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Chrysler AS Town Country Caravan Voyager 1994 Service Manual Body Components
Chrysler AS Town Country Caravan Voyager 1994 Service Manual Body Components
Chrysler AS Town Country Caravan Voyager 1994 Service Manual Body Components
BODY 23 - 1
BODY
CONTENTS
page page
soft bristle brush. If soap bubbles occur at a body VISUAL INSPECTION BEFORE TESTS
seam, joint, seal or gasket the leak entry point could Verify that floor and body plugs are in place and
be at that location. body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
WIND NOISE appropriate section of this group for proper proce-
Wind noise is the result of most air leaks. Air leaks dures.
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs ROAD TESTING WIND NOISE
in the engine compartment or door hinge pillar areas. (1) Drive the vehicle to verify the general location
All body sealing points should be air tight in normal of the wind noise.
driving conditions. Moving sealing surfaces will not (2) Apply 50 mm (2 in.) masking tape in 150 mm
always seal air tight under all conditions. At times, (6 in.) lengths along weatherstrips, weld seams or
side glass or door seals will allow wind noise to be moldings. After each length is applied drive vehicle.
noticed in the passenger compartment during high If noise goes away after a piece of tape is applied, re-
cross-winds. Over compensating on door or glass ad- move tape, locate and repair defect.
justments to stop wind noise that occurs under se-
vere conditions, can cause premature seal wear and POSSIBLE CAUSE OF WIND NOISE
excessive closing or latching effort. After a repair pro-
• Moldings standing away from body surface can
cedure has been performed, test vehicle to verify
catch wind and whistle.
noise has stopped before returning vehicle to use.
• Gaps in sealed areas behind overhanging body
Wind noise can also be caused by improperly fitted
flanges can cause wind rushing sounds.
exterior moldings or body ornamentation. Loose
moldings can flutter, creating a buzzing or chattering • Misaligned movable components.
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noise. An open cavity or protruding edge can create • Missing or improperly installed plugs in pillars.
whistling or howling noise. Inspect the exterior of the • Weld burn through holes.
vehicle to verify that these conditions do not exist.
23 - 4 BODY .
PAINT
INTRODUCTION Scratch Filler/Primer, Touch-Up Paints and Clear Top
A paint code is provided on the body code plate lo- Coat. Refer to Introduction group of this manual for
cated in the engine compartment. Refer to the Intro- Body Code Plate information.
duction section at the front of this manual for body
code plate description. TOUCH-UP PROCEDURE
(1) Scrape loose paint and corrosion from inside
BASE COAT/CLEAR COAT FINISH scratch or chip.
On most vehicles a two part paint application (base (2) Clean affected area with Mopart Tar/Road Oil
coat/clear coat) is used. Color paint that is applied to Remover and allow to dry.
primer is called base coat. The clear coat protects the (3) Fill the inside of the scratch or chip with a coat
base coat from ultra violet light and provides a dura- of filler/primer. Do not overlap primer onto good sur-
ble high gloss finish. face finish. The applicator brush should be wet
enough to puddle fill the defect without running. Do
WET SANDING,BUFFING AND POLISHING not stroke brush applicator on body surface. Allow
Minor acid etching, orange peel or smudging in the filler/ primer to dry hard.
clear coat can be reduced with light wet sanding, (4) Cover the filler/primer with color touch-up
hand buffing and polishing. If the finish has been paint. Do not overlap touch-up color onto the original
wet sanded in the past, it can not be repeated. Wet color coat around the scratch or chip. Butt the new
sanding operation should be performed by a trained color to the original color if possible. Do not stroke
automotive painter.
applicator brush on body surface. Allow touch-up
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WINDSHIELD
SAFETY PRECAUTIONS AND WARNINGS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT. BE SURE TO REFER TO THE URE-
THANE MANUFACTURER’S DIRECTIONS FOR CUR-
ING TIME SPECIFICATIONS, AND DO NOT USE
ADHESIVE AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY, USE THEM IN A WELL VENTI-
LATED AREA. SKIN CONTACT WITH URETHANE
ADHESIVE SHOULD BE AVOIDED, OR PERSONAL Fig. 1 Windshield Moldings
INJURY MAY RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
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Fig. 3 Center Windshield and Mark at Support Fig. 6 Lower Windshield Into Position
Spacers
23 - 8 BODY .
INDEX
page page
Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Converta-Bed Seat Back Hinge . . . . . . . . . . . . . . . 20
Bucket Seat Back . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Converta-Bed Seat Cushion Frame . . . . . . . . . . . . 21
Bucket Seat Cushion Frame . . . . . . . . . . . . . . . . . 13 Converta-Bed Seat Hinge Covers. . . . . . . . . . . . . . 19
Bucket Seat Cushion Pad . . . . . . . . . . . . . . . . . . . 13 Converta-Bed Seat Riser . . . . . . . . . . . . . . . . . . . . 18
Bucket Seat Cushion Side Cover . . . . . . . . . . . . . . 12 Converta-Bed Seats . . . . . . . . . . . . . . . . . . . . . . . 18
Bucket Seat Riser . . . . . . . . . . . . . . . . . . . . . . . . . 12 General Information . . . . . . . . . . . . . . . . . . . . . . . . 8
Bucket Seat Riser Trim Cover . . . . . . . . . . . . . . . . 12 Head Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Child Restraint Reclining Seat . . . . . . . . . . . . . . . . 15 Lumbar Support Handle . . . . . . . . . . . . . . . . . . . . 10
Child Seat Back . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Recliner Handle . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Child Seat Back Cover and Pads . . . . . . . . . . . . . . 16 Seat Back Assist Strap . . . . . . . . . . . . . . . . . . . . . 10
Child Seat Back Recliner . . . . . . . . . . . . . . . . . . . . 18 Seat Back Frame . . . . . . . . . . . . . . . . . . . . . . . . . 11
Child Seat Back Recliner Cover . . . . . . . . . . . . . . . 17 Seat Back Recliner . . . . . . . . . . . . . . . . . . . . . . . . 10
Child Seat Cushion Cover and Pad . . . . . . . . . . . . 17 Second Rear Seat Back . . . . . . . . . . . . . . . . . . . . 14
Child Seat Module . . . . . . . . . . . . . . . . . . . . . . . . 15 Second Rear Seat Back Hinge . . . . . . . . . . . . . . . 14
Child Seat Module Cushion Cover and Pad . . . . . . 16 Second Rear Seat Back Hinge Cover . . . . . . . . . . 14
Child Seat Module Head Restraint . . . . . . . . . . . . . 16 Second Rear Seat Back Pad . . . . . . . . . . . . . . . . . 15
Child Seat Module Head Restraint Cover and Pad . 16 Second Rear Seat Back Panel . . . . . . . . . . . . . . . 13
Converta-Bed Forward Rail and Pivot . . . . . . . . . . 19 Second Rear Seat Cushion Pad . . . . . . . . . . . . . . 15
Converta-Bed Latch Handle and Link Bar . . . . . . . 19 Second Rear Seat Riser . . . . . . . . . . . . . . . . . . . . 15
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GENERAL INFORMATION
On some trim styles, the cushion and back pads
are molded into the covers. Molded in place trim cov-
ers are not serviced separately from the base pad.
Molded in place trim cover and pad can be identified
by the lack of sewing stitches in areas the appear to
be sewn together.
HEAD RESTRAINT
REMOVAL (FIG. 1)
The head restraint is retained with a leaf spring
clip at the bottom of the sleeve attached to the seat
back frame.
(1) Fabricate a tool from 25 mm (1 in.) steel ship-
ping band stock 6 cm (24 in.) long.
(2) Lift head restraint to the highest position.
(3) Insert end of tool between the bar and sleeve at
the front of the head restraint. Push tool in until it
comes to a solid stop.
(4) Push downward on head restraint allowing the
tool to travel with the bar.
(5) Hold tool downward and pull upward on head Fig. 1 Remove Head Restraint
restraint. If head restraint stops, the tool was not in-
serted far enough. ARMREST
(6) Separate head restraint from seat back.
(7) Pull sleeve from seat back. REMOVAL (FIG. 3)
(1) Remove trim plug covering screw on side of
INSTALLATION (FIG. 2) armrest.
(1) Install sleeve through hole in trim cover at top (2) Remove screw holding armrest to mounting.
of seat back, open side forward. (3) Rotate armrest upward to align armrest stop to
(2) Insert bar into sleeve and push head restraint gate in mount.
downward. (4) Pull outward to separate armrest from mount.
. BODY 23 - 9
INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
INSTALLATION INSTALLATION
Reverse the preceding operation Reverse the preceding operation.
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INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
. BODY 23 - 13
INSTALLATION
Reverse the preceding operation.
SECOND REAR SEAT BACK HINGE COVER SECOND REAR SEAT BACK HINGE
REMOVAL (FIG. 22) REMOVAL (FIG. 24)
(1) Remove screw holding hinge cover to seat back (1) Remove seat back hinge cover.
hinge. (2) Remove bolts holding seat back hinge to cush-
(2) Separate cover from seat back hinge. ion frame.
(3) Remove nuts holding hinge to seat back.
INSTALLATION (4) Separate seat back hinge from seat.
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
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INSTALLATION
Reverse the preceding operation.
SECOND REAR SEAT RISER (6) Remove hog-rings holding cover to seat back
frame.
REMOVAL (FIG. 26) (7) Separate frame from back pad and cover.
(1) Remove seat track, if equipped. (8) Turn back pad upright on work surface.
(2) Remove bolts holding riser to bottom of seat (9) Roll cover inside out to top of back pad.
frame. (10) Remove hog-rings holding cover listing wires
(3) Separate riser from seat. to hold down wires in pad. Refer to Bucket Seat Back
Pad paragraph for typical illustrations.
INSTALLATION (11) Separate cover from back pad.
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
REMOVAL
(1) Remove seat from vehicle.
(2) Position seat on a clean work surface.
(3) Separate seat back hinges from cushion frame.
(4) Remove seat risers.
(5) Remove seat belts from rear rail of seat cushion
frame.
(6) Disengage J-strip retainers holding trim cover
to bottom cushion frame.
(7) Separate frame from cushion pad and cover.
(8) Turn cushion pad upright on work surface.
(9) Roll cover inside out to top of cushion pad.
(10) Remove hog-rings holding cover listing wire to
hold down wire in cushion pad. Refer to Bucket Seat
Cushion Pad paragraph for typical illustrations.
(11) Separate cover from pad. Fig. 27 Seat Back Cover Hog-ring
INSTALLATION (5) Disengage push-in fasteners holding seat back
Reverse the preceding operation. trim cover to module under head restraint.
(6) Pull seat back trim cover from under head re-
SECOND REAR SEAT BACK PAD straint.
(7) Remove screws holding top of module to seat
REMOVAL back frame (Fig. 28).
(1) Remove seat back hinge covers. (8) Close child restraint seat.
(2) Remove bolts holding hinges to cushion frame. (9) Deflect pad at base of module upward to gain
(3) Separate seat back from cushion. access to hidden screws under module.
(4) Position seat back on a clean work surface. (10) Remove screws holding bottom of module to
(5) Remove seat back trim panel. seat back frame (Fig. 28).
23 - 16 BODY .
(11) Rotate top of module forward while pulling up- CHILD SEAT MODULE HEAD RESTRAINT COVER
ward and separate module from seat back. AND PAD
INSTALLATION REMOVAL
Reverse the preceding operation. (1) Remove trim panel from rear of seat back.
(2) Disengage J-strip retainer holding head re-
straint trim cover to seat back frame.
(3) Open head restraint to the highest position.
(4) Disengage hook and loop closure at bottom of
head restraint.
(5) Turn head restraint cover inside-out from bot-
tom of cover up.
(6) Separate cover from head restraint armature
and pad.
(7) Separate pad from armature.
INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
Fig. 31 Child Seat Cushion Cover Fig. 33 Seat Back Cover J-strip
INSTALLATION
Reverse the preceding operation.
Fig. 35 Child Seat Back Recliner Cover Fig. 37 Child Seat Back Recliner
CHILD SEAT BACK CONVERTA-BED SEATS
The optional Converta-bed seats are removed from
REMOVAL (FIG. 36) the vehicle using the same procedure as the two and
(1) Remove seat back recliner covers. three passenger bench seats. Refer to the Owner’s
(2) Remove bolts holding bottom of seat back re- Manual provided with the vehicle for proper removal
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INSTALLATION
Reverse the preceding operation.
INSTALLATION
Fig. 40 Upper Hinge Cover
Reverse the preceding operation.
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REMOVAL
(1) If necessary, Remove seat from vehicle.
(2) Remove screw holding upper hinge cover to
seat back hinge.
(3) Separate upper hinge cover from seat (Fig. 40).
(4) Remove screw holding lower hinge cover to seat
back hinge.
(5) Separate lower hinge cover from seat (Fig. 41).
INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
INDEX
page page
A-Pillar and Roof Rail Moldings . . . . . . . . . . . . . . . 38 Liftgate Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Body Side Applique (Fig. 38) . . . . . . . . . . . . . . . . . 36 Liftgate Trim Panel . . . . . . . . . . . . . . . . . . . . . . . . 44
Cowl Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Outboard Seat Belts . . . . . . . . . . . . . . . . . . . . . . . 40
Cowl Trim and Scuff Plates . . . . . . . . . . . . . . . . . . 38 Outside Front Door Latch Release Handle . . . . . . . 27
Door Opening Weatherstrips . . . . . . . . . . . . . . . . . 35 Overhead Console . . . . . . . . . . . . . . . . . . . . . . . . 43
Exterior Moldings (Fig. 37) . . . . . . . . . . . . . . . . . . 35 Overhead Grab Handle . . . . . . . . . . . . . . . . . . . . . 38
Floor Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Rear Engine Compartment Splash Shield . . . . . . . 25
Front Center Console . . . . . . . . . . . . . . . . . . . . . . 42 Rear Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Front Door and Hinge . . . . . . . . . . . . . . . . . . . . . . 26 Rear Window Glass . . . . . . . . . . . . . . . . . . . . . . . 46
Front Door Belt Molding and Weatherstrip—Van . . . 28 Right B-Pillar Trim Cover . . . . . . . . . . . . . . . . . . . . 38
Front Door Belt Molding and Weatherstrip—Wagon . . 29
Front Door Frame Rear Molding—Van . . . . . . . . . . 28 Right Quarter Trim Panel . . . . . . . . . . . . . . . . . . . . 39
Front Door Glass . . . . . . . . . . . . . . . . . . . . . . . . . 28 Roof Top Luggage Rack . . . . . . . . . . . . . . . . . . . . 45
Front Door Glass Channel and Run Weatherstrip . . 29 Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Front Door Glass Lower Channel . . . . . . . . . . . . . . 29 Shoulder Harness Height Adjuster . . . . . . . . . . . . . 42
Front Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Sight Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Front Door Side View Mirror . . . . . . . . . . . . . . . . . 28 Sliding Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Front Door Trim Panel . . . . . . . . . . . . . . . . . . . . . . 26 Sliding Door Center Hinge . . . . . . . . . . . . . . . . . . . 31
Front Door Window Regulator—Manual . . . . . . . . . 29 Sliding Door Center Hinge Track Cover . . . . . . . . . 30
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GRILLE
REMOVAL (FIG. 1 OR 2)
(1) Remove bolt holding grille to bracket in front of
radiator.
(2) Remove headlamp bezel and park/turn signal
lamp on low line models. Refer to Group 8L, Lamps
for proper procedures.
(3) Remove screws holding grille to front headlamp
assemblies.
(4) Separate grille from vehicle.
INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
REMOVAL (FIG. 4)
(1) Support hood on the side that requires hinge
replacement.
(2) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation. When installing
hood hinge, align all marks and secure bolts. The
hood should be aligned to 4 mm (0.160 in.) gap to the
front fenders and flush across the top surfaces along
fenders. Shims can be added or removed between the
hood and hinge to achieve proper hood height.
(3) Remove cowl cover as necessary to gain access
to hood hinge pin.
Fig. 2 Grille—High Line
(4) Remove hood to hinge attaching bolts.
(5) Remove push-on retainer holding hood hinge
arm to hinge pin through access hole in cowl.
INSTALLATION
Reverse the preceding operation. If necessary, paint
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INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
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INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation. Align front fender
to 6 mm (0.240 in.) to forward edge of door and 4 mm
(0.160) to edge of hood. All surfaces across gaps
should be flush.
(5) Drive top hinge pin downward and remove pin INSTALLATION
from hinge. Reverse the preceding operation.
(6) Separate door from vehicle.
INSTALLATION
Reverse the preceding operation. The door should
not require re-alignment. If door does need align-
ment, refer to Front Door Hinge Installation para-
graph in this section.
INSTALLATION
Reverse the preceding operation. Align door to
achieve 6 mm (0.240 in.) gap to all surrounding pan-
els and flush across gaps.
INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
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INSTALLATION
Reverse the preceding operation.
Fig. 21 Glass Channel and Run Weatherstrip
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INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation. Align sliding door
to 6 mm (0.240 in.) gap to edge of quarter panel and
B-pillar, 7 mm (0.280 in.) gap to rocker and flush
across gaps.
Fig. 28 Inside Latch/Lock Control
SLIDING DOOR LATCH/LOCK LINKAGE
REMOVAL (FIG. 29)
(1) Remove sliding door trim panel and water
shield.
(2) Remove latch/lock control.
(3) Disconnect ends of linkage rod to be replaced.
(4) Separate linkage rod from door.
INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
LIFTGATE
(1) Open liftgate and remove nuts holding upper
molding to liftgate.
(2) Disengage clips holding upper molding to lift-
gate.
(3) Separate molding from liftgate.
To install, reverse the preceding operation.
Fig. 36 Vent Window Weatherstrip
SLIDING DOOR TRACK COVER
DOOR OPENING WEATHERSTRIPS (1) Disengage barrel clip fastener holding rear end
of upper molding to sliding door center track cover.
REMOVAL (2) Disengage clips holding upper molding to cen-
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(2) Separate lower molding from quarter panel. (2) Disengage clips holding sill molding to fender.
To install, reverse the preceding operation. (3) Separate sill molding from front fender.
To install, reverse the preceding operation.
WHEEL LIP MOLDINGS
(1) Remove screws holding wheel lip moldings to BODY SIDE APPLIQUE (FIG. 38)
wheel opening flange.
(2) Separate wheel lip molding from vehicle. DOOR APPLIQUE
To install, reverse the preceding operation. (1) Remove screws holding applique to bottom edge
of door.
SILL MOLDINGS (2) Lift applique upward to disengage from retain-
ing channel.
RIGHT QUARTER (3) Separate applique from door.
(1) Remove screws holding right quarter panel sill To install, reverse the preceding operation.
molding to wheel opening flange.
(2) Disengage clips holding sill molding to sill FRONT SILL APPLIQUE
panel. (1) Remove screws holding front sill applique to
To install, reverse the preceding operation. front wheel opening flange.
(2) Remove screws holding applique to under side
LEFT QUARTER of rocker panel.
(1) Disengage clips holding sill molding to sill. (3) Lift applique upward to disengage from retain-
(2) Separate sill molding from vehicle. ing channel.
To install, reverse the preceding operation. (4) Separate applique from sill.
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UPPER TRACK COVER (9) Separate quarter trim panel from vehicle.
INSTALLATION
Reverse the preceding operation.
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INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.
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INSTALLATION
Reverse the preceding operation.
OVERHEAD CONSOLE
REMOVAL (FIG. 52)
(1) Disengage sun visor ends from overhead con-
sole
Fig. 49 Front Seat and Riser—Typical (2) Remove screws holding overhead console to roof
(2) Remove screws holding top of console to instru- at front of console.
ment panel. (3) Slide overhead console forward to disengage
(3) Remove ash tray or open sun glass bin. Remove clips holding rear of console to roof.
screws holding console to instrument panel. (4) Disconnect wire connectors from back of con-
(4) Separate upper console module from instru- sole.
ment panel, if equipped. (5) Separate overhead console from vehicle.
(5) Disconnect ash tray lamp wire connector.
23 - 44 BODY .
INSTALLATION
Reverse the preceding operation. Align liftgate to 7
mm (0.280 in.) gap to roof panel and 6 mm (0.240 in.)
gap to quarter panels. Surfaces should be flush
across gaps.
INSTALLATION
Reverse the preceding operation.
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Fig. 54 LiftGate
(2) Position frog-leg fasteners below holes in lift-
gate, one at a time, push (do not pound) fasteners
into locked position.
(3) Install assist handle, courtesy lamps, outer cor- Fig. 56 LiftGate Latch
ner attaching screws, speaker grilles and push-in fas- ROOF TOP LUGGAGE RACK
teners above rear window.
REMOVAL (FIG. 57)
The luggage rack skid strips are attached to the
roof panel with adhesive strips using the same meth-
ods as stick-on body side moldings. Refer to Stick-on
Body Moldings paragraph for procedures.
(1) Slide side rail end covers from ends of side
rails.
(2) Remove screws holding rails to roof panel.
(3) Separate luggage rack from vehicle.
INSTALLATION
Reverse the preceding operation.
INSTALLATION
Reverse the preceding operation.