLDINGS, WIRE
INSULATION, STEERING
WHEELS
RIM REACTION INJECTED
MOLDED POLYURETHANERIM, BAYFLEX FRONT FASCIAS, MODULAR
WINDOWS
RRIM REINFORCED REACTION
INJECTED MOLDEDPUR, RRIM FASCIAS, BODY PANELS,
BODY TRIMS
TPE THERMO POLYETHYLENE TPE, HYTREL, BEXLOY-V FASCIAS, BUMPERS,
CLADDINGS
TPO THERMOPOLYOLEFIN POLYTROPE, RENFLEX,
SANTOPRENE, VISAFLEX,
ETA, APEX, TPO, SHIELDS,
CLADDINGSBUMPERS, END CAPS,
TELCAR, RUBBER, STRIPS,
SIGHT, INTERIOR B POST
TPP THERMO-POLYPROPYLENE TPP BUMPERS
TPU THERMOPOLYURETHANE,
POLYESTERTPU, HYTREL, TEXIN,
ESTANEBUMPERS, BODY SIDE,
MOLDINGS, FENDERS,
FASCIAS
RSBODY23-5
BODY (Continued)

²Panel repair for both flexible and rigid panels
are basically the same. The primary difference
between flexible panel repair and rigid panel repair
is in the adhesive materials used (Fig. 5).
²The technician should first decide what needs to
be done when working on any type of body panel.
One should determine if it is possible to return the
damage part to its original strength and appearance
without exceeding the value of the replacement part.
²When plastic repairs are required, it is recom-
mended that the part be left on the vehicle when
every possible. That will save time, and the panel
will remain stationary during the repair. Misalign-
ment can cause stress in the repair areas and can
result in future failure.
VISUAL INSPECTION
Composite materials can mask the severity of an
accident. Adhesive bond lines, interior structure of
the doors, and steel structures need to be inspected
carefully to get a true damage assessment. Close
inspection may require partial removal of interior
trim or inner panels.
Identify the type of repair: Puncture or Crack -
Damage that has penetrated completely through the
panel. Damage is confined to one general area; a
panel section is not required. However, a backer
panel, open fiberglass tape, or matted material must
be bonded from behind (Fig. 7) (Fig. 6).
PANEL SURFACE PREPARATION
If a body panel has been punctured, cracked, or
crushed, the damaged area must be removed from
the panel to achieve a successful repair. All spider
web cracks leading away from a damaged area must
be stopped or removed. To stop a running crack in a
panel, drilla6mm(0.250 in.) hole at the end of the
crack farthest away from the damage. If spider web
cracks can not be stopped, the panel would require
replacement. The surfaces around the damaged area
should be stripped of paint and freed from wax and
oil. Scuff surfaces around repair area with 360 grit
wet/dry sandpaper, or equivalent, to assure adhesion
of repair materials.
PATCHING PANELS
An panel that has extensive puncture type damage
can be repaired by cutting out the damaged material
(Fig. 7). Use a suitable reciprocating saw or cut off
wheel to remove the section of the panel that is dam-
aged. The piece cut out can be used as a template to
shape the new patch. It is not necessary to have
access to the back of the panel to install a patch.
Bevel edges of cutout at 20 degrees to expose a larger
bonding area on the outer side. This will allow for an
increased reinforcement areas.
PANEL PATCH FABRICATIONS
A patch can be fabricated from any rigid fiberglass
panel that has comparable contour with the repair
area. Lift gates and fenders can be used to supply
patch material. If existing material is not available
or compatible, a patch can be constructed with adhe-
sive and reinforcement mesh (dry wall tape). Perform
the following operation if required:
Fig. 4 BEVELING ANGLE - 20 DEGREE
Fig. 5 FIBERGLASS TAPE
Fig. 6 DAMAGE COMPONENT
1 - PUNCTURE
RSBODY23-7
BODY (Continued)

CHECK STRAP
REMOVAL
(1) Remove front door trim panel.
(2) Remove front door watershield (Refer to 23 -
BODY/DOOR - FRONT/WATERSHIELD -
REMOVAL).
(3) Remove front door speaker, if equipped.
(4) Remove bolts attaching door check strap to
A-pillar.
(5) Remove nuts attaching check strap to door end
frame (Fig. 2).
(6) Remove check strap from door through speaker
hole.
INSTALLATION
(1) Position check strap on door through speaker
hole.
(2) Install nuts to attach check strap to door end
frame. Tighten nuts to 11 N´m (90 in. lbs.) torque.
(3) Install bolts to attach check strap to A-pillar.
Tighten bolts to 12 N´m (105 in. lbs.) torque.
(4) Install door speaker, if equipped.
(5) Install front door trim panel.
DOOR
REMOVAL
(1) Remove front wheelhouse splash shield. (Refer
to 23 - BODY/EXTERIOR/LF WHEELHOUSE
SPLASH SHIELD - REMOVAL)
(2) Disengage clips attaching door harness wire
connector to inner fender brace.
(3) Disconnect positive lock slide on the side of the
wire connectors (Fig. 3).
(4) Depress lock tab attaching wire connector
halves together.
(5) Disconnect door harness from body wiring har-
ness.
(6) Remove bolts attaching door check strap to
A-pillar (Fig. 4).
(7) Support door on suitable lifting device.
(8) Remove bolts attaching lower hinge to door end
frame (Fig. 5).
(9) Steady door on lifting device and remove bolts
attaching upper hinge to door end frame.
(10) Remove door from vehicle.
Fig. 1 FRONT DOOR APPLIQUE
1 - GLASS RUN WEATHERSTRIP
2 - CLIPS
3 - APPLIQUE
4 - FRONT DOOR
Fig. 2 FRONT DOOR CHECK STRAP
1 - FRONT DOOR
2 - DOOR CHECK STRAP
RSDOOR - FRONT23-15
APPLIQUE (Continued)