2004 CHRYSLER VOYAGER window

the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations (Refer to LUBRI-
CATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE).
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
DIAGNOSIS AND TESTING - WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will not
always seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
23 - 2 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)

DOOR - FRONT
TABLE OF CONTENTS
page page
APPLIQUE
REMOVAL.............................14
INSTALLATION.........................14
CHECK STRAP
REMOVAL.............................15
INSTALLATION.........................15
DOOR
REMOVAL.............................15
INSTALLATION.........................16
DOOR GLASS
REMOVAL.............................17
INSTALLATION.........................17
FRAME CLOSEOUT MOLDING
REMOVAL ± A-PILLAR-HEADER, OR B-PILLAR . 17
INSTALLATION ± A-PILLAR-HEADER, OR
B-PILLAR............................17
HINGE
REMOVAL.............................17
INSTALLATION.........................18
LATCH
REMOVAL.............................18
INSTALLATION.........................18
LATCH STRIKER
REMOVAL.............................19INSTALLATION.........................19
LOCK CYLINDER
REMOVAL.............................19
INSTALLATION.........................19
TRIM PANEL
REMOVAL.............................20
INSTALLATION.........................20
WATERSHIELD
REMOVAL.............................21
INSTALLATION.........................21
WINDOW CRANK
REMOVAL.............................21
INSTALLATION.........................21
EXTERIOR HANDLE
REMOVAL.............................21
INSTALLATION.........................22
WINDOW REGULATOR - POWER
REMOVAL.............................22
INSTALLATION.........................22
WINDOW REGULATOR - MANUAL
REMOVAL.............................22
INSTALLATION.........................23
APPLIQUE
REMOVAL
(1) Roll door glass down.
(2) Remove outer door belt molding.
(3) Disengage clips holding front edge of applique
to door frame.
(4) Remove applique from vehicle (Fig. 1).
INSTALLATION
(1) Position applique on vehicle.
(2) Hook rear edge of applique over rear edge of
door frame and seat applique bottom edge on sheet
metal.
(3) Engage clips to hold front edge of applique to
door frame.
(4) Install outer door belt molding.
23 - 14 DOOR - FRONTRS

DOOR GLASS
REMOVAL
(1) Remove watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(2) Remove inner belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - REMOVAL)
(3) Position glass to gain access to front and rear
regulator lift plates through front and rear access
holes in door panel.
(4) Loosen two screws on regulator clamping glass
(Fig. 6).
(5) Remove glass from regulator lift plates.
(6) Disengage glass from glass run weatherstrip.
(7) Insert front of glass between glass run channel
and outer door panel.
(8) Lift glass upward and out of exterior side of
the opening at top of door (Fig. 7).
(9) Remove glass from vehicle.
INSTALLATION
(1) Ensure clamp opening is set to 6 mm (0.2 in.)
front and rear (Fig. 6).
(2) Place glass in window opening with front
inserted between run channel and outer door panel
(Fig. 7).
(3) Lower glass downward into door.
(4) Insert ends of glass into glass run weatherstrip
channels at front and rear of door.
(5) Place glass in position on regulator lift plates.
(6) Roll glass up to level to tie down two glass
clamps and fasten.(7) Install inner belt molding.(Refer to 23 - BODY/
WEATHERSTRIP/SEALS/FRONT DOOR INNER
BELT MOLDING - INSTALLATION)
(8) Verify door glass operation and fit.
(9) Install watershield. (Refer to 23 - BODY/DOOR
- FRONT/WATERSHIELD - INSTALLATION)
FRAME CLOSEOUT MOLDING
REMOVAL ± A-PILLAR-HEADER, OR B-PILLAR
(1) Roll door glass down.
(2) Using a hook tool, pull front door frame close-
out molding from window frame channel.
(3) Remove closeout molding from vehicle.
INSTALLATION ± A-PILLAR-HEADER, OR
B-PILLAR
(1) Position closeout molding in window frame.
(2) Insert closeout molding into window frame
channel starting at the corners and working inward.
(3) Verify door glass operation.
HINGE
REMOVAL
(1) Release front door latch and open door.
(2) Mark hinge foot print on both door and pillar
to aid when installing door.
(3) Support door on suitable lifting device.
(4) Remove bolts attaching front door to door
hinge.
Fig. 6 FRONT DOOR GLASS CLIPS
1 - DOOR GLASS
2 - REGULATOR GLASS CLAMP ASSEMBLY
3 - GLASS LIFT PLATE
Fig. 7 FRONT DOOR GLASS
1 - DOOR GLASS
2 - FRONT DOOR
3 - GLASS RUN CHANNEL
RSDOOR - FRONT23-17

TRIM PANEL
REMOVAL
(1) Remove the plug and remove screw attaching
door pull cup to inner door panel.
(2) Remove switch bezel and disconnect power win-
dow/memory switch.
(3) Remove screws attaching trim panel to door
from below map pocket.
(4) If equipped, remove window crank. (Refer to 23
- BODY/DOOR - FRONT/WINDOW CRANK -
REMOVAL)
(5) Remove screw holding door trim to door panel
from behind inside latch release handle.
(6) Disengage clips attaching door trim to door
frame around perimeter of panel.
(7) Lift trim panel upward to disengage flange
from inner belt molding at top of door.
(8) Tilt top of trim panel away from door to gain
access to latch linkage.
(9) Disengage clip attaching linkage rod to inside
latch release handle (Fig. 12).
(10) Separate linkage rod from latch handle.
(11) Disconnect the power door switch, courtesy
lamp electrical connectors.
(12) Remove front door trim panel from vehicle.
INSTALLATION
(1) Hold top of trim panel away from door to gain
access to latch linkage.
(2) Place linkage rod in position on latch handle.
(3) Engage clip to hold linkage rod to inside latch
release handle.
Fig. 11 OUTSIDE DOOR HANDLE
1 - CLIP
2 - LOCK CYLINDER
3 - KEY CYLINDER TO LATCH LINK
4 - OUTSIDE HANDLE TO LATCH LINK5 - LOCK KNOB LINK
6 - FRONT DOOR
7 - KEY POSITION SWITCH
8 - OUTSIDE HANDLE
Fig. 12 INSIDE DOOR HANDLE LINKAGE
1 - DOOR LATCH HANDLE
2 - DOOR TRIM
3 - LATCH LINKAGE
4 - CLIP
5 - MEMORY SEAT SWITCH
23 - 20 DOOR - FRONTRS
LOCK CYLINDER (Continued)

(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)

INSTALLATION
If outside door handle replacement is necessary,
transfer lock cylinder from the original handle to the
new one.
(1) Place outside door handle in position on vehi-
cle.
(2) Install nuts attaching outside door handle to
door outer panel (Fig. 11). Tighten nuts to 6 N´m (50
in. lbs.).
(3) Insert lock linkage into door latch.
(4) Engage clip to hold door lock linkage to latch.
(5) Insert latch linkage into door latch.
(6) Engage clip to hold door latch linkage to latch.
(7) Install push-in fasteners to hold VTSS switch
harness to inner door reinforcement bar, if equipped.
(8) Connect VTSS switch connector into door har-
ness, if equipped.
(9) Verify door latch operation.
(10) Install sound shield and door trim panel.
WINDOW REGULATOR -
POWER
REMOVAL
(1) Remove watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(2) Remove inner belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - REMOVAL)
(3) Remove door glass. (Refer to 23 - BODY/DOOR
- FRONT/DOOR GLASS - REMOVAL).
(4) Disconnect wire connector from power window
motor.
(5) Loosen screws attaching front and rear window
guide rails to inner door panel.
(6) Remove screw heads on guide rails from key
hole slots in inner door panel.
(7) Loosen screws attaching motor/housing to inner
door panel.
(8) Remove regulator from inner door panel.
(9) Extract rear guide rail through inner door
panel rear access hole (Fig. 14).
(10) Extract front guide rail through front access
hole.
INSTALLATION
(1) Insert front guide rail through front access
hole.
(2) Insert rear guide rail through rear access hole.
(3) Place window regulator in position on inner
door panel.
(4) Place screw heads on guide rails in position
through key hole slots in inner door panel.
(5) Tighten screws to attach front and rear guide
rails to inner door panel to 8.5±10.7 N´m (75±95 inlbs). Tighten top screw first and bottom screw sec-
ond.
(6) Tighten screws to attach motor/housing to
inner door panel to 2.8 N´m (25 in lbs).
(7) Connect wire connector into power window
motor.
(8) Install door glass. (Refer to 23 - BODY/DOOR -
FRONT/DOOR GLASS - INSTALLATION)
(9) Verify door glass alignment and operation.
(10) Install inner belt molding (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - INSTALLATION)
(11) Install watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - INSTALLATION)
WINDOW REGULATOR -
MANUAL
REMOVAL
(1) Remove watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(2) Remove inner belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - REMOVAL)
(3) Remove door glass. (Refer to 23 - BODY/DOOR
- FRONT/DOOR GLASS - REMOVAL).
(4) Loosen screws attaching front and rear window
guide rails to inner door panel. (Fig. 15).
(5) Remove screw heads on guide rails from key
hole slots in inner door panel.
(6) Loosen screws attaching regulator to inner door
panel.
(7) Remove regulator from inner door panel.
Fig. 14 FRONT DOOR POWER WINDOW
1 - POWER WINDOW MOTOR
2 - FRONT DOOR
3 - GUIDE RAILS
23 - 22 DOOR - FRONTRS
EXTERIOR HANDLE (Continued)

(8) Extract rear guide rail through inner door
panel rear access hole.
(9) Extract front guide rail through front access
hole.INSTALLATION
(1) Insert front guide rail through front access
hole.
(2) Insert rear guide rail through rear access hole.
(3) Place window regulator in position on inner
door panel.
(4) Place screw heads on guide rails in position
through key hole slots in inner door panel.
(5) Tighten screws to attach front and rear guide
rails to inner door panel to 8.5±10.7 N´m (75±95 in
lbs). Tighten top screw first and bottom screw second
on each rail.
(6) Tighten screws to attach regulator to inner
door panel to 2.8 N´m (25 in lbs).
(7) Install door glass. (Refer to 23 - BODY/DOOR -
FRONT/DOOR GLASS - INSTALLATION)
(8) Verify door glass alignment and operation.
(9) Install inner belt molding (Refer to 23 - BODY/
WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - INSTALLATION)
(10) Install watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - INSTALLATION)
Fig. 15 FRONT DOOR MANUAL WINDOW
REGULATOR
1 - FRONT DOOR
2 - MANUAL WINDOW REGULATOR
3 - GUIDE RAILS
RSDOOR - FRONT23-23
WINDOW REGULATOR - MANUAL (Continued)