2005 CHRYSLER VOYAGER Service Manual

infotainment oil hood open steering hood release dimensions

Page 1809 of 2339

CHRYSLER VOYAGER 2005 Service Manual (3) Position door rearward of the sliding door open-
ing.
CAUTION: Do not allow the center hinge roller to
contact the quarter glass. Glass can break.
(4) Engage the center hinge roller into the chann

Page 1810 of 2339

CHRYSLER VOYAGER 2005 Service Manual (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 step

(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 two 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) Check height of sliding door at the B-pillar and
C-pillar to determine which area is contributing the
greatest to the incorrect gaps.
(2) 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.
(3) If the sliding door is high at the C-pillar.
(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 to 13 N´m (115 in.
lbs.) torque.
(f) Verify alignment, adjust as necessary.
(4) If the sliding door is low at the B-pillar ;
(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 to 13
N´m (115 in. lbs.) torque.
(g) Verify alignment, adjust as necessary.
(5) If the sliding door is low at the C-pillar;
(a) Open the door to mid-point of travel.
(b) Mark outline of center hinge on sliding door
to assist in making adjustments.
(c) Adjust the adjustment bolt up or down to
move the door position. (Fig. 14).
(d) Move hinge downward to raise the door.
(e) Tighten center hinge bolts to 13 N´m (115 in.
lbs.) torque.
(f) Verify alignment adjust as necessary.
(6) If the sliding door is high at the B-pillar;
(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 to 13
N´m (115 in. lbs.) torque.
(g) Verify alignment, adjust as necessary.
(7) Fully open the sliding door.
(8) Verify that all center hinge bolts are tight.
(9) Adjust the rear of the sliding door up by turn-
ing the center hinge bolt clockwise (Fig. 14).
(10) Close the door and check the sliding door
alignment.
(11) Adjust the front of the sliding door up by
adjusting lower hinge bolts.
Fig. 14 SLIDING DOOR CENTER HINGE
1 - ADJUSTING BOLT
2 - WELD NUT
RSDOORS - SLIDING23-31
SLIDING DOOR (Continued)

Page 1811 of 2339

CHRYSLER VOYAGER 2005 Service Manual (12) Open door half way and remove lower hinge
bolt access plug.
(13) Loosen bolts as necessary to move the front of
door up or down.
(14) Check the upper hinge for possible bind,
adjust as necessary.

(12) Open door half way and remove lower hinge
bolt access plug.
(13) Loosen bolts as necessary to move the front of
door up or down.
(14) Check the upper hinge for possible bind,
adjust as necessary.
(15) Close the door and check the sliding door
alignment.
(16) 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 13 N´m (115 in. lbs.) torque. It may be
necessary to hold the center hinge bolt to prevent it
from turning while tightening nut.
(17) Verify alignment, adjust as necessary.
DOOR GAP ADJUSTMENT - FORE/AFT
(1) Check C-pillar and B-pillar for door to aperture
gaps (5 mm + 1 mm), and door to door gap (5 mm +
1 mm).
(2) If adjust gaps require adjustment, loosen cen-
ter hinge screws as necessary to move center hinge
forward or rearward.
(3) Moving center hinge rearward increases the
gap at C-pillar and decreases gap at B-pillar. Moving
center hinge forward decreases gap at the C-pillar
and increases gap at the B-pillar
(4) Move center hinge as necessary, and tighten
screws.
(5) Close the door and check the sliding door align-
ment.
(6) Verify door alignment, adjust as necessary.
(7) Tighten center hinge screws to 13 N´m (115 in.
lbs.) torque.
DOOR SEAL COMPRESSION
(1) First check Gap & Flush (Refer to 23 - BODY/
BODY STRUCTURE/GAP AND FLUSH - SPECIFI-
CATIONS). Check seal compression near the middle
of the door even with the latch assembly. Using a
piece of paper, place it across door seal and close
door. Pull paper out of door opening. If paper tears
setting is to tight, if paper slides thought to easily
the compression is insufficient and needs to be
adjusted.
(2) Adjust seal compression at the top of the B-pil-
lar seal;
(a) Open door to mid-point of travel.
(b) Mark outline of upper roller arm on door to
assist in making adjustments.
(c) Loosen bolts attaching upper roller arm to
door (Fig. 16).
(d) Decrease the length of the upper roller arm
to increase seal compression.
(e) Increase the length of the upper roller arm to
decrease seal compression.
(f) Tighten all upper roller arm bolts to 13 N´m
(115 in. lbs.) torque.
(g) Verify door alignment, adjust as necessary.
(3) Adjust seal compression at the bottom of B-pil-
lar seal.
(a) Open door to mid-point of travel.
(b) Mark outline of lower roller arm on lower
roller arm bracket to assist in making adjustments
(Fig. 17).
(c) Loosen bolts holding lower roller arm to
lower roller arm bracket.
(d) Pivot lower roller arm toward center of vehi-
cle to decrease seal compression.
Fig. 15 SLIDING DOOR LOWER ROLLER ARM
1 - LOWER ROLLER ARM BRACKET
2 - BOLTS
3 - SLIDING DOOR
Fig. 16 Sliding Door Upper Roller Arm
1 - UPPER STOP PLATE
2 - SLIDING DOOR
3 - UPPER SLIDING DOOR HINGE
23 - 32 DOORS - SLIDINGRS
SLIDING DOOR (Continued)

Page 1812 of 2339

CHRYSLER VOYAGER 2005 Service Manual (e) Pivot lower roller arm outward to increase
seal compression.
(f) Tighten lower roller arm bolts to 13 N´m (115
in. lbs.) torque.
(g) Verify alignment, adjust as necessary.
NOTE: Adjusting seal co

Page 1813 of 2339

CHRYSLER VOYAGER 2005 Service Manual (2) Install screws to hold stabilizer socket to B-pil-
lar. Tighten nuts to 5 N´m (45 in. lbs.) torque.
(3) Close sliding door and verify operation.
TRIM PANEL
REMOVAL
(1) Remove sliding door upper f

(2) Install screws to hold stabilizer socket to B-pil-
lar. Tighten nuts to 5 N´m (45 in. lbs.) torque.
(3) Close sliding door and verify operation.
TRIM PANEL
REMOVAL
(1) Remove sliding door upper frame molding.
(2) If removing the left sliding door trim panel,
remove screw from inside ash receiver bezel.
(3) Remove screw from pull cup.
(4) Disengage push-in fasteners holding trim to
door panel around perimeter and upper edge of door
(Fig. 20).
(5) Remove sliding door trim panel from vehicle.
INSTALLATION
(1) Place sliding door trim panel in position on
vehicle.
(2) Align locating pins on backside of trim panel to
mating holes in the inner door panel.
(3) Engage push-in fasteners to hold trim to door
panel around perimeter and upper edge of door (Fig.
20).
(4) Install pull cup screw.
(5) If necessary, install screw from inside ash
receiver bezel on left sliding door trim panel.(6) Install sliding door upper frame molding.
INSIDE LATCH HANDLE
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove screws attaching bottom of inside latch
handle to sliding door (Fig. 21).
(3) Remove two screw attaching top of inside latch
handle to sliding door.
(4) Remove latch handle from sliding door.
(5) Disengage cable end from clip on release han-
dle mechanism.
(6) Disengage cable end from release handle mech-
anism.
(7) Remove push pin fastener attaching cable end
to release handle.
(8) Disengage cable casing end from release handle
(Fig. 22).
(9) Disengage cable end from latch handle.
(10) Remove handle from vehicle.
INSTALLATION
(1) Place inside latch handle in position on vehicle.
(2) Engage cable end into latch handle.
(3) Engage cable casing end into release handle.
(4) Install push pin fastener to hold cable into
release handle.
(5) Engage cable end into release handle mecha-
nism.
Fig. 20 SLIDING DOOR TRIM PANEL
1 - PUSH-IN FASTENERS
2 - SLIDING DOOR UPPER FRAME MOLDING
3 - SLIDING DOOR TRIM PANEL
4 - PUSH-IN FASTENERS
5 - PUSH-IN FASTENERS
6 - SLIDING DOOR
Fig. 21 SLIDING DOOR INSIDE HANDLE
1 - INSIDE ASSIST HANDLE
2 - INSIDE RELEASE HANDLE CABLE
3 - ATTACHING SCREWS
23 - 34 DOORS - SLIDINGRS
STABILIZER SOCKET (Continued)

Page 1814 of 2339

CHRYSLER VOYAGER 2005 Service Manual (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) Ins

(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)

Page 1815 of 2339

CHRYSLER VOYAGER 2005 Service Manual 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 riggi

Page 1816 of 2339

CHRYSLER VOYAGER 2005 Service Manual (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 upp

(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)

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