2005 CHRYSLER VOYAGER Door locks

(4) Remove A-pillar trim panels.
(5) Place protective covers over instrument panel
and hood.
(6) Remove windshield molding. Using pliers, pull
outward on molding at the bottom of A-pillars.
(7) Using a sharp cold knife, cut urethane adhe-
sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 1). A power
cutting device can be used if available.
(8) Remove windshield from vehicle.
WINDSHIELD REMOVAL ± INTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Remove instrument panel top cover. Refer to
Group 8E, Instrument Panel and Systems.
(3) Remove A-pillar trim covers.
(4) Place protective covers over instrument panel
and hood.
(5) Using a reciprocating or oscillating power
knife, cut urethane adhesive holding the windshield
to the A-pillars, roof header and cowl pinch weld
fences. Refer to instructions provided with the equip-
ment being used.
(6) Remove windshield from vehicle.
INSTALLATION
The urethane adhesive holding the windshield to
the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment. If a door is slammed before
urethane bonding is cured, water leaks can result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.To avoid stressing the replacement windshield, the
urethane bonding material on the windshield fence
should be smooth and consistent to the shape of
the replacement windshield. The support spacers
should be cleaned and properly installed on weld
studs or repair screws at bottom of windshield
opening.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the compression spacers.
(2) Verify the glass lays evenly against the pinch
urethane adhesive remaining on the weld fence at
the sides, top and bottom of the replacement wind-
shield. If not, the pinch weld fence must be formed to
the shape of the new glass.
(3) Remove replacement windshield from wind-
shield opening.
(4) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 2).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(5) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.
(6) Install molding to perimeter of windshield.
(7) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of windshield and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.
(8) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying time.
(9) Using a razor knife, remove as much original
urethane as possible. Do not damage paint on wind-
shield fence.
(10) Apply pinch weld primer 19 mm (0.75 in.)
wide around the windshield fence. Allow at least
three minutes drying time.
(11) If a low viscosity urethane adhesive is used,
install compression spacers on the fence around the
windshield opening (Fig. 3).
(12) Apply a 10 mm (0.4 in.) bead of urethane on
center line of windshield fence.
(13) With the aid of a helper, position the wind-
shield over the windshield opening.
(14) Slowly lower windshield glass to windshield
opening fence. Guide the molding into proper position
as necessary. Push windshield inward until molding
is flush to roof line and A-pillars (Fig. 3).
(15) Clean access urethane from exterior with
MopartSuper Kleen or equivalent.
Fig. 1 CUT URETHANE AROUND WINDSHIELD
1 - COLD KNIFE
2 - WINDSHIELD
23 - 162 STATIONARY GLASSRS
WINDSHIELD (Continued)

(16) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place until urethane cures.
(17) Install A-pillar trim panels.
(18) Install cowl cover and wipers.
(19) Install inside rear view mirror.
(20) After urethane has cured, remove tape strips
and water test windshield to verify repair.SLIDING DOOR GLASS
REMOVAL
The temperature of the vehicle should be at least
21É C (70É F) before removing the stationary quarter/
sliding door glass. Butyl sealer becomes more pliable
at high temperatures.
(1) Remove interior trim as necessary to gain
access attaching locations on back of glass.
(2) Remove nuts holding stationary glass to fence.
(3)
Using razor knife, cut butyl sealer holding glass
to fence from between the mounting studs (Fig. 4).
(4) Push glass from opening.
INSTALLATION
The temperature of the vehicle should be at least
21É C (70É F) before removing the stationary quarter/
sliding door glass. Butyl sealer becomes more pliable
at high temperatures.
The stationary glass fence should be cleaned of all
old butyl sealer.
(1) Applya6mm(0.25 in.) butyl tape around
perimeter of glass assembly encapsulation track.
Ensure that the butyl tape is wrapped around the
mounting studs.
(2) Place the glass into the opening and insert
mounting studs through holes in fence.
(3) Install nuts to hold stationary glass to fence.
CAUTION: Tighten nuts to 3.4 N´m (30 in. lbs.)
torque in the sequence indicated. Do not over
torque, or glass breakage may result (Fig. 4).
(4) Water test before installing interior trim.
(5) Install interior trim. (Refer to 23 - BODY/
DOORS - SLIDING/TRIM PANEL - INSTALLATION)
(6) Verify alignment and flushness.
Fig. 2 WORK SURFACE SET UP AND MOLDING
INSTALLATION
1 - WINDSHIELD AND MOLDINGS
2 - BLOCKS
Fig. 3 LOWER WINDSHIELD INTO POSITION
1 - WINDSHIELD
2 - COMPRESSION SPACERS
Fig. 4 SLIDING DOOR STATIONARY GLASS
1 - NUMBERS INDICATE THE TIGHTENING SEQUENCE
2-6mmBEAD OF BUTYL TAPE
3 - BODY SIDE/SLIDING DOOR GLASS
RSSTATIONARY GLASS23 - 163
WINDSHIELD (Continued)

QUARTER WINDOW
REMOVAL
(1) Remove C-pillar trim.
(2) Open quarter glass to vent position.
(3) Disengage quarter window retainer from vent
motor arm.
(4) Remove nuts attaching quarter glass to C-pillar
(Fig. 5).
(5) Use magnetic socket to prevent dropping into
the pillar.
(6) Remove quarter glass from vehicle.
INSTALLATION
(1) Place quarter glass in position on vehicle.
(2) Install nuts attaching quarter glass to C-pillar.
(3) Engage quarter window retainer to vent motor
arm.
(4) Install screw attaching quarter window
retainer to vent motor arm.
(5) Close quarter glass.
(6) Verify alignment and flushness.
(7) Install C-pillar trim.
LIFTGATE GLASS
REMOVAL
Refer to the Safety Precautions in this section for
description of tools and adhesive systems that are
recommended for use in this procedure.
REAR WINDOW REMOVAL ± EXTERIOR METHOD
(1) Remove rear window wiper arm.
(2) Remove interior trim covers.
(3) Disconnect wires for electrically heated win-
dow, if equipped.
(4) Using a sharp cold knife, cut urethane adhe-
sive attaching the rear window to the liftgate. A
power cutting device can be used if available (Fig. 1).
(5) Remove rear window from vehicle.
INSTALLATION
Refer to the Safety Precautions in this section for
description of tools and adhesive systems that are
recommended for use in this procedure.
CAUTION: Open the left front door glass before
installing rear window to avoid pressurizing the
passenger compartment. If a door is slammed
before urethane bonding is cured, water leaks can
result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.
To avoid stressing the replacement rear window,
the urethane bonding material on the rear window
fence should be smooth and consistent to the
shape of the replacement glass.
(1) Place replacement glass into rear window open-
ing.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement rear window. If not, the urethane adhe-
sive remaining on the fence must be formed to the
shape of the new glass.
(3) Using a grease pencil, mark the glass and lift-
gate in several locations to aid installation.
(4) Remove replacement glass from liftgate open-
ing.
(5) Position the rear window inside up on a suit-
able work surface with two padded, wood 10 cm by
10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks,
placed parallel 75 cm (2.5 ft.) apart (Fig. 2).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN REAR WINDOW BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
Fig. 5 QUARTER GLASS
1 - VENT CONTROL
2 - QUARTER GLASS
3 - CLIP
23 - 164 STATIONARY GLASSRS

LEVEL, STANDARD PROCEDURE -CHECKING BATTERY ELECTROLYTE ......8F-14
LEVEL, STANDARD PROCEDURE - REFRIGERANT OIL ................... 24-94
LEVEL SWITCH - DESCRIPTION, BRAKE FLUID .............................. 5-10
LEVEL SWITCH - INSTALLATION, BRAKE FLUID .............................. 5-11
LEVEL SWITCH - INSTALLATION, WASHER FLUID ..................... 8R-11
LEVEL SWITCH - OPERATION, BRAKE FLUID .............................. 5-10
LEVEL SWITCH - REMOVAL, BRAKE FLUID .............................. 5-11
LEVEL SWITCH - REMOVAL, WASHER FLUID ............................. 8R-11
LEVEL TEST, DIAGNOSIS AND TESTING - SYSTEM CHARGE .................... 24-67
LEVER - PARKING BRAKE - INSTALLATION ........................ 5-76
LEVER - PARKING BRAKE - REMOVAL .....5-75
LEVER AND FRONT CABLE - INSTALLATION, PARKING BRAKE .........5-77
LEVER AND FRONT CABLE - REMOVAL, PARKING BRAKE ...................... 5-77
LHD - INSTALLATION .........5-106,5-39,5-50
LHD - REMOVAL .............5-102,5-36,5-46
LHD GEAR - INSTALLATION ............19-31
LHD GEAR - REMOVAL ................19-26
LICENSE LAMP - INSTALLATION .........8L-17
LICENSE LAMP - REMOVAL ............8L-17
LID LATCH - FOLD-IN-FLOOR - INSTALLATION, FLOOR CONSOLE ........23-90
LID LATCH - FOLD-IN-FLOOR - REMOVAL, FLOOR CONSOLE ...........23-90
LIFT GEAR & LINK ROD - DESCRIPTION . . 8N-16
LIFT GEAR & LINK ROD - INSTALLATION . 8N-17
LIFT GEAR & LINK ROD - OPERATION ....8N-16
LIFT GEAR & LINK ROD - REMOVAL .....8N-16
LIFTERS - DIAGNOSIS AND TESTING, HYDRAULIC ......................... 9-116
LIFTERS (CAM IN BLOCK) - DESCRIPTION, HYDRAULIC .............9-116
LIFTERS (CAM IN BLOCK) - INSTALLATION, HYDRAULIC ............9-117
LIFTERS (CAM IN BLOCK) - REMOVAL, HYDRAULIC ......................... 9-117
LIFTGATE - INSTALLATION .............23-42
LIFTGATE - REMOVAL .................23-42
LIFTGATE ADJUSTMENT, STANDARD PROCEDURE ......................... 8N-8
LIFTGATE CONTROL MODULE - DESCRIPTION, POWER ................8E-10
LIFTGATE CONTROL MODULE - OPERATION, POWER .................. 8E-10
LIFTGATE CONTROL MODULE, DIAGNOSIS AND TESTING - POWER .....8E-10
LIFTGATE GLASS - INSTALLATION ......23-164
LIFTGATE GLASS - REMOVAL ..........23-164
LIFTGATE LAMP - INSTALLATION ........8L-22
LIFTGATE LAMP - REMOVAL ............8L-22
LIFTGATE LEARN CYCLE, STANDARD PROCEDURE - POWER .................8N-8
LIFTGATE MOTOR - DESCRIPTION .......8N-15
LIFTGATE MOTOR - INSTALLATION ......8N-16
LIFTGATE MOTOR - OPERATION .........8N-15
LIFTGATE MOTOR - REMOVAL ..........8N-15
LIFTGATE SIDE - INSTALLATION .........23-44
LIFTGATE SIDE - REMOVAL ............23-44
LIFTGATE SILL PLATE - INSTALLATION . . . 23-95
LIFTGATE SILL PLATE - REMOVAL .......23-94
LIFTGATE SYSTEM - DESCRIPTION, POWER ............................. 8N-2
LIFTGATE SYSTEM - OPERATION, POWER ............................. 8N-2
LIFTGATE SYSTEM, DIAGNOSIS AND TESTING - POWER .................... 8N-3
LIMITS, DESCRIPTION - HIGH AND LOW . . . 25-9
LINE - INSTALLATION, A/C DISCHARGE . . . 24-80
LINE - INSTALLATION, LIQUID ....24-106,24-91
LINE - INSTALLATION, SUCTION . . . 24-107,24-97
LINE - REMOVAL, A/C DISCHARGE .......24-79
LINE - REMOVAL, LIQUID ........24-105,24-89
LINE - REMOVAL, SUCTION ......24-106,24-96
LINE EXTENSION, INSTALLATION - REAR A/C EVAPORATOR ................... 24-100
LINE EXTENSION, REMOVAL - REAR A/C EVAPORATOR ....................... 24-99LINE QUICK CONNECT FITTING
DISASSEMBLY/ASSEMBLY -
STANDARD PROCEDURE,
TRANSMISSION COOLER ...............7-38
LINES - DESCRIPTION, OIL COOLER .....9-141
LINES - DESCRIPTION, UNDERBODY ....24-108
LINES - INSTALLATION, OIL COOLER .....9-141
LINES - INSTALLATION, TRANSMISSION OIL COOLER ......................... 7-40
LINES - OPERATION, OIL COOLER .......9-141
LINES - OPERATION, UNDERBODY ......24-108
LINES - REMOVAL, OIL COOLER ........9-141
LINES - REMOVAL, TRANSMISSION OIL COOLER ............................. 7-39
LINES, INSTALLATION - UNDERBODY REFRIGERANT ...................... 24-112
LINES, REMOVAL - UNDERBODY REFRIGERANT ...................... 24-110
LINES/HOSES AND CLAMPS - DESCRIPTION, FUEL ................... 14-7
LINING - INSPECTION, REAR DRUM BRAKE SHOE ......................... 5-22
LINK - INSTALLATION, FUEL FILL DOOR BLOCKER LOCKOUT .................. 23-54
LINK - INSTALLATION, SEAT RISER LATCH LOCKING .................... 23-151
LINK - REMOVAL, FUEL FILL DOOR BLOCKER LOCKOUT .................. 23-54
LINK - REMOVAL, SEAT RISER LATCH LOCKING .......................... 23-151
LINK CONNECTOR - DESCRIPTION, DATA . . 8E-6
LINK CONNECTOR - OPERATION, DATA ......8E-6
LINK ROD - DESCRIPTION, LIFT GEAR . . . 8N-16
LINK ROD - INSTALLATION, LIFT GEAR . . . 8N-17
LINK ROD - OPERATION, LIFT GEAR .....8N-16
LINK ROD - REMOVAL, LIFT GEAR .......8N-16
LINKAGE - INSTALLATION, WIPER .......8R-14
LINKAGE - REMOVAL, WIPER ...........8R-13
LIQUID LINE - INSTALLATION .....24-106,24-91
LIQUID LINE - REMOVAL ........24-105,24-89
LOCATION - DESCRIPTION, CONNECTOR/ GROUND/SPLICE ...................8W -91-1
LOCATIONS - DESCRIPTION, FLUID FILL/CHECK ...........................0-7
LOCATIONS - FOLD-IN-FLOOR - SPECIFICATIONS, WELD ..............23-350
LOCATIONS - FOLD-IN-FLOOR ONLY - SPECIFICATIONS, BODY SEALING .......23-209
LOCATIONS - FOLD-IN-FLOOR ONLY - SPECIFICATIONS, STRUCTURAL
ADHESIVE ......................... 23-228
LOCATIONS - SPECIFICATIONS, BODY SEALING .......................... 23-183
LOCATIONS - SPECIFICATIONS, STRUCTURAL ADHESIVE ..............23-218
LOCATIONS - SPECIFICATIONS, WELD . . . 23-234
LOCK ASSEMBLY - INSTALLATION, LATCH ............................. 23-27
LOCK ASSEMBLY - REMOVAL, LATCH ....23-26
LOCK CYLINDER - INSTALLATION . . 23-19,23-42
LOCK CYLINDER - REMOVAL ......23-19,23-42
LOCK MOTOR - INSTALLATION, SLIDING DOOR ............................. 8N-25
LOCK MOTOR - REMOVAL, SLIDING DOOR ............................. 8N-25
LOCK MOTOR, DIAGNOSIS AND TESTING - DOOR ............................ 8N-23
LOCK SWITCH - EXPORT - DESCRIPTION, DOOR CYLINDER ........8N-22
LOCK SWITCH - EXPORT - OPERATION, DOOR CYLINDER .................... 8N-22
LOCK SWITCH, DIAGNOSIS AND TESTING - DOOR .................... 8N-23
LOCK SWITCH, EXPORT - DOOR CYLINDER .......................... 8N-22
LOCK TUMBLER - FOLD-IN-FLOOR - INSTALLATION, FLOOR CONSOLE KEY ....23-90
LOCK TUMBLER - FOLD-IN-FLOOR - REMOVAL, FLOOR CONSOLE KEY ........23-90
LOCKED ENGINE, STANDARD PROCEDURE - HYDROSTATIC ........9-10,9-87
LOCKING LINK - INSTALLATION, SEAT RISER LATCH ...................... 23-151
LOCKING LINK - REMOVAL, SEAT RISER LATCH ............................ 23-151
LOCK/LATCH - INSTALLATION, UNDER SEAT STORAGE BIN .................23-150LOCK/LATCH - REMOVAL, UNDER SEAT
STORAGE BIN ...................... 23-150
LOCKOUT LINK - INSTALLATION, FUEL FILL DOOR BLOCKER .................23-54
LOCKOUT LINK - REMOVAL, FUEL FILL DOOR BLOCKER ..................... 23-54
LOCKS - DESCRIPTION, POWER ........8N-20
LOCKS - OPERATION, POWER ..........8N-21
LOUVER - INSTALLATION, REAR HVAC . . . 23-97
LOUVER - REMOVAL, REAR HVAC .......23-96
LOW LIMITS, DESCRIPTION - HIGH .......25-9
LOWER - CLEANING, INTAKE MANIFOLD . . 9-151
LOWER - INSPECTION, INTAKE MANIFOLD ...................... 9-151,9-62
LOWER - INSTALLATION, INTAKE MANIFOLD ........................... 9-62
LOWER - INSTALLATION, SHROUD .......19-21
LOWER - REMOVAL, INTAKE MANIFOLD . . . 9-62
LOWER - REMOVAL, SHROUD ..........19-21
LOWER BALL JOINT - DESCRIPTION ......2-10
LOWER BALL JOINT - DIAGNOSIS AND TESTING ............................ 2-10
LOWER BALL JOINT - OPERATION ........2-10
LOWER CONSOLE - INSTALLATION ......23-73
LOWER CONSOLE - REMOVAL ..........23-73
LOWER CONTROL ARM - DESCRIPTION . . . 2-12
LOWER CONTROL ARM - INSPECTION .....2-14
LOWER CONTROL ARM - INSTALLATION . . . 2-15
LOWER CONTROL ARM - OPERATION .....2-12
LOWER CONTROL ARM - REMOVAL ......2-12
LOWER CONTROL ARM (REAR BUSHING - HYDRO) - ASSEMBLY .................2-15
LOWER CONTROL ARM (REAR BUSHING - HYDRO) - DISASSEMBLY ..............2-13
LOWER CONTROL ARM (REAR BUSHING - STANDARD) - ASSEMBLY ..............2-14
LOWER CONTROL ARM (REAR BUSHING - STANDARD) - DISASSEMBLY ...........2-13
LOWER DRIVE UNIT - DESCRIPTION .....8N-53
LOWER DRIVE UNIT - INSTALLATION ....8N-54
LOWER DRIVE UNIT - OPERATION .......8N-53
LOWER DRIVE UNIT - REMOVAL ........8N-53
LOWER DRIVE UNIT TRACK & RACK - DESCRIPTION ....................... 8N-57
LOWER DRIVE UNIT TRACK & RACK - INSTALLATION ...................... 8N-58
LOWER DRIVE UNIT TRACK & RACK - OPERATION ......................... 8N-57
LOWER DRIVE UNIT TRACK & RACK - REMOVAL .......................... 8N-57
LOWER EXTENSION TRIM - INSTALLATION, A-PILLAR ..............23-79
LOWER EXTENSION TRIM - REMOVAL, A-PILLAR ........................... 23-79
LOWER HINGE - INSTALLATION .........23-28
LOWER HINGE - REMOVAL .............23-28
LOWER INSTRUMENT PANEL - INSTALLATION ....................... 23-73
LOWER INSTRUMENT PANEL - REMOVAL .......................... 23-73
LOWER INTAKE MANIFOLD - INSTALLATION ....................... 9-151
LOWER INTAKE MANIFOLD - REMOVAL . . . 9-150
LOWER STEERING COLUMN COVER - INSTALLATION ....................... 23-74
LOWER STEERING COLUMN COVER - REMOVAL .......................... 23-74
LOWER TRIM - INSTALLATION, B-PILLAR ........................... 23-80
LOWER TRIM - REMOVAL, B-PILLAR .....23-79
LUBRICANTS - DESCRIPTION, ENGINE OIL .................................0-1
LUBRICATION - DESCRIPTION ......9-138,9-53
LUBRICATION - OPERATION ........9-138,9-53
LUBRICATION - STANDARD PROCEDURE ....2-2
LUBRICATION - STANDARD PROCEDURE, CABLE END CLEANING .................5-65
LUBRICATION POINTS - DESCRIPTION ......0-7
LUBRICATION, SPECIFICATIONS - BODY . . 23-12
LUGGAGE RACK CROSSBAR - INSTALLATION ....................... 23-59
LUGGAGE RACK CROSSBAR - REMOVAL . . 23-58
LUGGAGE RACK RISER - INSTALLATION . . 23-58
LUGGAGE RACK RISER - REMOVAL ......23-57
LUMBAR SUPPORT - INSTALLATION ....23-150
LUMBAR SUPPORT - REMOVAL ........23-150
RS INDEX19
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