2005 CHRYSLER VOYAGER roof rack

INSTALLATION
(1) Position outside door handle on vehicle.
(2) Install nuts attaching outside door handle to
outer door panel.
(3) Engage clip attaching linkage to outside door
handle.
(4) Engage rigging cam to latch/lock control mech-
anism.
(5) Move clip on latch/lock control to bottom of slot
and engage linkage to latch/lock control.
(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
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)

(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).
(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
RSDOORS - SLIDING23-37
UPPER HINGE (Continued)

EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL.............................45
INSTALLATION.........................46
COWL GRILLE
REMOVAL.............................50
INSTALLATION.........................50
EXTERIOR NAME PLATES - TAPE ATTACHED
REMOVAL.............................51
INSTALLATION.........................51
EXTERIOR NAME PLATES - ADHESIVE
ATTACHED
REMOVAL.............................51
INSTALLATION.........................51
FRONT FENDER
REMOVAL.............................51
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.............................54
INSTALLATION.........................54
GRILLE
DESCRIPTION.........................55REMOVAL.............................55
INSTALLATION.........................55
UPPER RADIATOR CROSSMEMBER
REMOVAL.............................56
INSTALLATION.........................56
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL.............................57
INSTALLATION.........................57
LUGGAGE RACK RISER
REMOVAL.............................57
INSTALLATION.........................58
LUGGAGE RACK CROSSBAR
REMOVAL.............................58
INSTALLATION.........................59
REAR QUARTER PANEL/FENDER AIR
EXHAUSTER
DESCRIPTION.........................59
REMOVAL.............................59
INSTALLATION.........................60
ROOF JOINT MOLDING
REMOVAL.............................60
INSTALLATION.........................60
SIDE VIEW MIRROR
REMOVAL.............................60
INSTALLATION.........................60
GLASS-OUTSIDE REARVIEW MIRROR
REMOVAL.............................61
INSTALLATION.........................61
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
(1) Insert headlining through liftgate opening (Fig.
23), (Fig. 24), (Fig. 25), and (Fig. 26).
(2) Place headlining in position on roof.
(3) Connect wire connectors.
(4) Install left sun visor support.
(5) Install push in locking fasteners attaching
headlining to rear roof header and bows (Fig. 22).
(6) Install right sun visor support.
(7) Install sun visors and vanity mirrors.
(8) If equipped, install roof rail modules.
(9) If equipped, install coat hooks.
(10) Install dome lamp.
(11) If equipped, install reading lamp.
(12) If equipped, install overhead console.
(13) Install liftgate opening header trim.
(14) Install D-pillar trim covers. (Refer to 23 -
BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL -
INSTALLATION), and (Refer to 23 - BODY/INTERI-
OR/RIGHT D-PILLAR TRIM PANEL - INSTALLA-
TION).(15) Install C-pillar upper trim covers. (Refer to 23
- BODY/INTERIOR/C-PILLAR TRIM - INSTALLA-
TION).
(16) Install B-pillar upper trim covers. (Refer to 23
- BODY/INTERIOR/B-PILLAR UPPER TRIM -
INSTALLATION).
(17) Install A-pillar trim covers. (Refer to 23 -
BODY/INTERIOR/A-PILLAR TRIM - INSTALLA-
TION).
Fig. 23 HEADLINER WITH SIDE CURTAINS
1 - 4-WAY LOCATOR AT FRONT OF HEADLINER
2 - PUSH IN CLIPS ON SUN VISOR RETAINER RACKET AND
TWO SCREWS IN SUN VISOR SWIVEL BRACKET
3 - ONE SCREW IN OVER HEAD CONSOLE
4 - PUSH PINS ATTACHING HEADLINER TO OVERHEAD5-2WAYLOCATOR AT REAR OF HEADLINER
6 - COAT HANGER HOOKS
7 - 2-WAY LOCATORS
8 - WIRE HARNESS
23 - 92 INTERIORRS
HEADLINER (Continued)

Fig. 24 HEADLINER WITH SIDE AIR CURTAINS AND SUNROOF
1 - 2-WAY LOCATOR AT FRONT OF HEADLINER
2 - LIP OUT WEATHERSTRIP ONTO HEADLINER
3 - HEADLINER
4 - 2-WAY LOCATOR PIN
5 - PUSH IN CLIP AND TWO SCREWS ATTACHING SUN VISOR
SWIVEL BRACKET
6 - 4-WAY LOCATOR PINS7 - PUSH ON CLIPS ON SUN VISOR CENTER SUPPORTS
8 - WIRE HARNESS
9 - COAT HANGER HOOK
10 - 2-WAY LOCATOR
11 - PUSH PIN FASTENERS
12 - PLASTIC NUT
Fig. 25 HEADLINING
1 - ROOF
2 - OVERHEAD CONSOLE BRACKET
3 - HEADLINING ASSEMBLYFig. 26 HEADLINING - SWB
1 - ROOF
2 - REAR HEADER TRIM
3 - PUSH-IN FASTENER
4 - HEADLINING
RSINTERIOR23-93
HEADLINER (Continued)

SUNROOF DIAGNOSIS CHART
SYMPTOM POSSIBLE CAUSE
Sunroof motor inoperative. Faulty control switch.
Faulty circuit ground between sunroof module, control switch,
and body harness.
Faulty power circuit between sunroof module, control switch,
and body harness.
Faulty sunroof drive motor.
Faulty sunroof module.
Audible whine when switch is depressed,
sunroof does not operate.Faulty sunroof drive motor.
Binding cable.
Audible clicking or ratcheting when switch is
pressed, sunroof does not operate.Broken or worn drive cable.
Worn drive motor gear.
Mechanisms not synchronized.
Sunroof vents and opens, but does not close. Broken or disengaged trough guide
Binding cable.
Faulty circuit.
Faulty control switch.
Faulty sunroof module.
Faulty drive motor.
Sunroof vents, but does not open. Binding cable or mechanism.
Faulty circuit.
Faulty switch.
Faulty sunroof module.
Sunroof does not vent Binding cable or mechanism.
Faulty circuit.
Faulty control switch.
Faulty sunroof module.
Sunroof water leak. Drain tubes clogged or kinked or disconnected from the
sunroof.
Glass panel improperly adjusted.
Faulty glass panel seal.
Gurgling sound from sunroof Low spot in drain hose routing, allowing water to stand.
Wind noise from sunroof. Glass panel compression to the roof opening not consistant.
Glass not installed or adjusted properly.
Faulty glass panel seal.
Buzz, Squeak,Rattles from sunroof Loose or broken attaching hardware.
No lubracation in track.
Worn or broken mechanism.
Cables bunched or kinked
RSSUNROOF23 - 171
SUNROOF (Continued)

SYMPTOM POSSIBLE CAUSE
Sunshade will not function or does not
operate smoothlySunshade feet are missing, broken or loose.
No lubracation in track.
Track obstructions or interference.
Glass movement not consistant or glass does
not operate smoothlyGlass and Track timing.
Glass and Track alignment
Cables and Guide alignment
WATER DRAINAGE AND WIND NOISE DIAGNOSIS
The sliding glass panel is designed to seal water
entry with a snug fit between the roof and the seal.
The fit can be checked by inserting a piece of paper
between the roof and the seal. The piece of paper
should have some resistance when pulled out when
the glass panel is in the closed position. Excessive
wind noise could result if the gap clearances are
exceeded. The sunroof glass panel may need to be
adjusted. Refer to Sunroof Glass Panel Adjustment
for proper procedures.
Adequate drainage is provided by a drain trough in
the sunroof housing which encircles the sliding glass
panel and leads to drain hoses. If a wet headliner or
other water leak complaints are encountered, before
performing any adjustments, first ensure that the
drainage system is not plugged or disconnected. Use
a pint container to pour water into the sunroof hous-
ing drain trough. If water flow is restricted in any of
the four drain holes, use compressed air to blow out
any material plugging the drain system. Retest sys-
tem again.
To further check for a disconnected drain hose:
(1) Remove A-pillar trim, sun visors, and map
lamps/mini console.
(2) Remove sunroof opening trim lace. Refer to
Sunroof Opening Trim Lace.
NOTE: Care must be taken not to fold or kink the
headliner upon removal.
(3) Lower headliner as necessary to gain access to
sunroof housing drain tubes. Refer to Headlining
Removal and Installation for proper procedures.
(4) Repair as necessary.
DRAIN TUBE
REMOVAL
FRONT HOSES
NOTE: Front A-pillars are filled with sound deaden-
ing foam and the front drain tubes are sealed into
the pillars.
(1) Move glass panel to the fully closed position.
(2) Disconnect negative battery cable.
(3) Remove headliner (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL).
(4) Disconnect the drain hose from the sunroof
housing (Fig. 1).
(5) Drain any liquid from hose connection, repair
as necessary.
REAR HOUSING HOSE
(1) Move glass panel to the fully closed position.
(2) Disconnect negative battery cable.
(3) Remove headliner (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL).
(4) Remove third seat or seats from vehicle.
(5) Remove second seat belt lower anchor.
(6) Remove third seat lower anchor.
(7) Remove quarter trim bolster.
(8) Remove trim panel screws.
(9) Remove quarter trim panel
(10) Disconnect the drain hose from the sunroof
housing. (Fig. 1).
(11) Drain any liquid from hose connection, if nec-
essary, and remove tube.
INSTALLATION
FRONT HOSES
(1) Connect the new drain hose to the sunroof
housing and test drainage (Fig. 1).
(2) Install headliner (Refer to 23 - BODY/INTERI-
OR/HEADLINER - INSTALLATION).
(3) Install sunroof opening trim lace.
(4) Connect the control switch wire connector and
install control switch.
23 - 172 SUNROOFRS
SUNROOF (Continued)

(5) Verify sunroof operation and alignment.
REAR HOUSING HOSE
(1) Connect the new drain hose to the sunroof
housing and test drainage (Fig. 1).
(2) Install headliner(Refer to 23 - BODY/INTERI-
OR/HEADLINER - INSTALLATION).
(3) Install sunroof opening trim lace.
(4) Connect the control switch wire connector and
install control switch.
(5) Verify sunroof operation and alignment.
GLASS PANEL
REMOVAL
(1) Move the glass panel to the vent position.
(2) Slide sunshade rearward to the open position.
(3) Remove the glass panel screws (Fig. 1).
(4) Lift off glass panel and remove from vehicle.
INSTALLATION
(1) Position glass panel on to mechanism lift arms.
(2) Start the attaching screws, and hand tighten
(Fig. 1).
(3) Adjust sunroof glass to fit flush with roof
line(Refer to 23 - BODY/SUNROOF/GLASS PANEL -
ADJUSTMENTS).
(4) Verify sunroof operation and alignment.
ADJUSTMENTS
SUNROOF GLASS PANEL ADJUSTMENT
(1) Move the sunshade rearward to the open posi-
tion.
(2) Move the sunroof glass panel to the fully closed
position.
(3) Loosen the forward attaching screws on each
side enough to make the front of the glass to adjust
up or down.
(4) Adjust the front surface of the sunroof glass
panel 0.00 mm to 1.75 mm (0.00 in. to 0.07 in.) below
the top surface of the roof.
(5) Tighten the front glass panel attaching screws
to 3.5 N´m (31 in. lbs.) torque (Fig. 1).
(6) Loosen the rear screws on each side enough to
make the rear adjustment (Fig. 1).
(7) Adjust the rear surface of the sunroof glass
panel 0.00 mm to 1.75 mm (0.03 in. to 0.07 in.) above
the top surface of the roof.
(8) Tighten the rear glass panel attaching screws
to 3.5 N´m (31 in. lbs.) torque (Fig. 1).
(9) Check for proper fit. If not OK, repeat glass
panel adjustment.
SUNROOF ASSEMBLY
REMOVAL
(1) Move glass panel to the fully closed position.
(2) Disconnect battery negative cable.
(3) Remove headliner (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL).
(4) Disconnect the four drain tubes from sunroof
housing (Fig. 1).
(5) Loosen fasteners attaching sunroof assembly
(Fig. 1).
(6) With the aid of a helper, support the sunroof
and remove the fasteners attaching sunroof assembly
to roof panel (Fig. 1).
(7) Remove sunroof from vehicle.
INSTALLATION
(1) Raise sunroof module assembly and guide it
carefully into position.
(2) While supporting the sunroof assembly tighten
the attaching screws (Fig. 1). Tighten to 6 N´m (53
in. lbs.) torque.
(3) Connect the drain tubes to the sunroof (Fig. 1).
(4) Connect battery negative cable.
(5) Test sunroof operation, adjust as necessary(Re-
fer to 23 - BODY/SUNROOF/GLASS PANEL -
ADJUSTMENTS).
(6) Install headliner (Refer to 23 - BODY/INTERI-
OR/HEADLINER - INSTALLATION).
(7) Install sunroof opening trim lace position(Refer
to 23 - BODY/SUNROOF/OPENING TRIM LACE -
INSTALLATION).
SUNSHADE
REMOVAL
(1) Place the sunroof glass panel in the vent posi-
tion.
(2) Remove glass panel (Refer to 23 - BODY/SUN-
ROOF/GLASS PANEL - REMOVAL).
(3) Remove water channel (Fig. 1).
(4) Cycle sunroof motor to the open position.
(5) Move sunshade towards the closed position
stopping three to four inches from the closed position.
(6) Depress the spring feet clips on one side of the
sun shade.
(7) Remove sunshade.
INSTALLATION
(1) Place one side of the sunshade spring feet clips
into the top track U-frame.
(2) Depress the both releasing clips on the other
side to allow them to go into the top track U-frame.
(3) Move sunshade to the open position.
(4) Install water channel (Fig. 1).
RSSUNROOF23 - 173
DRAIN TUBE (Continued)