Index Chrysler Chrysler RG Voyager - service repair manual 2005 year

Content .. 1115 1116 1117 1118 ..

Chrysler RG Voyager. Manual - part 1117

(4) Install liftgate opening weatherstrip to D-pillar

flange next to prop assembly end pivot.

(5) Close liftgate. Check liftgate operation.

TRIM PANEL

REMOVAL

(1) Remove the bolt attaching the lift motor link, if

equipped (Fig. 6).

(2) Remove liftgate upper frame molding (Fig. 7).
(3) Remove assist handle screws.
(4) Disengage hidden clips holding trim panel to

liftgate from around perimeter or liftgate (Fig. 7).

(5) Disconnect wire connector from lamps.
(6) Remove liftgate trim panel from vehicle.

INSTALLATION

(1) Place liftgate trim panel in position on vehicle.
(2) Engage hidden clips to hold trim panel to lift-

gate and fasteners around perimeter of liftgate (Fig.
7).

(3) Connect wire connector into lamp.
(4) Install courtesy lamps into liftgate trim.
(5) Install screws to hold assist handle to liftgate.
(6) Install upper frame side moldings.
(7) Install liftgate upper frame molding.
(8) Install the bolt attaching the lifgate motor link

and tighten to 28 N·m (21 ft. lbs.)

SLAM BUMPER

REMOVAL

REMOVAL - BODY SIDE

(1) Open liftgate.
(2) Remove liftgate stop bumper body side attach-

ing bolts (Fig. 8).

(3) Remove liftgate stop bumper.

REMOVAL - LIFTGATE SIDE

(1) Open liftgate.

Fig. 5 LIFTGATE PROP ASSEMBLY

1 - LIFTGATE
2 - PROP ASSEMBLY

Fig. 6 LIFTGATE MOTOR

1 - LIFTGATE MOTOR LINK BOLT
2 - LIFTGATE MOTOR
3 - LIFTGATE

Fig. 7 LIFTGATE TRIM

1 - LIFTGATE
2 - LOWER TRIM PANEL
3 - ASSIST HANDLE SCREWS
4 - UPPER TRIM
5 - UPPER TRIM CLIPS

RS

DECKLID/HATCH/LIFTGATE/TAILGATE

23 - 47

SUPPORT CYLINDER (Continued)

(2) Remove

liftgate

stop

bumper

liftgate

side

attaching rivets by drilling out old rivets.

(3) Remove liftgate stop bumper.

INSTALLATION

INSTALLATION - BODY SIDE

(1) Place liftgate stop bumper into position.
(2) Install bolts attaching liftgate stop bumper to

body side (Fig. 8).

(3) Close liftgate.

INSTALLATION - LIFTGATE SIDE

(1) Place liftgate stop bumper into position.
(2) Install rivets attaching liftgate stop bumper to

liftgate.

NOTE: Verify that ships or parts of drilled out rivet
does not rattle in the liftgate. If there is rattling
sound, detrim liftgate and retrieve debris.

(3) Close liftgate.

Fig. 8 LIFTGATE STOP BUMPER - BODY SIDE

1 - LIFTGATE STOP BUMPER
2 - LIFTGATE OPENING

23 - 48

DECKLID/HATCH/LIFTGATE/TAILGATE

RS

SLAM BUMPER (Continued)

EXTERIOR

TABLE OF CONTENTS

page

page

BODY SIDE MOLDINGS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

. . . . . . . . . . . . . . . . . . . . . . . . . 50

COWL GRILLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

. . . . . . . . . . . . . . . . . . . . . . . . . 54

EXTERIOR NAME PLATES - TAPE ATTACHED

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

. . . . . . . . . . . . . . . . . . . . . . . . . 55

EXTERIOR NAME PLATES - ADHESIVE

ATTACHED
REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

. . . . . . . . . . . . . . . . . . . . . . . . . 55

FRONT FENDER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

. . . . . . . . . . . . . . . . . . . . . . . . . 56

FUEL FILL DOOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

. . . . . . . . . . . . . . . . . . . . . . . . . 56

FUEL FILL DOOR BLOCKER LATCH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

. . . . . . . . . . . . . . . . . . . . . . . . . 57

FUEL FILL DOOR BLOCKER LATCH STRIKER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

. . . . . . . . . . . . . . . . . . . . . . . . . 57

FUEL FILL DOOR BLOCKER LOCKOUT LINK

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

. . . . . . . . . . . . . . . . . . . . . . . . . 58

GRILLE

. . . . . . . . . . . . . . . . . . . . . . . . . 58

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

. . . . . . . . . . . . . . . . . . . . . . . . . 58

UPPER RADIATOR CROSSMEMBER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

. . . . . . . . . . . . . . . . . . . . . . . . . 60

FRONT WHEELHOUSE SPLASH SHIELD

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

. . . . . . . . . . . . . . . . . . . . . . . . . 61

LUGGAGE RACK RISER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

. . . . . . . . . . . . . . . . . . . . . . . . . 62

LUGGAGE RACK CROSSBAR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

. . . . . . . . . . . . . . . . . . . . . . . . . 63

REAR QUARTER PANEL/FENDER AIR

EXHAUSTER
DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 63

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

. . . . . . . . . . . . . . . . . . . . . . . . . 64

ROOF JOINT MOLDING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

. . . . . . . . . . . . . . . . . . . . . . . . . 64

SIDE VIEW MIRROR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

. . . . . . . . . . . . . . . . . . . . . . . . . 64

GLASS-OUTSIDE REARVIEW MIRROR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

. . . . . . . . . . . . . . . . . . . . . . . . . 67

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 38° C (100° 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-Brite™ 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.

RS

EXTERIOR

23 - 49

INSTALLATION

Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig.

5)for proper location of fasteners to hold the molding
to the wheelhouse lip and rocker panels.

(1) If molding is to be reused;

(a) Remove tape residue from molding.
(b) Clean back of molding with Mopar

t Super

Kleen, or equivalent.

(c) Wipe molding dry with lint free cloth.
(d) Apply a single coat of Mopar

t TPO Molding

Prep to tape side of molding and allow to dry thor-
oughly.

(e) Apply new body side molding (two sided

adhesive) tape to back of molding.

(2) Clean body surface with Mopar

t Super Kleen,

or equivalent. Wipe surface dry with lint free cloth.

(3) Remove protective cover from tape on back of

molding.

(4) Apply molding to body from front to rear,

inserting locator pins into hole in body panel.

(5) Using a roller tool, roll molding onto body

panel with enough force to assure adhesion. Do not
apply excessive force, or damage to body panels may
result.

(6) Install pop rivets to hold molding edge to

wheelhouse lip, if necessary.

Fig. 1 BODY SIDE MOLDINGS - BASE TYPICAL

1 - GUIDE PINS
2 - FRONT DOOR MOLDING

3 - SLIDING DOOR MOLDING
4 - QUARTER PANEL MOLDING

23 - 50

EXTERIOR

RS

BODY SIDE MOLDINGS (Continued)

Content .. 1115 1116 1117 1118 ..