2005 CHRYSLER VOYAGER Water

INSTALLATION
CAUTION: When installing a new hinge, make sure
that the head of each hinge pin is fully seated into
the door hinge. Also, remove the plastic shipping
clip and replace it with the correct metal retaining
clip once the hinge pin is seated.
(1) Paint hinge prior to installation, if necessary.
(2) Position door to vehicle. Verify net pierce nub-
bin is engaged if reusing original hinges. Applies to
body half of hinge only.
(3) Install bolts attaching hinge to pillar. Tighten
bolts to 34 N´m (25 ft. lbs.).
(4) Install bolts attaching front door to door hinge.
Tighten bolts to 34 N´m (25 ft. lbs.).
(5) Align door to achieve equal spacing to sur-
rounding body panels. Panels should be flush across
all gaps.
(6) Verify door alignment and operation. Adjust as
necessary.
LATCH
REMOVAL
(1) Roll door glass up.
(2) Remove front door trim panel. (Refer to 23 -
BODY/DOOR - FRONT/TRIM PANEL - REMOVAL)
(3) Remove watershield as necessary to gain access
to the outside door handle.
(4) Through access hole at rear of inner door
panel, disconnect wire connector from power door
lock motor, if equipped.
(5) Disengage clips holding linkage to door latch
(Fig. 8).
(6) Remove linkages from door latch.
(7) Remove screws attaching door latch to door end
frame (Fig. 9).
(8) Remove door latch from door.
INSTALLATION
NOTE: The screws attaching the door latch to the
door end frame have nylon patches on the threads.
All screws must be replaced when the latch has
been removed.
(1) Insert inside handle latch link to door latch
and engage clip (Fig. 8).
(2) Place door latch in position on door end frame.
(3) Install screws attaching door latch to door end
frame. Tighten screws to 10 N´m (90 in. lbs.) torque
(Fig. 9).
(4) Insert other linkages to door latch and engage
clips.(5) Connect wire connector into power door lock
motor, if equipped.
(6) Insert a hex wrench through the elongated hole
located in the door shut face above the latch.
(7) Loosen allen head screw.
(8) Pull outward on the outside door handle and
release.
(9) Tighten allen head screw.
Fig. 8 LATCH ASSEMBLY
1 - OUTSIDE HANDLE TO LATCH LINK
2 - KEY CYLINDER TO LATCH LINK
3 - LATCH ASSEMBLY
4 - INSIDE HANDLE LINK AND SLEEVE
5 - LOCK KNOB LINK
Fig. 9 FRONT DOOR LATCH
1 - FRONT DOOR
2 - LATCH ASSEMBLY
3 - INSIDE HANDLE LINK
23 - 18 DOOR - FRONTRS
HINGE (Continued)

(10) Verify door latch and power door lock opera-
tion.
(11) Install watershield and front door trim panel.
LATCH STRIKER
REMOVAL
(1) Mark outline of door striker on B-pillar to aid
in installation.
(2) Remove screws attaching door latch striker to
B-pillar (Fig. 10).
(3) Remove door latch striker from vehicle.
(4) Retrieve any shims found between latch striker
and B-pillar.
INSTALLATION
(1) Position latch striker and any shims retrieved
on vehicle.
(2) Loosely install screws attaching latch striker to
B-pillar.
(3) Align latch striker to outline on B-pillar made
previously.
(4) Tighten fasteners to 28 N´m (21 ft. lbs.) torque.
(5) Verify door fit and operation. Adjust latch
striker as necessary.
LOCK CYLINDER
REMOVAL
(1) Roll door glass up.
(2) Remove front door 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 attaching outside door handle to
door outer panel.
(10) Remove outside door handle from vehicle.
(11) Disengage clip holding lock cylinder into out-
side handle.
(12) Pull lock cylinder from door handle.
INSTALLATION
(1) Engage clip into outside handle to hold lock
cylinder (Fig. 11).
(2) With link arm toward rear of vehicle, push lock
cylinder into door handle until clip snaps into place.
(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 attaching 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 watershield and door trim panel.
Fig. 10 DOOR LATCH STRIKER
1 - B-PILLAR
2 - SHIM
3 - DOOR LATCH STRIKER
RSDOOR - FRONT23-19
LATCH (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.
Fig. 13 WINDOW CRANK - TYPICAL
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
RSDOOR - FRONT23-21
TRIM PANEL (Continued)

(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.
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 in
lbs). 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).
Fig. 14 FRONT DOOR POWER WINDOW
1 - POWER WINDOW MOTOR
2 - FRONT DOOR
3 - GUIDE RAILS
23 - 22 DOOR - FRONTRS
EXTERIOR HANDLE (Continued)

(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.
(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)

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) If equipped, engage wire connector into power
door lock motor (Fig. 4).
(3) Place latch/lock in position on door (Fig. 5).
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)

(6) Engage clip to hold cable end into release han-
dle mechanism.
(7) Place latch handle in position on sliding door.
(8) Install screw to hold top of inside release han-
dle to sliding door.
(9) Install screws to hold bottom of inside latch
handle to sliding door.
(10) Verify sliding door operation. Adjust as neces-
sary. (Refer to 23 - BODY/DOORS - SLIDING/SLID-
ING DOOR - ADJUSTMENTS)
(11) Install sliding door trim panel.(Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
BELLCRANK
REMOVAL
(1) Remove stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - REMOVAL).
(2) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel as necessary to gain
access to latch bellcrank.
(4) Disengage lock link (Fig. 23).
(5) Disengage link and sleeve
(6) Remove bellcrank by rotating bellcrank to
release it from door.
(7) Remove bellcrank from vehicle.
INSTALLATION
(1) Position bellcrank on vehicle.
(2) Rotate bellcrank into position.(3) Place lock link into position and engage clip
(Fig. 23).
(4) Place link and sleeve into position and engage
clip.
(5) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(6) Install sliding door trim panel (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION).
(7) Install stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - INSTALLA-
TION).
OUTSIDE HANDLE
REMOVAL
(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 as necessary to access
outside release handle fasteners.
(4) Disengage clip attaching outside door handle
linkage to door cable.
(5) Remove linkage from outside door handle.
(6) Remove three nuts attaching outside door han-
dle to outer door panel (Fig. 24).
(7) Remove outside door handle from vehicle.
Fig. 22 RELEASE HANDLE CABLE
1 - ASSIST HANDLE MECHANISM
2 - SLIDING DOOR INSIDE ASSIST HANDLE
3 - RELEASE HANDLE CABLE
Fig. 23 BELLCRANK
1 - OUTSIDE HANDLE
2 - OUTSIDE HANDLE BRACKET ATTACHING NUT
3 - LOCK KNOB
4 - LATCH LINK
5 - LOCKING LINK
6 - DOOR LOCKING LEVER (BELLCRANK)
RSDOORS - SLIDING23-35
INSIDE LATCH HANDLE (Continued)