Chrysler Caravan/Voyager/Town and Country 1996-1999

Doors

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REMOVAL & INSTALLATION



Front Door

See Figures 1 and 2

If the door hinge pins and retaining clips are being removed, they must be replaced with new pins and clips, which can be purchased at the dealership. Once the hinge pins are removed, they lose their structural integrity.

  1. Disconnect the negative battery cable.
  2.  
  3. Open the front door.
  4.  
  5. Remove the front wheelhouse splash shield.
  6.  
  7. Disengage the clips attaching the door wiring harness connector to the inner fender brace.
  8.  



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Fig. Fig. 1: Front door wiring harness connectors

  1. Disconnect the positive lock slide located on the side of the wiring connectors.
  2.  
  3. Depress the locking tab attaching the wiring harness connector halves together.
  4.  
  5. Disconnect the door harness from the body wiring harness.
  6.  
  7. Remove the door check strap-to-A pillar mounting bolts.
  8.  
  9. Support the weight of the door on a suitable lifting device.
  10.  



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Fig. Fig. 2: Remove the front door hinge bolts

  1. Remove the lower hinge-to-door end frame mounting bolts.
  2.  
  3. While holding the door steady on the lifting device, remove the upper hinge-to-door end frame mounting bolts.
  4.  
  5. Remove the door from the vehicle.
  6.  

To install:
  1. Support the weight of the door on a suitable lifting device.
  2.  
  3. Position the door to the vehicle. While holding the door steady on the lifting device, install the upper hinge-to-door end frame mounting bolts. Tighten the bolts to 105 inch lbs. (12 Nm).
  4.  
  5. Install the door check strap to the A pillar and tighten the mounting bolts to 105 inch lbs. (12 Nm).
  6.  
  7. Install the lower hinge-to-door end frame mounting bolts and tighten to 25 ft. lbs. (34 Nm). Be sure to align the door to achieve equal spacing to the surrounding body panels. These panels should be flush across all gaps.
  8.  
  9. Connect the door harness to the body wiring harness.
  10.  
  11. Connect the positive lock slide on the side of the wiring connectors.
  12.  
  13. Connect the clips attaching the door wiring harness connector to the inner fender brace.
  14.  
  15. Install the front wheelhouse splash shield.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Verify door operation and alignment. Adjust as necessary.
  20.  

Sliding Door

See Figures 3, 4, 5, 6, 7 and 8

To avoid damaging the body paint, apply several layers of masking tape to the body around the rear end of the upper roller channel and the forward edge of the quarter panel.

  1. Disconnect the negative battery cable.
  2.  
  3. Open the door.
  4.  
  5. Apply masking tape to the door jamb area.
  6.  



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Fig. Fig. 3: Sliding door upper stop



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Fig. Fig. 4: Sliding door center stop bumper

  1. Remove the screw holding the upper roller arm stop bumper to upper roller arm.
  2.  
  3. Remove the stop bumper from the upper roller arm.
  4.  
  5. Remove the center stop bumper trim cover from the sliding door.
  6.  
  7. Remove the center stop from the sliding door.
  8.  
  9. Remove the sliding door sill plate.
  10.  



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Fig. Fig. 5: Sliding door hold open latch striker



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Fig. Fig. 6: Center roller channel end cover

  1. Remove the hold open latch striker.
  2.  
  3. Open the quarter glass.
  4.  
  5. Remove the center roller channel end cover.
  6.  


WARNING
Do not allow the center hinge roller to contact the quarter glass. This glass can break.

  1. Support the sliding door on a suitable lifting device with a padded upper surface. The door must be moveable with the lifting device in position.
  2.  
  3. Roll the door rearward until the lower rollers disengage from the lower channel.
  4.  



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Fig. Fig. 7: Sliding door upper roller



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Fig. Fig. 8: Sliding door center roller

  1. Roll the door rearward until the upper and center hinge rollers disengage from the upper and center channels.
  2.  
  3. Remove the sliding door from the vehicle.
  4.  

To install:
  1. Place the sliding door in position on a lifting device.
  2.  
  3. Position the door rearward of the sliding door opening.
  4.  


WARNING
Do NOT allow the center hinge roller to contact the quarter glass. The glass can break.

  1. Engage the center hinge rollers into the center channels.
  2.  
  3. Roll door forward until lower rollers engage into rear of lower channel.
  4.  
  5. Engage the upper hinge into the upper channels.
  6.  
  7. Install the hold open latch striker.
  8.  
  9. Install the sliding door sill plate.
  10.  
  11. Install the center roller channel end cover.
  12.  
  13. Install the center stop on the sliding door.
  14.  
  15. Install the center stop bumper trim cover on the sliding door.
  16.  
  17. Place the upper roller stop bumper in position on the upper roller arm.
  18.  
  19. Install screw to secure the upper roller arm stop bumper to upper roller arm.
  20.  
  21. Remove masking tape from body surfaces.
  22.  
  23. Verify sliding door operation and fit. Adjust if necessary.
  24.  

ADJUSTMENT



Front Door
  1. With the door fully closed, check the flush and gaps of the door.
  2.  
  3. The door should be aligned to 0.20 inch (5mm) gap to the front fenders and rear door. The door should fit flush across all of the gaps.
  4.  
  5. If necessary, loosen the bolts to reposition the door, then tighten the bolts to 105 inch lbs. (12 Nm).
  6.  

Sliding Door
Preliminary checks
  1. Close the sliding door, visually inspecting the C-post striker alignment entry into latch. The striker at this point must not affect alignment.
  2.  
  3. On vehicles equipped with a left side sliding door, inspect the fuel door blocker striker entry into latch. The striker at this point must not affect alignment.
  4.  
  5. Inspect the C-post and B-post for door-to-aperture gaps and door-to-door gaps. All gaps should measure 0.160-0.240 inch (4-6mm).
  6.  
  7. Inspect the door for height using character lines as a reference, as well as the roof contour as a controlling factor.
  8.  

up/down adjustment

See Figure 9

  1. Visually inspect the sliding door for fitting low at the rear of the door by checking the alignment of the belt line of the door to quarter panel.
  2.  
  3. Fully open the sliding door.
  4.  
  5. Check to be sure that all of the center hinge bolts are tight.
  6.  



Click image to see an enlarged view

Fig. Fig. 9: Sliding door center hinge

  1. Adjust the rear of the sliding door up by rotating the center hinge bolts clockwise.
  2.  
  3. Close the door and inspect the alignment.
  4.  
  5. Re-adjust the center hinge if necessary to obtain alignment between the belt line of the sliding door and quarter panel.
  6.  
  7. Fully open the sliding door and install a locknut to the center hinge bolt. Tighten the locknut until it butts up against the welded nut on the center hinge. Tighten the nut to 11 ft. lbs. (15 Nm). It may be necessary to use a backup wrench to hold the center hinge bolt to prevent it from turning while tightening the nut.
  8.  
  9. Verify door alignment and re-adjust if necessary.
  10.  

Fore/Aft Adjustment

See Figures 9 and 10

  1. Inspect the height of the sliding door at the B-post and C-post to determine which area is contributing the greatest to the incorrect gaps.
  2.  
  3. If the sliding door is high at the C-post;
    1. Open the sliding door to mid-point of travel.
    2.  
    3. Matchmark outline of center hinge on the sliding door to assist in making adjustments.
    4.  
    5. Loosen the center hinge bolts.
    6.  
    7. Move hinge fore or aft to position the sliding door into the correct location.
    8.  
    9. Tighten the center hinge bolts.
    10.  
    11. Verify door alignment and re-adjust if necessary.
    12.  

  4.  
  5. If the sliding door is low at the B-post;
  6.  



Click image to see an enlarged view

Fig. Fig. 10: Sliding door lower roller arm bracket

  1. Remove access plug in the sliding door trim panel.
  2.  
  3. Open the sliding door to mid-point of travel.
  4.  
  5. Matchmark outline of the lower roller arm bracket on the sliding door to assist in making adjustments.
  6.  
  7. Loosen the lower roller arm bracket bolts.
  8.  
  9. Move the hinge downward to raise the door.
  10.  
  11. Tighten the lower roller arm bracket bolts.
  12.  
  13. Verify door alignment and re-adjust if necessary.
  14.  

  1. If the sliding door is low at the C-post;
    1. Open the sliding door to mid-point of travel.
    2.  
    3. Matchmark outline of center hinge on the sliding door to assist in making adjustments.
    4.  
    5. Rotate the adjustment bolt up or down to move the door position.
    6.  
    7. Move the hinge downward to raise the door.
    8.  
    9. Tighten the center hinge bolts.
    10.  
    11. Verify door alignment and re-adjust if necessary.
    12.  

  2.  
  3. If the sliding door is high at the B-post;
    1. Remove access plug in the sliding door trim panel.
    2.  
    3. Open the sliding door to mid-point of travel.
    4.  
    5. Matchmark outline of lower roller arm bracket on the sliding door to assist in making adjustments.
    6.  
    7. Loosen the lower roller arm bracket bolts.
    8.  
    9. Move the hinge upward to raise the door.
    10.  
    11. Tighten the lower roller arm bracket bolts.
    12.  
    13. Verify door alignment and re-adjust if necessary.
    14.  

  4.  

Seal Compression

Adjusting seal compression at the B-post can affect door flushness at the C-post.

  1. Inspect the seal compression at top and bottom of B-post seal.
  2.  
  3. Adjust the seal compression at the top of the B-post seal as follows:
    1. Open the sliding door to mid-point of travel.
    2.  
    3. Matchmark the outline of the upper roller arm on the bracket to assist in making adjustments.
    4.  
    5. Loosen bolts securing the upper roller arm to the bracket.
    6.  
    7. To increase seal compression, shorten the length of the upper roller arm.
    8.  
    9. To decrease seal compression, increase the length of the upper roller arm.
    10.  
    11. Tighten all of the upper roller arm bolts.
    12.  
    13. Verify door alignment and re-adjust if necessary.
    14.  

  4.  
  5. Adjust the seal compression at the bottom of the B-post seal as follows:
    1. Open the sliding door to mid-point of travel.
    2.  
    3. Matchmark the outline of the lower roller arm on the lower roller arm bracket to assist in making adjustments.
    4.  
    5. Loosen bolts securing the lower roller arm to the lower roller arm bracket.
    6.  
    7. To decrease seal compression, pivot the lower roller arm toward the center of the vehicle.
    8.  
    9. To increase seal compression, pivot the lower roller arm outward.
    10.  
    11. Tighten all of the lower roller arm bolts.
    12.  
    13. Verify door alignment and re-adjust if necessary.
    14.  

  6.  

Stabilizer Adjustment
  1. Open sliding door.
  2.  
  3. Loosen the bolts securing the stabilizers to the sliding door enough that the stabilizers can move with some effort.
  4.  
  5. Close and then reopen the sliding door.
  6.  
  7. Tighten all bolts.
  8.  

 
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