body · (6) apply molding to top of windshield. (7) apply glass prep adhesion promoter 25 mm (1...

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BODY

TABLE OF CONTENTS

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AINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1TATIONARY GLASS. . . . . . . . . . . . . . . . . . . . . . . . 4EATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

page

WET SANDING, BUFFING, AND POLISHING . . . . . 1

S

BODY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 12SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 60

PAINT

TABLE OF CONTENTS

page

ESCRIPTION AND OPERATIONPAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1BASE COAT/CLEAR COAT FINISH. . . . . . . . . . . . . 1

PAINTED SURFACE TOUCH-UP . . . . . . . . . . . . . . 1PECIFICATIONSAFTERMARKET PAINT REPAIR PRODUCTS . . . . . 2

ESCRIPTION AND OPERATION

AINT CODEA paint code is provided on the body code plate

ocated in the engine compartment. Refer to thentroduction section at the front of this manual forody code plate description. The paint and trim codesre also included on the Vehicle Safety Label locatedn the driver’s door end frame.

ASE COAT/CLEAR COAT FINISHOn most vehicles a two-part paint application (base

oat/clear coat) is used. Color paint that is applied torimer is called base coat. The clear coat protects thease coat from ultraviolet light and provides a dura-le high-gloss finish.

AUTION: Do not use abrasive chemicals or com-ounds on painted surfaces. Damage to finish canesult.

Do not use harsh alkaline based cleaning sol-ents on painted surfaces. Damage to finish orolor can result.

ET SANDING, BUFFING, AND POLISHINGMinor acid etching, orange peel, or smudging in

lear coat or single-stage finishes can be reducedith light wet sanding, hand buffing, and polishing.

f the finish has been wet sanded in the past, it

cannot be repeated. Wet sanding operationshould be performed by a trained automotivepaint technician.

CAUTION: Do not remove clear coat finish, ifequipped. Base coat paint must retain clear coat fordurability.

PAINTED SURFACE TOUCH-UPWhen a painted metal surface has been scratched

or chipped, it should be touched-up as soon as possi-ble to avoid corrosion. For best results, use MopartScratch Filler/Primer, Touch-Up Paints and Clear TopCoat. Refer to Introduction group of this manual forBody Code Plate information.

CAUTION: USE A OSHA APPROVED BREATHINGFILTER WHEN SPRAYING PAINT OR SOLVENTS INA CONFINED AREA. PERSONAL INJURY CANRESULT.

TOUCH-UP PROCEDURE(1) Scrape loose paint and corrosion from inside

scratch or chip.(2) Clean affected area with Mopart Tar/Road Oil

Remover, and allow to dry.(3) Fill the inside of the scratch or chip with a coat

of filler/primer. Do not overlap primer onto good sur-

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DESCRIPTION AND OPERATION (Continued)

ace finish. The applicator brush should be wetnough to puddle-fill the defect without running. Doot stroke brush applicator on body surface. Allowhe filler/primer to dry hard.

(4) Cover the filler/primer with color touch-upaint. Do not overlap touch-up color onto the originalolor coat around the scratch or chip. Butt the newolor to the original color, if possible. Do not strokepplicator brush on body surface. Allow touch-upaint to dry hard.(5) On vehicles without clear coat, the touch-up

olor can be lightly wet sanded (1500 grit) and pol-shed with rubbing compound.

(6) On vehicles with clear coat, apply clear top coatto touch-up paint with the same technique asdescribed in Step 4. Allow clear top coat to dry hard.If desired, Step 5 can be performed on clear top coat.

CAUTION: AVOID PROLONGED SKIN CONTACTWITH PETROLEUM OR ALCOHOL – BASED CLEAN-ING SOLVENTS. PERSONAL INJURY CAN RESULT.

PECIFICATIONS

FTERMARKET PAINT REPAIR PRODUCTS

EXTERIOR COLORS

EXTERIORCOLOR

CHRYCODE*

PPG DUPONTS-W

M-S **A-N/S ** S-H ** ICI **

Black ClearCoat

DX8 9700 F0206 34858 CHA85:DX8 73328 TC60B

Bright WhiteClear Coat

GW7 4037 B8833 37298 CHA88:GW7 11751 TA45B

Bright SilverMetallic Clear

CoatWS2 5464 F7999 56150 CHA99:WS2 74611 KDP8B

CinnamonGlaze Metallic

Clear Coat

VLB 5313 B9824 54469 CHA98:VLB 80758 HMT2B

DeepAmethyst

Pearl CoatTCN

5246 B9751 52566 CHA97:TCN 54755 FNE4B

DeepCranberryPearl Coat

VMT5359 B9842 54119 CHA98:VMT 33686 GJX2B

Flame RedClear Coat

PR4 4679 B9326 46916 CHA93:PR4 30116 2NNGB

Forest GreenPearl Coat

SG8 5065 B9609 51062 CHA95:SG8 61633 7MR8B

Patriot BluePearl Coat

WB75512 F7991 56683 CHA99:WB7 56580 LEC6B

Salsa RedPearl Coat

WE5 5442 F7998 56147 CHA99:WE5 34462 5WS8B

*BASF, Glasurit, and Standox use the DaimlerChrysler paint code.** S-W = Sherwin Williams, M-S = Martin Senour,

A-N/S = Akzo Nobel/Sikkens, S-H = Spies Hecker and ICI = Autocolor

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SPECIFICATIONS (Continued)

INTERIOR COLORS

INTERIORCOLOR

CHRYCODE *

PPG DUPONTS-W

M-S **A-N/S ** S-H ** ICI**

Agate AZ9856

C9208 45994 CHALAZI 75016 7WC82-1461

Taupe WL528653

C9881 54420 CHAWL5I 81650 KXE62-1652

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STATIONARY GLASS

TABLE OF CONTENTS

page page

ESCRIPTION AND OPERATIONSAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . 4EMOVAL AND INSTALLATION
WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . 6


AFETY PRECAUTIONS

ARNING: DO NOT OPERATE THE VEHICLEITHIN 24 HOURS OF WINDSHIELD INSTALLATION.

T TAKES AT LEAST 24 HOURS FOR URETHANEDHESIVE TO CURE. IF IT IS NOT CURED, THEINDSHIELD MAY NOT PERFORM PROPERLY INN ACCIDENT.URETHANE ADHESIVES ARE APPLIED AS A SYS-

EM. USE GLASS CLEANER, GLASS PREP SOL-ENT, GLASS PRIMER, PVC (VINYL) PRIMER ANDINCH WELD (FENCE) PRIMER PROVIDED BY THEDHESIVE MANUFACTURER. IF NOT, STRUCTURAL

NTEGRITY COULD BE COMPROMISED.CHRYSLER DOES NOT RECOMMEND GLASS

DHESIVE BY BRAND. TECHNICIANS SHOULDEVIEW PRODUCT LABELS AND TECHNICAL DATAHEETS, AND USE ONLY ADHESIVES THAT THEIRANUFACTURES WARRANT WILL RESTORE AEHICLE TO THE REQUIREMENTS OF FMVSS 212.ECHNICIANS SHOULD ALSO INSURE THAT PRIM-RS AND CLEANERS ARE COMPATIBLE WITH THEARTICULAR ADHESIVE USED.BE SURE TO REFER TO THE URETHANE MANU-

ACTURER’S DIRECTIONS FOR CURING TIMEPECIFICATIONS, AND DO NOT USE ADHESIVEFTER ITS EXPIRATION DATE.VAPORS THAT ARE EMITTED FROM THE URE-

HANE ADHESIVE OR PRIMER COULD CAUSEERSONAL INJURY. USE THEM IN A WELL-VENTI-ATED AREA.SKIN CONTACT WITH URETHANE ADHESIVE

HOULD BE AVOIDED. PERSONAL INJURY MAYESULT.ALWAYS WEAR EYE AND HAND PROTECTIONHEN WORKING WITH GLASS.

AUTION: Protect all painted and trimmed surfacesrom coming in contact with urethane or primers.

Be careful not to damage painted surfaces whenemoving moldings or cutting urethane aroundindshield.

It is difficult to salvage a windshield during theremoval operation. The windshield is part of thestructural support for the roof. The urethane bondingused to secure the windshield to the fence is difficultto cut or clean from any surface. If the moldings areset in urethane, it would also be unlikely they couldbe salvaged. Before removing the windshield, checkthe availability of the windshield and moldings fromthe parts supplier.

REMOVAL AND INSTALLATION

WINDSHIELDThe urethane adhesive holding the windshield to

the opening pinch weld (fence) can be cut using asharp 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 theinterior of the vehicle using a reciprocating or oscil-lating power knife is recommended.

RECOMMENDED TOOLS AND ADHESIVE

POWER KNIFE• Feint Power Cutout Knife• Equalizert Magnum, Interior Auto Glass Cut

Out Knife

ADHESIVE, PRIMER AND CLEANERThe following urethane adhesive systems are OEM

certified and conform to the FMVSS 212 windshieldretention standard and the FMVSS 216 roof crushstandard.

WINDSHIELD REMOVAL – EXTERIOR METHOD(1) Remove inside rear view mirror.(2) Remove windshield wiper arms.(3) Remove cowl cover.

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REMOVAL AND INSTALLATION (Continued)

(4) Place protective covers over instrument panelnd hood.(5) Remove windshield A-pillar moldings (Fig. 1)

sing a suitable hook tool and trim stick.(6) Using a sharp cold knife, cut urethane adhe-

ive holding the windshield to the A-pillars, roofeader and cowl pinch weld fences (Fig. 2). A powerutting device can be used if available.(7) Separate windshield from vehicle.

INDSHIELD REMOVAL - INTERIOR METHOD(1) Remove inside rear view mirror.(2) Remove instrument panel top cover, refer toroup 8E, Instrument Panel.(3) Remove A-pillar trim covers.(4) Place protective covers over instrument panel

nd hood.

Fig. 1 Windshield Header and Outside Molding1 – WINDSHIELD HEADER MOLDING2 – A-PILLAR OUTSIDE MOLDING3 – A-PILLAR

Fig. 2 Cut Urethane Around Windshield1 – COLD KNIFE2 – WINDSHIELD

(5) Using a reciprocating or oscillating powerknife, cut urethane adhesive holding the windshieldto the A-pillars, roof header and cowl pinch weldfences. Refer to instructions provided with the equip-ment being used.

(6) Remove windshield from vehicle.

WINDSHIELD INSTALLATION

CAUTION: Open the left front door glass beforeinstalling windshield to avoid pressurizing the pas-senger compartment. If a door is slammed beforeurethane bonding is cured, water leaks can result.

Allow the urethane at least 24 hours to curebefore returning the vehicle to use.

To avoid stressing the replacement windshield,the urethane bonding material on the windshieldfence should be smooth and consistent to theshape of the replacement windshield. The supportspacers should be cleaned and properly installedon weld studs or repair screws at bottom of wind-shield opening.

(1) Place replacement windshield into windshieldopening and position glass in the center of the open-ing against the support spacers.

(2) Verify the glass lays evenly against the pinchweld fence at the sides, top and bottom of thereplacement windshield. If not, the pinch weld fencemust 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 suitablework surface with two padded, wood 10 cm by 10 cmby 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-allel 75 cm (2.5 ft.) apart (Fig. 3).

WARNING: DO NOT USE SOLVENT BASED GLASSCLEANER TO CLEAN WINDSHIELD BEFOREAPPLYING GLASS PREP AND PRIMER. POORADHESION CAN RESULT.

(5) Clean inside of windshield with ammonia basedglass cleaner and lint-free cloth.

(6) Apply molding to Top of windshield.(7) Apply Glass Prep adhesion promoter 25 mm (1

in.) wide around perimeter of windshield and wipewith clean/dry lint-free cloth until no streaks are vis-ible.

(8) Apply Glass Primer 25 mm (1 in.) wide aroundperimeter of windshield. Allow at least three minutesdrying time.

(9) Using a razor knife, remove as much originalurethane as possible. Do not damage paint on wind-shield fence.

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(10) Apply pinch weld primer 15 mm (.75 in.) wideround the windshield fence. Allow at least threeinutes drying time.(11) Apply a 10 mm (0.4 in.) bead of urethane on

enter line of windshield fence.(12) With the aid of a helper, position the wind-

hield over the windshield opening. Align the refer-nce marks at the bottom of the windshield to theupport spacers.(13) Slowly lower windshield glass to windshield

pening fence. Guide the molding into proper positions necessary. Push windshield inward molding islush to roof line and A-pillars (Fig. 4).

(14) Clean access urethane from exterior withopart, Super Clean or equivalent.(15) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)asking tape spaced 250 mm (10 in.) apart to holdolding in place until urethane cures.(16) Install A-pillar moldings.(17) Install cowl cover and wipers.(18) Install inside rear view mirror.(19) After urethane has cured, remove tape strips

nd water test windshield to verify repair.

EAR WINDOW

ARNING: DO NOT OPERATE THE VEHICLEITHIN 24 HOURS OF WINDSHIELD INSTALLATION.

Fig. 3 Work Surface Set up and Molding Installation1 – WINDSHIELD AND MOULDINGS2 – URETHANE BEAD AROUND GLASS 7mm (.3 in.) FROM

EDGE3 – BLOCKS

IT TAKES AT LEAST 24 HOURS FOR URETHANEADHESIVE TO CURE. IF IT IS NOT CURED, THEWINDSHIELD MAY NOT PERFORM PROPERLY INAN ACCIDENT. BE SURE TO REFER TO THE URE-THANE MANUFACTURER’S DIRECTIONS FOR CUR-ING TIME SPECIFICATIONS, AND DO NOT USEADHESIVE AFTER ITS EXPIRATION DATE.

CAUTION: Open the left front door glass beforeinstalling the rear window to avoid pressurizing thepassenger compartment if a door is slammedbefore the urethane bonding is fully cured. Waterleaks can result

Refer to the windshield paragraph of this sectionfor a description of tools and adhesive systems thatare recommended for use in this procedure.

REAR WINDOW REMOVAL(1) Remove rear window moldings.(2) Remove upper quarter trim panel.(3) Disconnect wire connectors from rear window

defogger.

WARNING: WEAR EYE AND HAND PROTECTIONWHEN HANDLING SAFETY GLASS. PERSONALINJURY CAN RESULT.

CAUTION: Do not damage body or trim finish whencutting out glass or applying fence primer.

(4) Cut the urethane around the perimeter of therear window glass. Refer to Windshield section ofthis group for proper procedures.

(5) Remove the rear window from the vehicle.

REAR WINDOW INSTALLATION(1) Prepare the work area, window fence, and

glass the same way as described in the Windshieldsection of this group.

(2) Place fence spacers at the locations shown (Fig.5).

(3) Install the rear window molding on glass.(4) Apply a 10 mm (0.4 in.) bead of urethane

around the perimeter of the glass.(5) Install the glass in the same manner described

in the Windshield section of this group (Fig. 5).(6) Connect rear window defogger wiring and inte-

rior trim.(7) After urethane has cured, water test rear win-

dow to verify repair. Verify rear window defoggeroperation.

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Fig. 4 Lower Windshield Into Position1 – WINDSHIELD2 – WINDSHIELD TO FENCE RETAINER3 – SECTION D-D4 – SECTION B-B5 – SECTION C-C

6 – SECTION A-A (FENCE)7 – SECTION A-A (GLASS)8 – HIGH VISCOSITY ADHESIVE9 – WINDSHIELD FENCE SUPPORT SPACERS

Fig. 5 Rear Window Glass1 – 9.5 MM2 – REAR WINDOW3 – SECTION F-F

4 – SECTION E-E5 – 3 MM6 – 12.7 MM

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SEATS

TABLE OF CONTENTS

page page

EMOVAL AND INSTALLATIONFRONT SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8FRONT SEAT BACK. . . . . . . . . . . . . . . . . . . . . . . . 8
FRONT SEAT BACK COVER . . . . . . . . . . . . . . . . . 9
FRONT SEAT CUSHION COVER . . . . . . . . . . . . . . 9FRONT SEAT CUSHION . . . . . . . . . . . . . . . . . . . . 9REAR SEAT BACK . . . . . . . . . . . . . . . . . . . . . . . . 10
REAR SEAT CUSHION. . . . . . . . . . . . . . . . . . . . . 11
EMOVAL AND INSTALLATION

RONT SEAT

EMOVAL(1) Move seat to forward position.(2) Remove bolts attaching rear of seat track to

loor.(3) Move seat to rearward position.(4) Remove bolts attaching front of seat track to

loor crossmember (Fig. 1).(5) Remove seat from vehicle.

NSTALLATION(1) Move seat to mid-position and verify that both

eat tracks are locked into same position with eighteeth behind the latch mechanism.

(2) Move seat into position in vehicle. Do not usehe head restraint, side shield, recliner handle, or thedjuster lift bar to move the seat.

Fig. 1 Front Seat1 – SEAT2 – SEAT BELT BOLT

(3) Ensure that the locating tabs on the frontmounting feet are installed through the slits in thecarpet and into the openings in the floor pan cross-member.

(4) Install and tighten front inboard bolt attachingseat track to floor crossmember.

(5) Install front outboard bolt attaching seat trackto floor crossmember. Tighten front seat bolt to 55N·m (40 ft. lbs.) torque.

(6) Install rear seat track attaching bolts to floor.Tighten rear seat bolts outboard first then inboard to55 N·m (40 ft. lbs.) torque.

FRONT SEAT BACK

REMOVAL(1) Remove seat from vehicle.(2) Remove seat cushion side shields.(3) Remove bolts attaching recliner to seat back

cushion frame (Fig. 2).(4) Remove inboard pivot bolt (Fig. 3).(5) Disconnect any electrical connectors to the seat

back, if equipped.(6) Remove seat back from seat cushion.

Fig. 2 Recliner Attaching Bolt1 – RECLINER BOLT

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NSTALLATION(1) Position seat back on cushion.(2) Connect electrical connectors to the seat back,

f equipped.(3) Install inboard pivot bolt. Tighten bolt to 40·m (30 ft. lbs.) torque.(4) Install bolts attaching recliner to seat cushion

rame. Tighten bolts to 12 N·m (9 ft. lbs.) torque.(5) Install seat cushion side shields.(6) Install seat in vehicle.

RONT SEAT BACK COVER

EMOVAL(1) Remove seat from vehicle.(2) Remove head restraint.(3) Remove front seat back.(4) Disengage the J-strap retainer.(5) Roll cover upward to hog rings. Cut hog rings

o free cover (Fig. 4).(6) Roll cover to top of seat back and remove head

estraint sleeve guides.(7) Remove cover from seat back.

NSTALLATION

OTE: Do not reuse the recliner assembly attach-ng bolts.

(1) Position cover at the top of seat back.(2) Carefully roll cover down to the area that hog

ings are to be installed.(3) Install hog rings.(4) Roll cover downward.(5) Engage the J-strap retainer

Fig. 3 Remove Seat Back1 – RECLINER BOLT HOLE2 – SEAT BACK BOLT HOLE3 – J-STRAP RETAINER

(6) Install new head restraint sleeve guides.

(7) Install seat back to seat cushion. Tighten boltsto 40 N·m (30 ft. lbs.) torque.

(8) Install seat in vehicle.(9) Install head restraint.(10) Check seat back and headrest operation.

FRONT SEAT CUSHION COVER

REMOVAL(1) Remove seat from vehicle.(2) Remove front seat cushion side shields.(3) Remove seat back.(4) Remove track and recliner assembly.(5) Disengage J-strap attaching seat cover from

the seat cushion frame.(6) Pull cover off to the hog rings.(7) Cut hog rings attaching seat cover to seat cush-

ion pad.(8) Remove seat cushion cover from seat cushion.

INSTALLATION(1) Position seat cover on cushion.(2) Align seat cover with cushion alignment inden-

tations.(3) Install hog rings.(4) Engage J-strap attaching seat cover to front of

seat cushion frame.(5) Install track and recliner assembly. Tighten

front track to pan bolts to 12 N·m (9 ft. lbs.) torque.(6) Install seat back.(7) Install front seat cushion side shields.(8) Install seat in vehicle.

FRONT SEAT CUSHION

REMOVAL(1) Remove seat from vehicle.(2) Remove front seat cushion side shield.

Fig. 4 Front Seat Back Hog Rings1 – SEAT COVER2 – HOG RINGS3 – CUSHION

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(3) Remove seat back.(4) Remove track and recliner assembly.(5) Remove seat cushion (Fig. 5).

NSTALLATION(1) Connect seat cushion heater element connector,

f equipped.(2) Install track and recliner assembly. Tighten

olts to 12 N·m (9 ft. lbs.) torque.(3) Install seat back. Tighten bolts to 40 N·m (30

t. lbs.) torque.(4) Install cushion side shields.(5) Install seat in vehicle.

EAR SEAT BACK

EMOVAL(1) Remove rear seat cushion.(2) Remove bolts attaching rear seat back and seat

elts to floor.(3) Push rear seat back upward to disengage hooks

t top of seat back (Fig. 6).(4) Remove rear seat from vehicle.

Fig. 5 Front Seat Cushion1 – FRONT SEAT CUSHION
INSTALLATION
(1) Move rear seat back into position in vehicle.(2) Push seat back downward to engage hooks at

top of seat back.(3) Install bolts attaching rear seat back and seat

belts to floor.

NOTE: The torque specification for the inner seatbelt/rear seat back retaining bolts is 57 N·m (42 ft.lbs.).

(4) Install rear seat cushion.

Fig. 6 Rear Seat Back1 – REAR SEAT BACK2 – REAR OUTER RIGHT SEAT BELT3 – REAR INNER LEFT SEAT BELT4 – REAR INNER RIGHT SEAT BELT

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EAR SEAT CUSHION

EMOVAL(1) Pull upward at each end of the rear seat cush-

on to disengage retainer loops from cups in floor.(2) Remove rear seat cushion from vehicle (Fig. 7).

NSTALLATION(1) Place rear seat cushion in position under bot-

om of seat back.(2) Position inboard seat belts on top of seat cush-

on.(3) Guide seat cushion loops into retainer cups in

loor pan.(4) Push downward on the front corners of the seat

ushion to engage retainers.

Fig. 7 Rear Seat Cushion1 – REAR SEAT CUSHION2 – CUSHION ATTACHING RETAINER

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BODY COMPONENTS

TABLE OF CONTENTS

page page

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ESCRIPTION AND OPERATIONGRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 14SPLASH SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . 16IAGNOSIS AND TESTINGWATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . 18WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19ERVICE PROCEDURESHEAT STAKING . . . . . . . . . . . . . . . . . . . . . . . . . . 19PLASTIC BODY PANEL REPAIR. . . . . . . . . . . . . . 19EMOVAL AND INSTALLATIONGRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23HOOD LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 24HOOD LATCH STRIKER. . . . . . . . . . . . . . . . . . . . 24HOOD RELEASE CABLE . . . . . . . . . . . . . . . . . . . 25HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26HOOD SILENCER . . . . . . . . . . . . . . . . . . . . . . . . 26HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 26COWL COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 27FRONT WHEELHOUSE SPLASH SHIELD . . . . . . 28FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28EXTERIOR BADGEING ATTACHED WITH

DOUBLE SIDED FOAM TAPE . . . . . . . . . . . . . . 28EXTERIOR BADGEING/TAPE STRIPES

ATTACHED WITH ADHESIVES . . . . . . . . . . . . . 28FRONT/REAR DOOR WINDOW CRANK. . . . . . . . 29FRONT DOOR TRIM . . . . . . . . . . . . . . . . . . . . . . 30FRONT DOOR WATER DAM . . . . . . . . . . . . . . . . 30DOOR OUTER BELT WEATHERSTRIP. . . . . . . . . 30FRONT/REAR DOOR INNER BELT

WEATHERSTRIP. . . . . . . . . . . . . . . . . . . . . . . . 32FRONT DOOR GLASS RUN WEATHERSTRIP . . . 32FRONT DOOR OUTSIDE HANDLE. . . . . . . . . . . . 33DOOR LOCK CYLINDER . . . . . . . . . . . . . . . . . . . 33FRONT DOOR LATCH . . . . . . . . . . . . . . . . . . . . . 33FRONT DOOR LATCH STRIKER . . . . . . . . . . . . . 34FRONT VERTICAL GUIDE BAR . . . . . . . . . . . . . . 34FRONT DOOR GLASS . . . . . . . . . . . . . . . . . . . . . 36FRONT DOOR CHECK STRAP . . . . . . . . . . . . . . 36FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 36FRONT DOOR HINGE . . . . . . . . . . . . . . . . . . . . . 38FRONT/REAR DOOR APPLIQUE . . . . . . . . . . . . . 38SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . . . . . . 39SIDE VIEW MIRROR TRIM BEZEL . . . . . . . . . . . . 39DOOR UPPER SECONDARY WEATHERSTRIP . . 39SILL SECONDARY WEATHERSTRIP . . . . . . . . . . 40
REAR DOOR TRIM . . . . . . . . . . . . . . . . . . . . . . . 40
REAR DOOR WATER DAM . . . . . . . . . . . . . . . . . 40REAR DOOR OUTSIDE HANDLE . . . . . . . . . . . . . 40REAR DOOR LATCH . . . . . . . . . . . . . . . . . . . . . . 41REAR DOOR LATCH STRIKER . . . . . . . . . . . . . . 43REAR DOOR GLASS . . . . . . . . . . . . . . . . . . . . . . 43REAR DOOR WINDOW REGULATOR . . . . . . . . . 43REAR DOOR GLASS RUN WEATHERSTRIP . . . . 43REAR DOOR CHECK STRAP. . . . . . . . . . . . . . . . 45REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45REAR DOOR HINGE . . . . . . . . . . . . . . . . . . . . . . 45FUEL FILL DOOR. . . . . . . . . . . . . . . . . . . . . . . . . 46DECKLID LATCH . . . . . . . . . . . . . . . . . . . . . . . . . 47DECKLID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47DECKLID LIFT SPRINGS . . . . . . . . . . . . . . . . . . . 47DECKLID LOCK CYLINDER . . . . . . . . . . . . . . . . . 48DECKLID LATCH STRIKER . . . . . . . . . . . . . . . . . 48DECKLID OPENING WEATHERSTRIP . . . . . . . . . 49TRUNK CARPET . . . . . . . . . . . . . . . . . . . . . . . . . 49DECKLID COVER. . . . . . . . . . . . . . . . . . . . . . . . . 50ROOF RAIL WEATHERSTRIP. . . . . . . . . . . . . . . . 50ROOF RAIL WEATHERSTRIP RETAINER

CHANNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50B-PILLAR WEATHERSTRIP CHANNEL. . . . . . . . . 51A-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . 51DOOR SILL TRIM. . . . . . . . . . . . . . . . . . . . . . . . . 51SIDE COWL TRIM . . . . . . . . . . . . . . . . . . . . . . . . 52B-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . 52UPPER QUARTER TRIM . . . . . . . . . . . . . . . . . . . 53LOWER QUARTER TRIM . . . . . . . . . . . . . . . . . . . 53FLOOR CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . 54FRONT SEAT BELT BUCKLE . . . . . . . . . . . . . . . . 54FRONT SEAT BELT RETRACTOR . . . . . . . . . . . . 54FRONT SHOULDER BELT ADJUSTER . . . . . . . . . 54REAR SEAT BELT BUCKLE . . . . . . . . . . . . . . . . . 55REAR SEAT BELT RETRACTOR . . . . . . . . . . . . . 55CARPET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56SUN VISOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56HEADLINER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57INSIDE REAR VIEW MIRROR . . . . . . . . . . . . . . . 57REAR SHELF TRIM PANEL . . . . . . . . . . . . . . . . . 57BODY VENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58DJUSTMENTSFRONT DOOR LATCH ADJUSTMENT . . . . . . . . . 58REAR DOOR LATCH ADJUSTMENT . . . . . . . . . . 58PECIFICATIONSBODY LUBRICATION . . . . . . . . . . . . . . . . . . . . . . 59PECIAL TOOLS
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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RILLE

OOD

1 – GRILLE

HOOD H

1 – HOOD LATCH RELEASE CABLE2 – HOOD PROP ROD

ARDWARE

3 – HOOD SECURITY ALARM4 – HOOD LATCH

HOOD SILENCER

1 – HOOD2 – HOOD SILENCER

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RONT DOORFRONT D

1 – BODY ASSEMBLY2 – UPPER HINGE

HOOD ADJUST BUMPER

1 – HOOD STATIONARY BUMPER2 – HOOD ADJUST BUMPER

HOOD HINGE

1 – HOOD HINGE2 – HOOD3 – HOOD HINGE

OOR HINGE

3 – FRONT DOOR4 – LOWER HINGE

PL BODY 23 - 15


FRONT DOOR LATCH

1 – LOCK TO LATCH LINK & SLEEVE2 – FRONT DOOR3 – CENTRAL LOCKING SWITCH4 – OUTSIDE DOOR HANDLE

FRONT D

1 – OUTSIDE HANDLE TO LATCH2 – KEY CYLINDER TO LATCH3 – POWER DOOR LOCK CONNECTOR4 – POWER

AND OUTER HANDLE

5 – LOCK CYLINDER RETAINING CLIP6 – LOCK CYLINDER7 – FRONT DOOR LATCH8 – INSIDE DOOR HANDLE LINK & SLEEVE

OOR LATCH

5 – FRONT DOOR LATCH6 – MANUAL7 – INSIDE DOOR HANDLE TO LATCH8 – INSIDE LOCK TO LATCH

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PLASH SHIELDFRONT DOOR POWER

1 – FRONT DOOR GLASS2 – FRONT DOOR3 – POWER WINDOW REGULATOR

FRONT DOOR MANUA

1 – FRONT DOOR2 – FRONT WINDOW MANUAL REGULATOR

WINDOW REGULATOR

4 – POWER WINDOW CONNECTORS5 – WINDOW TO REGULATOR FASTENER

L WINDOW REGULATOR

3 – WINDOW TO REGULATOR FASTENERS4 – FRONT DOOR GLASS

PL BODY 23 - 17


FRONT FENDER

1 – PUSH IN PLUG2 – FRONT FASCIA3 – PULLEY SPLASH SHIELD

REAR WHEEL HOUSING SPLASH SHIELD

1 – REAR FASCIA2 – REAR WHEEL HOUSING SPLASH SHIELD

SPLASH SHIELD

4 – FRONT FASCIA5 – FRONT FENDER SPLASH SHIELD6 – PULLEY SPLASH SHIELD

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IAGNOSIS AND TESTING

ATER LEAKSWater leaks can be caused by poor sealing,

mproper body component alignment, body seamorosity, missing plugs, or blocked drain holes. Cen-rifugal and gravitational force can cause water torip from a location away from the actual leak point,aking leak detection difficult. All body sealing

oints should be water tight in normal wet-drivingonditions. Water flowing downward from the front ofhe vehicle should not enter the passenger or luggageompartment. Moving sealing surfaces will notlways seal water tight under all conditions. Atimes, side glass or door seals will allow water tonter the passenger compartment during high pres-ure washing or hard driving rain (severe) condi-ions. Overcompensating on door or glassdjustments to stop a water leak that occurs underevere conditions can cause premature seal wear andxcessive closing or latching effort. After completingrepair, water-test vehicle to verify leak has stopped

efore returning vehicle to use.

ISUAL INSPECTION BEFORE WATER LEAK TESTSVerify that floor and body plugs are in place, body

rains are clear, and body components are properlyligned and sealed. If component alignment or seal-ng is necessary, refer to the appropriate section ofhis group for proper procedures.

ATER LEAK TESTS

ARNING: DO NOT USE ELECTRIC SHOP LIGHTSR TOOLS IN WATER TEST AREA. PERSONAL

NJURY CAN RESULT.

When the conditions causing a water leak haveeen determined, simulate the conditions as closelys possible.• If a leak occurs with the vehicle parked in a

teady light rain, flood the leak area with an open-nded garden hose.• If a leak occurs while driving at highway speeds

n a steady rain, test the leak area with a reasonableelocity stream or fan spray of water. Direct thepray in a direction comparable to actual conditions.• If a leak occurs when the vehicle is parked on an

ncline, hoist the end or side of the vehicle to simu-ate this condition. This method can be used whenhe leak occurs when the vehicle accelerates, stops orurns. If the leak occurs on acceleration, hoist theront of the vehicle. If the leak occurs when braking,oist the back of the vehicle. If the leak occurs on lefturns, hoist the left side of the vehicle. If the leakccurs on right turns, hoist the right side of the vehi-

cle. For hoisting recommendations refer to Group 0,Lubrication and Maintenance, General Informationsection.

WATER LEAK DETECTIONTo detect a water leak point-of-entry, do a water

test and watch for water tracks or droplets formingon the inside of the vehicle. If necessary, remove inte-rior trim covers or panels to gain visual access to theleak area. If the hose cannot be positioned withoutbeing held, have someone help do the water test.

Some water leaks must be tested for a considerablelength of time to become apparent. When a leakappears, find the lowest point of the water track ordrop. After leak point has been found, repair the leakand water test to verify that the leak has stopped.

Locating the entry point of water that is leakinginto a cavity between panels can be difficult. Thetrapped water may splash or run from the cavity,often at a distance from the entry point. Most waterleaks of this type become apparent after accelerating,stopping, turning, or when on an incline.

MIRROR INSPECTION METHODWhen a leak point area is visually obstructed, use

a suitable mirror to gain visual access. A mirror canalso be used to deflect light to a limited-access areato assist in locating a leak point.

BRIGHT LIGHT LEAK TEST METHODSome water leaks in the luggage compartment can

be detected without water testing. Position the vehi-cle in a brightly lit area. From inside the darkenedluggage compartment inspect around seals and bodyseams. If necessary, have a helper direct a drop lightover the suspected leak areas around the luggagecompartment. If light is visible through a normallysealed location, water could enter through the open-ing.

PRESSURIZED LEAK TEST METHODWhen a water leak into the passenger compart-

ment cannot be detected by water testing, pressurizethe passenger compartment and soap test exterior ofthe vehicle. To pressurize the passenger compart-ment, close all doors and windows, start engine, andset heater control to high blower in HEAT position. Ifengine can not be started, connect a charger to thebattery to ensure adequate voltage to the blower.With interior pressurized, apply dish detergent solu-tion to suspected leak area on the exterior of thevehicle. Apply detergent solution with spray device orsoft bristle brush. If soap bubbles occur at a bodyseam, joint, seal or gasket, the leak entry point couldbe at that location.

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DIAGNOSIS AND TESTING (Continued)

IND NOISEWind noise is the result of most air leaks. Air leaks

an be caused by poor sealing, improper body compo-ent alignment, body seam porosity, or missing plugs

n the engine compartment or door hinge pillar areas.ll body sealing points should be airtight in normalriving conditions. Moving sealing surfaces will notlways seal airtight under all conditions. At times,ide glass or door seals will allow wind noise to beoticed in the passenger compartment during highross winds. Over compensating on door or glassdjustments to stop wind noise that occurs underevere conditions can cause premature seal wear andxcessive closing or latching effort. After a repair pro-edure has been performed, test vehicle to verifyoise has stopped before returning vehicle to use.Wind noise can also be caused by improperly fitted

xterior moldings or body ornamentation. Looseoldings can flutter, creating a buzzing or chatteringoise. An open cavity or protruding edge can create ahistling or howling noise. Inspect the exterior of theehicle to verify that these conditions do not exist.

ISUAL INSPECTION BEFORE TESTSVerify that floor and body plugs are in place and

ody components are aligned and sealed. If compo-ent alignment or sealing is necessary, refer to theppropriate section of this group for proper proce-ures.

OAD TESTING WIND NOISE(1) Drive the vehicle to verify the general location

f the wind noise.(2) Apply 50 mm (2 in.) masking tape in 150 mm

6 in.) lengths along weatherstrips, weld seams oroldings. After each length is applied, drive the vehi-

le. If noise goes away after a piece of tape is applied,emove tape, locate, and repair defect.

OSSIBLE CAUSE OF WIND NOISE• Moldings standing away from body surface can

atch wind and whistle.• Gaps in sealed areas behind overhanging body

langes can cause wind-rushing sounds.• Misaligned movable components.• Missing or improperly installed plugs in pillars.• Weld burn through holes.

ERVICE PROCEDURES

EAT STAKING(1) Remove trim panel.(2) Bend or move the trim panel components at

he heat staked joints. Observe the heat staked loca-ions and/or component seams for looseness.

(3) Heat stake the components.(a) If the heat staked or component seam loca-

tion is loose, hold the two components tightlytogether and using a soldering gun with a flat tip,melt the material securing the componentstogether. Do not over heat the affected area, dam-age to the exterior of the trim panel may occur.

(b) If the heat staked material is broken or miss-ing, use a hot glue gun to apply new material tothe area to be repaired. The panels that are beingheat staked must be held together while the apply-ing the glue. Once the new material is in place, itmay be necessary to use a soldering gun to meltthe newly applied material. Do not over heat theaffected area, damage to the exterior of the trimpanel may occur.(4) Allow the repaired area to cool and verify the

repair.(5) Install trim panel.

PLASTIC BODY PANEL REPAIR

DESCRIPTION OPERATIONResin Transfer Molded (RTM) body panels are rein-

forced with a continuous fiberglass mesh. Epoxyresin is injected into a gel-coated and fiberglass-linedmold to form a body panel. Sheet molded compound(SMC) body panels are constructed with fiberglassstrands usually 1 inch or shorter, epoxy resin formedinto sheet stock and pressed in mold flowing materialto form a sheet molded compound (SMC) body panel.RTM and SMC body panels can be repaired withepoxy adhesive after market products. Refer toinstructions provided by the manufacturer of prod-ucts being used to repair RTM or SMC. Daimler-Chrysler Corporation recommends that a trainedautomotive body technician perform body panelrepair procedures (Fig. 1).

Fig. 1 Panel Repair

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23 - 20 BODY PL

SERVICE PROCEDURES (Continued)

AFETY PRECAUTION AND WARNINGS

ARNING: EYE PROTECTION SHOULD BE USEDHEN SERVICING RTM AND SMC COMPONENTS.ERSONAL INJURE CAN RESULT.USE AN OSHA APPROVED BREATHING DEVICEHEN MIXING EPOXY, GRINDING RTM AND SMC,ND SPRAYING PAINT OR SOLVENTS IN A CON-INED AREA. PERSONAL INJURY CAN RESULT.AVOID PROLONGED SKIN CONTACT WITH

POXY RESIN, PETROLEUM, OR ALCOHOL BASEDOLVENTS. PERSONAL INJURY CAN RESULT.DO NOT VENTURE UNDER A HOISTED VEHICLE

HAT IS NOT PROPERLY SUPPORTED ON SAFETYTANDS. PERSONAL INJURY CAN RESULT.

• When holes must be drilled or cut in body pan-ls, verify locations of internal body components andlectrical wiring. Damage to vehicle can result.• Do not use abrasive chemicals or compounds on

ndamaged painted surfaces around repair areas.amage to finish can result.

ANEL SECTIONINGIf it is required to section a large panel for an SMC

r RTM repair, it will be necessary to reinforce theanel with epoxy structural adhesive (rigid repairdhesive) (Fig. 2). To bond two plastic panelsogether, a reinforcement must overlap both panels.he panels must be “V’d” at a 20 degree angle. Therea to be reinforced should be washed, then sanded.e sure to wipe off any excess soap and water when

inished. Lightly sand or abrade the plastic with anbrasive pad or sandpaper. Blow off any dust withompressed air or wipe with a clean dry rag.

Fig. 2 Panel Sectioning1 – EXISTING PANEL2 – NEW PANEL3 – PANEL ADHESIVE4 – BONDING STRIP

When bonding SMC or RTM panels, use a two-partepoxy adhesive. Properly mix parts A and B, andapply it to the panels being repaired. Be sure thatenough adhesive has been applied to allow squeezeout and to fill the full bond line. Once the pieceshave been brought together, do not move them untilthe adhesive is cured. The assembly can be heldtogether with clamps, rivets, etc. A faster cure can beobtained by heating with a heat lamp or heat gun.

After the parts have been bonded and have hadtime to cure, rough sand the seam and apply thefinal adhesive filler to the area being repaired.Smooth the filler with a spatula, wooden tonguedepressor, or squeegee. For fine texturing, a smallamount of water can be applied to the filler surfacewhile smoothing. The cured filler can be sanded asnecessary and, as a final step, cleanup can be donewithy soapy water. Wipe the surface clean with a drycloth allowing time for the panel to dry before mov-ing on with the repair.

PANEL REINFORCEMENTStructural repair procedures for rigid panels such

as Sheet Molded compound (SMC) or Resin TransferMolded (RTM) with large cracks and holes willrequire a reinforcement backing. Reinforcements canbe made with several applications of glass cloth sat-urated with epoxy structural adhesive, semirigid orflexible repair materials should be used for semirigidor flexible part repairs (Fig. 3) and (Fig. 4). Openmeshed fiberglass dry wall tape can be used to forma reinforcement. The dry wall tape allows the resinto penetrate through and make a good bond betweenthe panel and the epoxy adhesive. Structurally, themore dry wall tape used, the stronger the repair.

Another kind of repair that can be done to repairlarge cracks and holes is to use a scrap piece of sim-ilar plastic and bond with structural adhesive. Thereinforcement should cover the entire break andshould have a generous amount of overlap on eitherside of the cracked or broken area.

When repairing plastic, the damaged area is first“V’d” out, or beveled. Large bonding areas are desir-able when repairing plastic because small repairs areless likely to hold permanently. Beveling the areaaround a crack at a 20 degree angle will increase thebonding surface for a repair (Fig. 5). It is recom-mended that sharp edges be avoided because thejoint may show through after the panel is refinished.

• Panel repair for both flexible and rigid panelsare basically the same. The primary differencebetween flexible panel repair and rigid panel repairis in the adhesive materials used (Fig. 6).

• The technician should first decide what needs tobe done when working on any type of body panel.One should determine if it is possible to return the

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amage part to its original strength and appearanceithout exceeding the value of the replacement part.• When plastic repairs are required, it is recom-ended that the part be left on the vehicle when

very possible. That will save time, and the panelill remain stationary during the repair. Misalign-ent can cause stress in the repair areas and can

esult in future failure.

ISUAL INSPECTIONSheet Molded Compound (SMC) and Resin Trans-

er Molded (RTM), because they are composites, react

Fig. 3 Softened Edges1 – SOFTENED EDGES2 – PANEL ADHESIVE3 – BONDING STRIP

Fig. 4 Panel Reinforcement1 – PANEL ADHESIVE2 – REINFORCEMENT

Fig. 5 Beveling Angle—20 Degrees

differently to impact that sheet metal does. Compos-ite materials can mask the severity of an accident.Adhesive bond lines, interior structure of the doors,and steel structure need to be inspected carefully toget a true damage assessment. Close inspection mayrequire partial removal of interior trim or inner pan-els.

Identify the type of repair:Puncture or Crack – Damage that has penetrated

completely through the panel. Damage is confined toone general area; a panel section is not required.However, a backer panel, open fiberglass tape, ormatted material must be bonded from behind (Fig.7).

PANEL SURFACE PREPARATIONIf a body panel has been punctured, cracked, or

crushed, the damaged area must be removed fromthe panel to achieve a successful repair. All spiderweb cracks leading away from a damaged area mustbe stopped or removed. To stop a running crack in aSMC or RTM panel, drill a 6 mm (0.250 in.) hole atthe end of the crack farthest away from the damage.If spider web cracks can not be stopped, the panelwould require replacement. The surfaces around thedamaged area should be stripped of paint and freed

Fig. 6 Fiberglass Tape

Fig. 7 Damage Component1 – PUNCTURE

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23 - 22 BODY PL


rom was and oil. Scuff surfaces around repair areaith 360 grit wet/dry sand paper, or equivalent, tossure adhesion of epoxy repair materials.

ATCHING PANELSAn RTM or SMC panel that has extensive punc-

ure type damage can be repaired by cutting out theamaged material (Fig. 8). Use a suitable reciprocat-ng saw or cut off wheel to remove the section of theMC or RTM panel that is damaged. The piece cutut can be used as a template to shape the newatch. It is not necessary to have access to the backf the panel to install a patch. Bevel edges of cutoutt 20 degrees to expose a larger bonding area on theuter side. This will allow for an increased reinforce-ent areas.

ANEL PATCH FABRICATIONSA patch can be fabricated from any rigid fiberglass

anel that has comparable contour with the repairrea. discard SMC or RTM panels. Lift gates andenders can be used to supply patch material. Ifxisting material is not available or compatible, aatch can be constructed with epoxy and reinforce-ent mesh (dry wall tape). Perform the following

peration if required:(1) Cover waxed paper or plastic with adhesive

acked nylon mesh (dry wall tape) larger than theatch required (Fig. 9).(2) Tape waxed paper or plastic sheet with mesh tosurface that has a compatible contour to the repair

rea.(3) Apply a liberal coat of epoxy adhesive over the

einforcement mesh (Fig. 9). If necessary apply a sec-nd or third coat of epoxy and mesh after firs coat

Fig. 8 Damaged Panel Cutout and Patch1 – CUTOUT2 – DAMAGED BODY PANEL3 – 4MM (0.160 IN.) HOLES4 – PATCH CUT TO SIZE

has cured. The thickness of the patch should be thesame as the repair area.

(4) After patch has cured, peel waxed paper orplastic from the back of the patch.

(5) If desired, a thin film coat of poesy can beapplied to the back of the patch to cover mesh foradded strength.

PANEL PATCH INSTALLATION(1) Make a paper or cardboard pattern the size

and shape of the cutout hole in the panel.(2) Trim 3 mm (0.125 in.) from edges of pattern so

patch will have a gap between connecting surfaces.(3) Using the pattern as a guide, cut the patch to

size.(4) Cut scrap pieces of patch material into 50 mm

(2 in.) squares to use as patch supports to sustainthe patch in the cutout.

(5) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) infrom edge of cutout hole (Fig. 8).

(6) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) infrom edge of cutout hole (Fig. 8).

(7) Drill 3 mm (0.125 in.) holes in the supportsquares 13 mm (0.5 in.) from the edge in the centerof one side.

(8) Scuff the backside of the body panel around thecutout hole with a scuff pad or sandpaper.

(9) Mix enough epoxy to cover one side of all sup-port squares.

(10) Apply epoxy to the support squares on thehalf with the hole pre-drilled in it.

(11) Using number 8 sheet metal screws, securesupport squares to back side of body panel withepoxy sandwiched between the panel and squares(Fig. 10).

Fig. 9 Fabricated Panel1 – STRUCTURAL ADHESIVE OR EPOXY RESIN2 – FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE3 – WIDTH OF V-GROOVE4 – WAXED PAPER

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PL BODY 23 - 23


(12) Position patch in cutout against supportquares and adjust patch until the gap is equal alongll sides (Fig. 11).(13) Drill 3 mm (0.125 in.) holes in the support

quares through the pre-drilled holes in the patch.(14) Apply a coat of epoxy to the exposed ends of

he support squares (Fig. 12).(15) Install screws to hold the patch to support

quares (Fig. 13). Tighten screws until patch surfaces flush with panel surface.

(16) Allow epoxy to cure, and remove all screws.(17) Using a 125 mm (5 in.) 24 grit disc grinder,

rind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2m (0.080 in.) deep path across the gaps around the

atch (Fig. 14). With compressed air, blow dust fromround patch.(18) Apply adhesive backed nylon mesh (dry wall

ape) over gaps around patch (Fig. 15).(19) Mix enough epoxy to cover the entire patch

rea.(20) Apply epoxy over the mesh around patch, and

mooth epoxy with a wide spreader to reduce finishrinding. Use two to three layers of mesh and epoxyo create a stronger repair (Fig. 16).

ATCHED PANEL SURFACINGAfter patch panel is installed, the patch area can

e finished using the same methods as finishingther types of body panels. If mesh material isxposed in the patched area, grind surface down, andpply a coat of high quality rigid plastic body filler.rime, block sand, and paint as required.

Fig. 10 Secure Support Squares To Body Panel1 – SUPPORT SQUARES2 – SCREWS3 – DAMAGED BODY PANEL

REMOVAL AND INSTALLATION

GRILLE

REMOVAL(1) Release hood latch, open and support hood on

prop rod.(2) Remove screws attaching grille to parking

lamps (Fig. 17).(3) Remove screw attaching grille to radiator clo-

sure panel.(4) Remove grille from vehicle.

INSTALLATION(1) Place grille into position on vehicle.

Fig. 11 Position Patch In Cutout And Align1 – CUTOUT2 – SUPPORT SQUARES

Fig. 12 Apply Epoxy To Support Squares1 – APPLICATOR2 – SUPPORT SQUARES3 – EPOXY

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(2) Install screw attaching grille to radiator clo-ure panel.(3) Install screws attaching grille to parking

amps.

OOD LATCH

EMOVAL(1) Release hood latch and open hood.(2) Support hood on prop rod.(3) Remove grille.(4) Remove screws attaching hood latch to radiator

losure panel (Fig. 18).(5) Remove hood latch from closure panel.(6) Disengage remote release cable from latch.

Fig. 13 Install Screws1 – PATCH2 – GAP

Fig. 14 Grind Surface1 – PATCH2 – GAP3 – DISC GRINDER

INSTALLATION(1) Engage remote release cable into latch.(2) Place hood latch onto radiator closure panel.(3) Install bolts attaching latch to closure panel.(4) Install grille.(5) Close hood and verify alignment of hood and

that latch is securely engaged.

HOOD LATCH STRIKER

REMOVAL(1) Release hood latch and open hood.(2) Remove bolts attaching striker to inside of

hood.

Fig. 15 Cover Gaps With Mesh1 – GROUND DOWN AREA2 – PATCH3 – MESH

Fig. 16 Cover Mesh With Epoxy1 – EPOXY2 – MESH3 – PATCH4 – SPREADER

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(3) Remove hood latch striker from vehicle.

NSTALLATION(1) Position hood latch striker on vehicle.(2) Install bolts attaching hood latch striker to

ood. Tighten bolts to 13.5 N·m (10 ft. lbs.) torque.(3) Align hood latch striker to engage smoothly

nto hood latch.

Fig. 18 H1 – HOOD LATCH RELEASE CABLE2 – HOOD PROP ROD

Fig. 17 Grille1 – GRILLE

(4) Verify hood operation and alignment. Adjust asnecessary.

(5) Tighten attaching bolts to 13.5 N·m (10 ft. lbs.)torque.

HOOD RELEASE CABLE

REMOVAL(1) Disconnect remote hood release cable from

hood latch.(2) Remove left front cowl trim panel.(3) Remove screws attaching hood release handle

to cowl panel (Fig. 19).(4) Disconnect rubber grommet from dash panel

behind instrument panel.(5) Pull release cable through hole in dash panel.(6) Remove cable and handle from vehicle.

INSTALLATION(1) Assemble cable and handle onto vehicle.(2) Push release cable through hole in dash panel.(3) Connect rubber grommet into dash panel.(4) Install screws attaching hood release handle to

cowl panel.(5) Install left front cowl trim panel.(6) Connect remote hood release cable to hood

latch.(7) Close hood and verify operation.

Latch3 – HOOD SECURITY ALARM4 – HOOD LATCH

ood

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23 - 26 BODY PL


OOD

EMOVAL(1) Raise hood to full up position.(2) Disengage under hood lamp wire connector

rom engine compartment wire harness.(3) Remove hood cover (Fig. 20).(4) Mark all bolt and hinge attachment locationsith a grease pencil or other suitable device to pro-ide reference marks for installation. When installingood, align all marks and secure bolts. The hoodhould be aligned to 4 mm (0.160 in.) gap to the frontenders and flush across the top surfaces along fend-rs.(5) Remove the top bolts attaching hood to hinge

nd loosen the bottom bolts until they can beemoved by hand.(6) With assistance from a helper at the opposite

ide of the vehicle to support the hood, remove bot-om bolts attaching hood to hinge.

(7) Remove the hood from the vehicle.

NSTALLATION(1) Place hood in position on vehicle. With assis-

ance from a helper at the opposite side of the vehicleo support the hood, install bottom bolts to hold hoodo hinge finger tight.

(2) Install top bolts attaching hood to hinge fingeright.

(3) Position bolts at marks and tighten bolts. Theood should be aligned to 4 mm (0.160 in.) gap to theront fenders and flush across the top surfaces alongenders.

Fig. 19 Hood Release Cable1 – HOOD RELEASE HANDLE2 – COWL SIDE TRIM PANEL

(4) Install hood cover.(5) Engage under hood lamp wire connector to

engine compartment wire harness.(6) Verify hood operation and alignment.

HOOD SILENCER

REMOVAL(1) Release hood latch and open hood.(2) Disconnect hood lamp wire connector and

remove hood lamp (Fig. 21).(3) Remove fasteners attaching hood silencer to

hood.(4) Remove hood silencer from vehicle.

INSTALLATION(1) Place hood silencer in position on vehicle.(2) Install fastener attaching hood silencer to hood.(3) Install hood lamp and connect wire connector.(4) Close hood.

HOOD HINGE

REMOVAL(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 installinghood hinge, align all marks and secure bolts. Thehood should be aligned to 4 mm (0.160 in.) gap to thefront fenders and flush across the top surfaces alongfenders. Shims can be added or removed under hoodhinge to achieve proper hood height.

(3) Remove bolts holding hood to hinge.(4) Remove bolts holding hood hinge to load beam

flange and separate hinge from vehicle. If necessary,paint new hinge before installation.

INSTALLATION(1) If necessary, paint new hinge before installa-

tion.(2) Place hinge in position on vehicle.(3) Install bolts to hold hood hinge to front fender

flange.(4) Install bolts to hold hood to hinge.(5) Align all marks and secure bolts. The hood

should be aligned to 4 mm (0.160 in.) gap to the frontfenders and flush across the top surfaces along fend-ers. Shims can be added or removed under hoodhinge to achieve proper hood height.

(6) Remove support from under hood and verifyhood operation.

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OWL COVER

EMOVAL(1) Release hood latch and open hood.(2) Remove windshield wiper arms, refer to Group

K, Windshield Wiper and Washer Systems forroper procedures.(3) Remove the five screws holding cowl cover to

owl at base of windshield opening (Fig. 23).

Fig. 21 – FENDER TO HOOD HINGE SEAL2 – HOOD TO RADIATOR WEATHERSTRIP3 – FENDER TO HOOD SEAL

Fig. 211 – HOOD2 – HOOD SILENCER

(4) Remove hood to cowl seal, at the leading edgeof cowl cover. Pull the seal towards the front of thevehicle.

(5) Separate the cowl cover from the vehicle.

INSTALLATION(1) Place cowl panel in place on vehicle.

ood4 – COWL SIDE TO COWL TOP5 – COWL PLENUM TO HOOD WEATHERSTRIP

Fig. 22 Hood Hinge1 – HOOD HINGE2 – HOOD3 – HOOD HINGE

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23 - 28 BODY PL


(2) Install the five screws holding cowl panel toowl at base of windshield opening.(3) Push the hood to cowl seal over the forward

lange of the cowl cover and cowl plenum.(4) Install windshield wiper arms, refer to Group

K, Windshield Wiper and Washer Systems, forroper procedures.

RONT WHEELHOUSE SPLASH SHIELD

EMOVAL(1) Hoist and support vehicle on safety stands.(2) Remove front wheel.(3) Remove push-in fasteners attaching splash

hield to frame rail forward of suspension (Fig. 24).(4) Remove push in fasteners attaching splash

hield to frame rail rearward of suspension.(5) Remove screws attaching wheelhouse splash

hield to front fender.(6) Remove splash shield from vehicle.

NSTALLATION(1) Place splash shield in position on vehicle.(2) Install screws attaching wheelhouse splash

hield to front fender.(3) Install push in fasteners attaching splash

hield to frame rail rearward of suspension.(4) Install push in fasteners attaching splash

hield to frame rail forward of suspension.(5) Install front wheel.(6) Lower vehicle.

ENDER

EMOVAL(1) Remove headlamp housing.(2) Right side of vehicle remove pulley splash

hield.

Fig. 23 Cowl Cover1 – COWL TOP SCREEN

(3) Remove inner splash shield.(4) Remove fender to fascia nuts.(5) Remove fender bolt to lower rocker panel.(6) Remove fender bolt to lower cowl.(7) Pull fascia away from fender.(8) Remove bolts attaching fender to upper rail.(9) Remove fender from vehicle (Fig. 25).

INSTALLATION(1) Place fender in position on vehicle.(2) Start the center upper rail bolt.(3) From inside engine compartment, install all

the bolts attaching fender to upper rail and tighten.(4) Install lower cowl panel bolt to fender.(5) Install rocker panel bolt to fender.(6) Place fascia into position.(7) Install fender to fascia nuts.(8) Install inner splash shield.(9) Install right side pulley splash shield.(10) Install headlamp assembly.(11) Check fender for flush and gap.

EXTERIOR BADGEING ATTACHED WITHDOUBLE SIDED FOAM TAPE

REMOVAL(1) Mark reference points before removing.(2) Using a heat gun gently apply heat in a circu-

lar motion to loosen the adhesive bond.(3) Using a nonmetallic prying device, such as a

plastic or wood trim stick gently pry up at cornersand remove.

(4) Clean off all traces of adhesive or double sidedtape from the panel with a general purpose adhesiveremover.

INSTALLATION(1) Clean panel surface with isopropy alcohol.(2) Align badgeing to reference points.(3) Install and press securely to full adhesive con-

tact(4) Clean away any reference points.

EXTERIOR BADGEING/TAPE STRIPESATTACHED WITH ADHESIVES

REMOVAL(1) Mark reference points before removing.(2) Using a heat gun gently apply heat in a circu-

lar motion to loosen the adhesive bond.(3) With your fingernail lift up and peel away

badgeing /tape from panel, using a heat gun as yougo.

(4) Clean off all traces of adhesive from the pan-el(s) with a general purpose adhesive remover.

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NSTALLATION(1) Clean panel surface with isopropy alcohol.(2) Remove paper carrier and align badgeing/tape

o reference points or adjacent panel.(3) Install and press securely, using a plastic

preader to eliminate all air bubbles.(4) Remove top protective carrier.(5) Clean away any reference points.

Fig. 21 – FENDER

Fig. 24 Front Wheel1 – PUSH IN PLUG2 – FRONT FASCIA3 – PULLEY SPLASH SHIELD

FRONT/REAR DOOR WINDOW CRANK

REMOVAL(1) Open door.(2) Slide a window crank removal tool behind the

window crank to release crank handle lock clip (Fig.26).

(3) Remove handle from regulator shaft.

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23 - 30 BODY PL


NSTALLATION(1) Place the lock clip on the window crank.(2) Place window crank on regulator shaft with theindow in the down position.(3) Orientate the window regulator crank handle

ppropriately at the 10 o’clock position and the leftandle at the 2 o’clock position.(4) Push the handle in to the lock position on the

egulator shaft.

RONT DOOR TRIM

EMOVAL(1) Release door latch and open door.(2) Lower door glass.(3) Remove window regulator crank, if so equipped

Fig. 26).(4) Remove screw from inside arm rest pull cup

Fig. 27).(5) Remove screw from behind inside latch release

andle.(6) Disengage push-in fasteners attaching trim to

oor panel around perimeter of trim panel.(7) Tilt trim panel outward to clear locator pins on

ackside of trim panel.(8) Disconnect trim panel from retainer channel in

nner belt weatherstrip at top of door by lifting whileently jiggling.(9) Move trim panel away from door and disengage

lip attaching latch rod to handle.(10) Remove latch rod from handle.

AUTION: Do not allow door trim panel to hang byhe wire connector or wiring.

Fig. 26 Window Crank1 – WINDOW CRANK REMOVAL TOOL2 – WINDOW CRANK

(11) Disconnect wire connector from power doorlock switch, mirror switch, and power window switchif so equipped.

(12) Remove trim panel from door.

INSTALLATION(1) Replace any damaged or missing push in fas-

teners from around perimeter of door trim panel.(2) Place trim panel near door.(3) Connect wire connector into power door lock

switch, mirror switch, and power window switch, ifso equipped.

(4) Insert latch rod into handle and engage clip.(5) Install trim panel into retainer channel at top

of door and push down to seat.(6) Locate door trim panel to inner door panel by

aligning locating pins on backside of trim panel tomating holes in inner door panel.

(7) Install push in fasteners to hold trim to doorpanel around perimeter of trim panel.

(8) Install screw inside latch release handle.(9) Install screw inside arm rest pull cup.(10) With the window in the down position, orien-

tate the window regulator crank handle appropri-ately. Install the right handle at the 10 o’clockposition and the left handle at the 2 O’clock position,if so equipped.

FRONT DOOR WATER DAM

REMOVAL(1) Remove door trim panel.(2) Remove door speaker, if equipped.(3) Remove door trim pull cup mount bracket.(4) Disconnect clip attaching lock linkage to lock

button bell-crank.(5) Peel water dam away from adhesive around

perimeter of inner door panel (Fig. 28).

INSTALLATION(1) Insure that enough adhesive remains to

securely retain the water dam. Replace as necessary.(2) Place the water dam into position and press

securely to adhesive making sure to properly routewiring and linkages.

(3) Engage clip attaching lock linkage to lock but-ton bell-crank.

(4) Install door trim pull cup mount bracket.(5) Install door speaker, if equipped.(6) Install door trim panel.

DOOR OUTER BELT WEATHERSTRIP

REMOVAL(1) Open door glass.

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PL BODY 23 - 31


(2) Pull upward at rear end of outer belt weather-trip.(3) Remove outer belt weatherstrip from vehicle

Fig. 29).

Fig. 27 Fro1 – FRONT DOOR2 – LINK AND SLEEVES3 – INNER REMOTE HANDLE4 – POWER DOOR LOCK SWITCH

Fig. 28 W1 – U NUTS2 – LINK AND SLEEVES3 – FRONT DOOR

INSTALLATION(1) Starting at leading edge of door, press weather-

strip onto door.(2) Operate window and check for interference

oor Trim5 – DOOR TRIM SCREWS6 – FRONT DOOR TRIM PANEL7 – INSIDE DOOR HANDLE

r Dam4 – WATER DAM5 – TRIM ATTACHING BRACKET

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23 - 32 BODY PL


RONT/REAR DOOR INNER BELTEATHERSTRIP

EMOVAL(1) Remove door trim panel.(2) Remove weatherstrip from door. Use a rubberallet and a block of wood, tap upward at each clipolding the molding to the door (Fig. 30).

Fig. 29 Door Oute1 – REAR DOOR OUTER BELT WEATHERSTRIP2 – FRONT DOOR OUTER BELT WEATHERSTRIP

Fig. 30 Front/Rear Door Inner Belt Weatherstrip1 – REAR DOOR2 – FRONT DOOR3 – INNER BELT WEATHERSTRIP

INSTALLATION(1) Push down on weatherstrip to engage channel

to door panel.(2) Install door trim panel.

FRONT DOOR GLASS RUN WEATHERSTRIP

REMOVAL(1) Remove flag cover, door trim panel, water dam

as necessary.(2) Remove door glass.(3) Loosen side view mirror, as necessary.(4) Remove weatherstrip fasteners.(5) Pull weatherstrip from lower front channel

above door latch.(6) Pull run weatherstrip from window frame

channel (Fig. 31).

INSTALLATION(1) Clean butyl material from door flange area.(2) Place door run weatherstrip in position on win-

dow frame channel.(3) Push door run weatherstrip into window frame

channel.(4) Push weatherstrip into lower front channel

above door latch.(5) Install weatherstrip fasteners.(6) Install door glass.(7) Tighten side view mirror.(8) Install pull cup support bracket, water shield,

door trim panel and flag trim.

lt Weatherstrip3 – DOOR MOLDING4 – OUTER BELT WEATHERSTRIP

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RONT DOOR OUTSIDE HANDLE

EMOVAL(1) Remove door trim panel and water dam.(2) Close door glass.(3) Disconnect lock and latch rods from door latch.(4) Remove nut attaching door handle retainer to

uter door panel (Fig. 32).(5) Remove retainer from back of door handle.(6) Remove door handle from vehicle.

NSTALLATION(1) Position door handle into door and install

etainer at back of handle.(2) Install nut attaching door handle retainer to

uter door panel.(3) Connect lock and latch rods to door latch.(4) Install door trim panel and water dam.

OOR LOCK CYLINDER

EMOVAL(1) Remove door trim panel and water dam.(2) Close door glass.(3) Disconnect door lock rod from latch.(4) Remove clip attaching lock cylinder to door

andle.(5) Pull lock cylinder from door handle (Fig. 33).

Fig. 31 Door Glas1 – FRONT DOOR GLASS RUN WEATHERSTRIP2 – FRONT DOOR3 – B-PILLAR4 – SPACER5 – DOOR LATCH STRIKER6 – WINDOW REGULATOR HANDLE

INSTALLATION(1) Push lock cylinder into door handle.(2) Install clip attaching lock cylinder to door han-

dle.(3) Connect door lock rod from latch.(4) Install door trim panel and water dam.

FRONT DOOR LATCH

REMOVAL(1) Remove door trim panel and water shield.(2) Close door glass.(3) Disconnect lock and latch rods from door latch

(Fig. 34).(4) Disengage wire connector from power door lock

motor, if equipped.(5) Remove screws holding latch to door end

frame.(6) Remove door latch from vehicle.

INSTALLATION

CAUTION: Do not close door before adjusting thedoor latch. Door may fail to open.

(1) Position door latch inside door and installscrews holding latch to door end frame.

(2) Engage wire connector into power door lockmotor, if so equipped.

n Weatherstrip7 – SPACER8 – DOOR TRIM PANEL9 – WINDOW REGULATOR10 – DOOR CHECK STRAP11 – FRONT DOOR GLASS RUN BRACKET WEATHER

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23 - 34 BODY PL


(3) Connect latch and lock rods to door latch.(4) Install door trim panel and water shield.(5) Adjust door latch using procedure in this sec-

ion.

RONT DOOR LATCH STRIKER

EMOVAL(1) Mark outline of door latch striker on B-pillar to

id installation.

Fig. 32 Front Do1 – LOCK TO LATCH LINK & SLEEVE2 – OUTSIDE HANDLE TO LATCH3 – REAR DOOR

Fig. 33 Door Lock Cylinder1 – OUTSIDE DOOR HANDLE2 – LOCK CYLINDER3 – RETAINER

(2) Remove screws attaching door latch striker toB-pillar (Fig. 35).

(3) Remove door latch striker from vehicle.

INSTALLATION(1) Install door latch striker into the door.(2) Install screws attaching door latch striker to

B-pillar loosely.(3) Align door latch striker to outline marks on the

B-pillar(4) Tighten screws attaching door latch striker to

B-pillar.(5) Check door alignment and adjust as necessary.

FRONT VERTICAL GUIDE BAR

REMOVAL(1) Remove door trim panel and water dam.(2) Remove door speaker, if equipped.(3) Remove front lift guide.(4) Remove bolt attaching top of front guide bar to

inner door panel.(5) Using a Snap-ont flare-nut socket (FRXM10)

and a hex wrench, remove nut attaching bottom ofguide bar to door panel while holding jack screws.

INSTALLATION(1) Install nut attaching bottom of guide bar to

door panel.(2) Install bolt attaching top of front guide bar to

inner door panel.(3) Install front lift guide.

utside Handle4 – OUTSIDE DOOR HANDLE5 – CHILD SAFETY LATCH6 – INSIDE DOOR HANDLE LINK & SLEEVE

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PL BODY 23 - 35


(4) Install door speaker, if equipped.(5) Verify door glass alignment, adjust if necessary.(6) Install door trim panel and water dam.

Fig. 34 Fron1 – INSIDE LOCK TO LATCH2 – OUTSIDE HANDLE TO LATCH3 – POWER DOOR LOCK CONNECTOR4 – REAR DOOR LATCH

Fig. 35 Front D1 – FRONT DOOR GLASS RUN WEATHERSTRIP2 – FRONT DOOR3 – B-PILLAR4 – SPACER5 – DOOR LATCH STRIKER6 – WINDOW REGULATOR HANDLE

t Door Latch5 – MANUAL6 – POWER7 – INSIDE DOOR HANDLE TO LATCH

oor Latch Striker7 – SPACER8 – DOOR TRIM PANEL9 – WINDOW REGULATOR10 – DOOR CHECK STRAP11 – FRONT DOOR GLASS RUN BRACKET WEATHER

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RONT DOOR GLASS

EMOVAL(1) Remove door trim panel and water dam.(2) Remove inner door belt weatherstrip.(3) Loosen window inner belt stabilizer.(4) Lower door glass to bottom of door to gain

ccess to attaching bolts.(5) Remove bolts attaching door glass to window

egulator lift plates (Fig. 36).(6) Disengage door glass from regulator.(7) Lift door glass upward out of the opening at

he top of door.

NSTALLATION(1) Carefully lower door glass through opening in

op of door.(2) Position door glass into window regulator lift

lates.(3) Install bolts door glass to lift plates and do not

ighten.(4) Tighten window inner belt stabilizer.(5) Raise glass to the full up position and then

ighten the lift plate bolts.(6) Install inner door belt weatherstrip.(7) Install door trim panel and water dam.

RONT DOOR CHECK STRAP

EMOVAL(1) Remove door trim panel and water dam.

Fig. 36 Front Door G1 – FRONT DOOR GLASS2 – FRONT DOOR3 – POWER WINDOW REGULATOR

(2) Remove bolt attaching check strap to hinge pil-lar.

(3) Remove door speaker.(4) Remove glass run.(5) Remove bolts attaching check strap to door end

frame (Fig. 38).(6) Remove check strap from vehicle.

INSTALLATION

NOTE: Do not grease check strap.

(1) Position door check on vehicle and install boltsattaching strap to door end frame.

(2) Install glass run.(3) Install door speaker, if so equipped.(4) Install bolt attaching door check strap to hinge

pillar.(5) Install door trim panel and water dam.

FRONT DOOR

REMOVAL

NOTE: The retaining clips used on the door hingepins are not to be reused. Verify availability prior toproceeding.

(1) Open and support door on a suitable liftingdevice.

– Power Window4 – POWER WINDOW CONNECTORS5 – WINDOW TO REGULATOR FASTENER

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(2) Disconnect wire connector at hinge pillar, ifecessary.(3) Remove bolts attaching door check strap to

inge pillar.(4) Remove bolts attaching lower hinge to door.

Fig. 37 Front Door Gl1 – FRONT DOOR2 – FRONT WINDOW MANUAL REGULATOR

Fig. 38 Front D1 – FRONT DOOR GLASS RUN WEATHERSTRIP2 – FRONT DOOR3 – B-PILLAR4 – SPACER5 – DOOR LATCH STRIKER6 – WINDOW REGULATOR HANDLE

(5) Remove bolts attaching upper hinge to door.(Fig. 39).

(6) Remove door from vehicle.

– Manual Window3 – WINDOW TO REGULATOR FASTENERS4 – FRONT DOOR GLASS

Check Strap7 – SPACER8 – DOOR TRIM PANEL9 – WINDOW REGULATOR10 – DOOR CHECK STRAP11 – FRONT DOOR GLASS RUN BRACKET WEATHER

ass

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23 - 38 BODY PL


NSTALLATION(1) Apply Mopart Multimileage Grease to inside of

oor hinge bushings.(2) Position door to the hinges on vehicle.(3) Install bolt into hinge top hole on the right side

r bottom hole left side (smallest hole).(4) Install bolt into hinge bottom hole on the right

ide or top hole left side (slotted hole).(5) Install bolts attaching door check strap to

inge pillar.(6) Connect wire connector at hinge pillar, if nec-

ssary.

RONT DOOR HINGE

EMOVAL(1) Open and support door on a suitable lifting

evice.(2) Remove bolts attaching door check strap to

ower A-pillar for greater access, if necessary.(3) Mark position of hinge on both the door end

rame and lower A-pillar to ease installation.(4) Remove bolts attaching hinge to door end

rame (Fig. 39).(5) Remove bolts attaching hinge to lower A-pillar.(6) Remove door hinge from vehicle.

Fig. 39 F1 – BODY ASSEMBLY2 – UPPER HINGE

INSTALLATION

CAUTION: When installing a new hinge, make surethat the head of each hinge pin is fully seated intothe door hinge. Also, remove the plastic shippingclip and replace it with the correct metal retainingclip once the hinge pin is seated.

(1) If necessary, paint new door hinge prior toinstallation.

(2) Position door hinge on vehicle.(3) Loosely install bolts attaching hinge to lower

A-pillar.(4) Loosely install bolts attaching hinge to door

end frame.(5) Align hinge to marks made previously and

tighten all bolts.(6) Install bolts attaching door check strap to

lower A-pillar, if removed previously.(7) Verify door fit and operation. Adjust door hinge

for proper door alignment, if necessary.

FRONT/REAR DOOR APPLIQUE

REMOVAL(1) Using a fork type prying tool, disengage push

in fasteners attaching applique to door.(2) Remove applique from door (Fig. 40).

t Door3 – FRONT DOOR4 – LOWER HINGE

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NSTALLATION(1) Place applique into position on door.(2) Install fasteners into door applique.

IDE VIEW MIRROR

EMOVAL(1) Remove side view mirror bezel or door trim

anel as necessary.(2) Remove nuts attaching mirror to door inner

anel (Fig. 41).(3) Manual mirrors snap left side manual remote

rom bezel.(4) Electrical mirrors disconnect.(5) Remove mirror from vehicle.

NSTALLATION(1) Position side view mirror on vehicle and install

uts attaching mirror to door inner panel.(2) Connect electrical mirror connector.(3) Install nuts attaching mirror.(4) Install mirror bezel or door trim panel as nec-

ssary.

IDE VIEW MIRROR TRIM BEZEL

EMOVAL(1) Disengage clips attaching side view mirror

ezel to stanchion. Left side only with manual mir-ors (Fig. 41).(2) Remove mirror bezel from vehicle.

Fig. 40 Front and1 – FRONT B-PILLAR APPLIQUE2 – REAR B-PILLAR APPLIQUE

INSTALLATION(1) Place mirror bezel in position.(2) Engage clips attaching side view mirror bezel

to stanchion.

DOOR UPPER SECONDARY WEATHERSTRIP

REMOVAL(1) Using a fork-type prying tool, disengage push

in fasteners attaching door upper secondary weather-strip to door opening.

(2) Remove weatherstrip from door.

r Door Applique3 – REAR DOOR SIDE GLASS APPLIQUE

Fig. 41 Side View Mirror1 – MIRROR ASSEMBLY2 – MIRROR BEZEL

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NSTALLATION(1) Position weatherstrip to opening door.(2) Press door upper secondary weatherstrip fas-

eners into position.

ILL SECONDARY WEATHERSTRIP

EMOVAL(1) Using a fork-type prying tool, disengage push

n fasteners attaching sill secondary weatherstrip tooor (Fig. 42).(2) Remove weatherstrip from door.

NSTALLATION(1) Position weatherstrip to door.(2) Press sill secondary weatherstrip fasteners into

osition.

EAR DOOR TRIM

EMOVAL(1) Release door latch and open door.(2) Lower window glass.(3) Remove window regulator crank.(4) Remove screw from inside arm rest pull cup.(5) Remove screw from behind inside latch release

andle (Fig. 43).(6) Disengage push in fasteners attaching trim to

oor panel around perimeter of trim panel.(7) Disengage push-in metal spring clip holding

rim in sail flag area.(8) Lift trim panel up off belt weatherstrip.

Fig. 42 Front/Rear Sill Secondary Weatherstrip1 – FRONT DOOR2 – REAR DOOR3 – SILL SECONDARY WEATHERSTRIP

(9) Tilt top of trim panel away from door and dis-engage clip attaching latch rod to handle.

(10) Remove latch rod from handle.(11) Remove trim panel from door.

INSTALLATION(1) Replace any damaged or missing push in fas-

teners from around perimeter of door trim panel.(2) Place trim panel in position on door.(3) Insert latch rod into handle and engage clip.(4) Engage trim panel into retainer channel at top

of door.(5) Locate door trim panel to inner door panel by

aligning locating pins on backside of trim panel tomating holes in inner door panel.

(6) Engage push in fasteners attaching trim todoor panel around perimeter of trim panel.

(7) Install screw behind inside latch release han-dle.

(8) Install screw inside arm rest pull cup.(9) Install window regulator crank.

REAR DOOR WATER DAM

REMOVAL(1) Remove door trim panel.(2) Remove door speaker, if equipped.(3) Remove door trim pull cup mount bracket.(4) Disconnect clip attaching lock linkage to lock

button bell-crank.(5) Peel water dam away from adhesive around

perimeter of inner door panel (Fig. 44).

INSTALLATION(1) Insure that enough adhesive remains to

securely retain the water dam. Replace as necessary.(2) Place the water dam into position and press

securely to adhesive making sure to properly routewiring and linkages.

(3) Engage clip attaching lock linkage to lock but-ton bell-crank.

(4) Install door trim pull cup mount bracket.(5) Install door speaker, if equipped.(6) Install door trim panel.

REAR DOOR OUTSIDE HANDLE

REMOVAL(1) Remove door trim panel.(2) Close door glass.(3) Disengage clips attaching linkage rods to door

handle.(4) Remove nuts attaching outside handle to door

(Fig. 45).(5) Remove outside handle.

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PL BODY 23 - 41


NSTALLATION(1) Position door outside handle in opening.(2) Tighten attaching nuts.(3) Connect linkage rods to latch.(4) Connect lock and latch rods to door handle.(5) Install door trim panel.

Fig. 43 Re1 – REAR DOOR2 – LINK AND SLEEVES3 – DOOR TRIM SCREWS4 – POWER DOOR LOCK SWITCH

Fig. 44 W1 – LINK AND SLEEVES2 – REAR DOOR3 – WATER DAM

REAR DOOR LATCH

REMOVAL(1) Remove door trim panel.(2) Close door glass.(3) Loosen lower rear run channel.

oor Trim5 – LINK AND SLEEVES6 – REAR DOOR TRIM PANEL7 – INSIDE DOOR HANDLE8 – WATER DAM

r Dam4 – TRIM ATTACHING BRACKET5 – REAR DOOR TYPICAL

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(4) Disconnect clips attaching linkage rods to dooratch.

(5) Remove linkage rods from latch (Fig. 46).(6) Remove screws attaching latch to door end

rame(7) Remove door latch from vehicle.

Fig. 45 Rear Do1 – LOCK TO LATCH LINK & SLEEVE2 – OUTSIDE HANDLE TO LATCH3 – REAR DOOR

Fig. 46 Rea1 – INSIDE LOCK TO LATCH2 – OUTSIDE HANDLE TO LATCH3 – POWER DOOR LOCK CONNECTOR4 – REAR DOOR LATCH

INSTALLATION

CAUTION: Do not close door before adjusting thedoor latch. Door may fail to open.

utside Handle4 – OUTSIDE DOOR HANDLE5 – CHILD SAFETY LATCH6 – INSIDE DOOR HANDLE LINK & SLEEVE

oor Latch5 – MANUAL6 – POWER7 – INSIDE DOOR HANDLE TO LATCH

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PL BODY 23 - 43


(1) Position door latch on vehicle and installcrews attaching latch to door end frame.(2) Connect linkage rods to latch.(3) Connect lock and latch rods to door latch.(4) Tighten lower rear run channel.(5) Install door trim panel.

EAR DOOR LATCH STRIKER

EMOVAL(1) Mark outline of door latch striker on B-pillar to

id installation.(2) Remove screws attaching door latch striker to-pillar (Fig. 47).(3) Remove door latch striker from vehicle.

NSTALLATION(1) Install door latch striker from vehicle.(2) Install screws attaching door latch striker to-pillar.(3) Align marked outline of door latch striker on-pillar to aid installation.

EAR DOOR GLASS

EMOVAL(1) Remove door trim panel and inner belt weath-

rstrip.(2) Lower the window to 50 mm (2 ins.) from bot-

om of travel.(3) Loosen bolts attaching rear lower run channel

o inner door panel (Fig. 47).(4) Remove rear run channel from door.(5) Loosen screws attaching window regulator

hannel to glass.(6) Slide channel rearward to allow screw heads to

ass through key hole slots in channel.(7) Remove glass from roller channel.(8) Lift door glass upward out of the opening at

he top of door.

NSTALLATION(1) Lower door glass through opening in top of

oor and into position in the window regulator.(2) Position door glass onto roller channel.(3) Slide roller channel forward to allow screw

eads to engage key hole slots in channel.(4) Tighten screws attaching window regulator

oller channel to glass.(5) Install inner door belt door trim panel inner

elt weatherstrip.(6) Operate window and check for interference.djust glass as necessary.

REAR DOOR WINDOW REGULATOR

REMOVAL(1) Remove door trim panel.(2) Remove door glass from regulator channel.(3) Loosen screws attaching window regulator

channel and crank housing to door panel (Fig. 47).(4) Disengage screw and bolt heads from keyhole

slots in door panel.(5) Loosen bolts attaching window regulator to

door panel.(6) Disengage regulator from door panel, and

crank housing.(7) Slide regulator rearward and rotate forward

end of roller channel through access hole in doorpanel,

(8) Remove window regulator from door throughaccess hole in inner panel.

INSTALLATION(1) position window regulator and crank housing

on door panel through access hole in door panel.(2) Tighten bolts attaching window regulator to

door panel.(3) Engage window regulator bolt heads on chan-

nel to key hole slots in door panel.(4) Tighten screw attaching window regulator

channel and crank housing.(5) Position glass to regulator roller channel.(6) Tighten fasteners attaching door glass to roller

channel.(7) Install door trim panel.

REAR DOOR GLASS RUN WEATHERSTRIP

REMOVAL(1) Remove door trim panel, water dam as neces-

sary.(2) Remove door glass.(3) Remove weatherstrip fasteners.(4) Pull weatherstrip from lower front channel

above door latch.(5) Pull run weatherstrip from window frame

channel (Fig. 48).

INSTALLATION(1) Clean butyl material from door flange area.(2) Place door run weatherstrip in position on win-

dow frame channel.(3) Push door run weatherstrip into window frame

channel.(4) Push weatherstrip into lower front channel

above door latch.(5) Install weatherstrip fasteners.(6) Install door glass.

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23 - 44 BODY PL


(7) Install pull cup support bracket, water shield,nd door trim panel.

Fig. 48 Door Glas1 – REAR DOOR GLASS RUN WEATHERSTRIP2 – REAR DOOR3 – DOOR TRIM PANEL

Fig. 47 Rea1 – REAR DOOR GLASS2 – REAR DOOR3 – LATCH STRIKER

s Run Weatherstrip4 – SPACER5 – WINDOW REGULATOR HANDLE6 – DOOR CHECK STRAP

r Door Glass4 – SPACER5 – REAR WINDOW MANUAL REGULATOR6 – WINDOW TO REGULATOR FASTENERS

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PL BODY 23 - 45


EAR DOOR CHECK STRAP

EMOVAL(1) Remove door trim panel.(2) Remove bolts attaching check strap to hinge

illar.(3) Remove check strap seal from door end frame.(4) Remove bolts attaching check strap to door end

rame (Fig. 49).(5) Remove check strap from vehicle.

NSTALLATION

AUTION: Do not close door before adjusting theoor latch. Door may fail to open.

(1) Position door check strap on vehicle.(2) Install check strap attaching bolts to the door

nd frame.(3) Install check strap seal. If seal is damaged ororn replace seal.(4) Install check strap attaching bolts to the hinge

illar.(5) Install door trim panel.

EAR DOOR

EMOVAL(1) Open door and support on a suitable lifting

evice.

Fig. 49 Rear D1 – REAR DOOR GLASS RUN WEATHERSTRIP2 – REAR DOOR3 – DOOR TRIM PANEL

(2) Disconnect the wire connector at the hinge pil-lar.

(3) Remove bolts attaching door check strap toB-pillar.

(4) Remove bolts attaching lower hinge to door(Fig. 50).

(5) Remove bolts attaching upper hinge to door.

INSTALLATION(1) Apply Mopart Multimileage Grease to the

inside of the door hinge bushings.(2) Install bolts to the upper hinge to door.(3) Install bolts to the lower hinge to door.(4) Connect the wire connector at the B-pillar.(5) Remove lifting device.(6) Adjust door as necessary.

REAR DOOR HINGE

NOTE: If both hinges on one door are to bereplaced, remove and install one hinge completelyprior to beginning the second hinge.

REMOVAL(1) Open and support door on a suitable lifting

device.(2) Remove bolts attaching door check strap to

lower B-pillar for greater access, if necessary.(3) Mark position of hinge on both the door end

frame and lower B-pillar to ease installation.

Check Strap4 – SPACER5 – WINDOW REGULATOR HANDLE6 – DOOR CHECK STRAP

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23 - 46 BODY PL


(4) Remove bolts attaching hinge to door endrame (Fig. 50).

(5) Remove bolts attaching hinge to lower B-pillar.(6) Remove door hinge from vehicle.

NSTALLATION

OTE: Do not grease door hinges.

(1) If necessary, paint new door hinge prior tonstallation.

(2) Position door hinge on vehicle.(3) Loosely install bolts attaching hinge to lower-pillar.(4) Loosely install bolts attaching hinge to door

nd frame.(5) Align hinge to marks made previously and

ighten all bolts.(6) Install bolts attaching door check strap to

ower B-pillar, if removed previously.(7) Verify door fit and operation. Adjust door hinge

or proper door alignment, if necessary.

UEL FILL DOOR

EMOVAL(1) Open the fuel filler door.(2) Remove the screws attaching the door to the

uarter panel (Fig. 51).

Fig. 501 – UPPER HINGE2 – REAR DOOR3 – CHECK STRAP

(3) Remove the door from the panel.

INSTALLATION(1) Position the fuel filler door on the quarter

panel with the screw holes aligned.(2) Install the screws attaching the fuel filler door

to the quarter panel.

r Door4 – LOWER HINGE5 – BODY ASSEMBLY

Fig. 51 Fuel Filler Door1 – BODY ASSEMBLY2 – FUEL FILLER DOOR

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PL BODY 23 - 47


ECKLID LATCH

EMOVAL(1) Open decklid.(2) Remove bolts attaching decklid latch to decklid

Fig. 52).(3) Remove attaching latch from decklid.(4) Disconnect remote decklid latch release cable

orm decklid latch.(5) Disconnect decklid ajar switch connector from

atch.(6) Remove latch from vehicle.

NSTALLATION(1) Position latch in vehicle and engage decklid

jar switch connector to latch.(2) Connect remote decklid latch release cable to

ecklid latch.(3) Install bolts attaching decklid latch to decklid

id.

ECKLID

EMOVAL(1) Open decklid.(2) Mark bolt locations on inside of decklid to aid

nstallation.(3) Disengage clips attaching wire harness and

ecklid release cable to decklid.

Fig. 52 D1 – DECKLID2 – POWER DECKLID CONNECTOR3 – RETAINER CLIP4 – DECKLID SECURITY ALARM SWITCH5 – VIEW Y

(4) Disconnect wire connector and release cablefrom decklid latch.

(5) Remove bolts attaching top of hinge to decklid(Fig. 53).

(6) With aid from a helper, remove bolts holdingbottom of hinge to decklid.

(7) Remove decklid from vehicle.

INSTALLATION(1) Place decklid in position on vehicle.(2) With aid from a helper, install bolts attaching

bottom of hinge to decklid.(3) Install bolts attaching top of hinge to decklid.(4) Align decklid to achieve equal spacing on all

sides and flush across gaps.(5) Verify decklid operation and sealing.(6) Connect wire connector and release cable on

latch.(7) Install clips attaching wire harness and cable

to decklid.

DECKLID LIFT SPRINGS

REMOVAL

WARNING: USE EYE AND HAND PROTECTIONWHEN REMOVING SPRINGS, PERSONAL INJURYCAN RESULT.

d Latch6 – LOCK CYLINDER7 – GASKET8 – DECKLID LATCH9 – POWER DECKLID LATCH10 – DECKLID OVERSLAM BUMPER

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(1) Release and open decklid.(2) Support decklid on a suitable prop device.(3) Pull split cover from lift spring (Fig. 53).(4) Using a common pliers, disengage spring from

djustment slot under decklid opening side trough.(5) Disengage spring from decklid hinge.

NSTALLATION(1) Engage spring to decklid hinge.(2) Engage spring to the adjustment slot under

ecklid opening side trough.(3) Remove decklid support device.(4) Close decklid.

ECKLID LOCK CYLINDER

EMOVAL(1) Remove decklid latch.(2) Remove clip attaching decklid lock cylinder to

ecklid.(3) Pull lock cylinder from decklid (Fig. 53).

NSTALLATION(1) Place lock cylinder into position.(2) Install clip attaching decklid lock cylinder to

ecklid.(3) Install decklid latch.

ECKLID LATCH STRIKER

EMOVAL(1) Release decklid latch and open decklid.

Fig. 531 – DECKLID2 – DECKLID HINGE

(2) Remove push in fasteners attaching decklid lin-ing to tail panel.

(3) Remove trunk lining from tail panel.(4) Remove bolts attaching decklid latch striker to

tail panel (Fig. 54).(5) Remove striker from vehicle.

INSTALLATION(1) Install striker in vehicle.(2) Install trunk lining from tail panel.(3) Install push in fasteners attaching decklid lin-

ing to tail panel.(4) Close decklid.

cklid3 – DECKLID SPRING

Fig. 54 Decklid Latch Striker1 – DECKLID LATCH STRIKER

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PL BODY 23 - 49


ECKLID OPENING WEATHERSTRIP

EMOVAL(1) Open decklid.(2) Pull decklid weatherstrip form decklid opening

ence (Fig. 55).(3) Remove weatherstrip from vehicle.

NSTALLATION(1) Place decklid opening weatherstrip into posi-

ion.(2) Press the weatherstrip onto the decklid open-

ng fence.(3) Close decklid.

RUNK CARPET

EMOVAL(1) Remove fasteners (three per side) attaching

arpet to shelf panel. Fasteners are accessed fromnside the vehicle (Fig. 56).

(2) Pull out leading flaps of the carpet through thepening from the shelf panel.(3) Pull carpet from under the springs.(4) Remove trunk carpet from vehicle.

NSTALLATION(1) Place carpet in truck and smooth out.(2) Tuck both sides of the carpet ends under

prings.(3) Position the leading flaps of the carpet through

he opening onto the shelf panel.

Fig. 55 Decklid Op1 – DECKLID HINGE2 – DECKLID UP STOP BUMPER

(4) Install fasteners (three per side) to secure thecarpet to shelf panel (install fasteners from insidethe vehicle).

(5) Overlap the slits in the back of the carpet sothe center section lays over the outer sections.

g Weatherstrip3 – DECKLID OPENING WEATHERSTRIP

Fig. 56 Trunk Carpet1 – TRUNK CARPET2 – REAR FASCIA

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23 - 50 BODY PL


ECKLID COVER

EMOVAL(1) Remove fasteners attaching decklid cover to

ehicle (Fig. 57).(2) Remove decklid cover from vehicle.

NSTALLATION(1) Position cover on decklid over the striker.(2) Install push in fasteners.(3) Seat the lower edges of the carpet and smooth

ut.(4) Close decklid.

OOF RAIL WEATHERSTRIP

EMOVAL(1) Open front and rear doors.(2) Using a door trim removing tool, disengage the

ush-in fasteners holding A-pillar and C-pillareatherstrip molding.(3) Starting at the bottom of the A-pillar, pull the

oof rail weatherstrip from the windshield side mold-ng.

(4) Pull roof rail weatherstrip from the roof railinch flange above the door opening (Fig. 58).(5) Separate roof rail weatherstrip from vehicle.

NSTALLATION(1) Place weatherstrip in position on pinch flange.(2) Starting at the bottom of the C-pillar, install

he roof rail weatherstrip molding to the pinch rail.(3) Install push-in fasteners to hold weatherstrip

o A-pillar and C-pillar.

Fig. 57 Decklid Trim Panel1 – DECKLID COVER

ROOF RAIL WEATHERSTRIP RETAINERCHANNEL

REMOVAL(1) Open door(s).(2) Using trim stick disconnect the top and bottom

push in fasteners from B-pillar applique. Gently pulloutward on the applique to remove from the vehicle.

NOTE: The applique is attached to the vehicle withtwo sided tape between the push in fasteners,ensure all of the old two sided tape is removedfrom the vehicle surface before installation of newpart.

(3) Remove weatherstrip from the retainer channel(Fig. 59).

(4) Remove retainer channel from the body sideaperture.

INSTALLATION(1) Install retainer channel to the body side aper-

ture.(2) Remove weatherstrip from the retainer chan-

nel.(3) Connect the top and bottom push in fasteners

to B-pillar applique. Gently push on the applique toinstall from the vehicle.

Fig. 58 Roof Rail Weatherstrip1 – ROOF RAIL WEATHER STRIP2 – ROOF RAIL CHANNEL3 – PUSH-IN FASTENER4 – RETAINING LIP

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PL BODY 23 - 51


-PILLAR WEATHERSTRIP CHANNEL

EMOVAL(1) Remove B-pillar applique (Fig. 60).(2) Remove push in fasteners attaching weather-

trip to B-pillar.(3) Pull weatherstrip from B-pillar channels.(4) Remove screws attaching channels to B-pillar.(5) Remove channels from B-pillar.

NSTALLATION(1) Install channels from B-pillar.(2) Install screws attaching channels to B-pillar.(3) Install weatherstrip to B-pillar channels.(4) Install push in fasteners attaching weather-

trip to B-pillar.(5) Install B-pillar applique

-PILLAR TRIM

EMOVAL(1) Disengage clips holding trim to A-pillar.(2) Separate A-pillar trim from vehicle (Fig. 61).

NSTALLATION(1) Position A–pillar trim panel to A–pillar.(2) Align locating pins on backside of trim panel toating holes in A–pillar.(3) Push clips on trim panel into slots in A–pillar.

Fig. 59 Roof Rail Weatherstrip Retainer Channel1 – PUSH PIN2 – ROOF RAIL

WEATHERSTRIPRETAINER CHANNEL

3 – PUSH PIN4 – REMOVE BACKING

STRIP FROM FOAMTAPE

DOOR SILL TRIM

REMOVAL(1) Open door to gain access to sill trim.(2) Disengage clips attaching sill trim to door sill

and door opening flange.(3) Remove door sill trim from vehicle (Fig. 62).

INSTALLATION(1) Position door sill trim on door sill.(2) Align locating pins on backside of trim panel to

holes in door sill.

Fig. 60 B-Pillar Weatherstrip Channel1 – B-PILLAR APPLIQUE2 – TAPE ON BACK OF APPLIQUE3 – B-PILLAR

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23 - 52 BODY PL


(3) Engage clips on trim panel into slots in doorill.(4) Engage clips on trim panel onto door opening

lange.(5) Press downward on trim panel to fully engage

ll clips.

IDE COWL TRIM

EMOVAL(1) Disengage clips attaching cowl trim to cowl

ide panel.(2) Remove cowl trim from vehicle (Fig. 63).

Fig. 61 A-pillar Trim1 – WINDSHIELD A-PILLAR2 – CLIPS3 – A-PILLAR TRIM

Fig. 62 Door Sill Trim1 – FRONT DOOR SILL2 – REAR DOOR SILL3 – SILL TRIM

INSTALLATION(1) Position cowl trim panel to inner cowl panel.(2) Align locating pins on backside of cowl trim

panel to mating holes in inner cowl panel.(3) Push clips on trim panel into slots in inner

cowl panel.

B-PILLAR TRIM

REMOVAL(1) Remove bolt attaching lower seat belt anchor to

floor pan kick-up (Fig. 64).(2) Remove shoulder belt height control knob.(3) Remove bolt attaching turning loop to belt

adjuster (Fig. 65).(4) Remove access cover from B-pillar trim.(5) Disengage clips attaching trim to B-pillar.(6) Feed seat belt turning loop and seat belt

through trim panel.(7) Remove B-pillar trim from vehicle.

INSTALLATION

NOTE: Tighten all seat belt bolts to 40 N·m (40 ft.lbs.) torque.

(1) Position B-pillar trim panel near B-pillar.(2) Feed seat belt turning loop and seat belt

through trim panel.(3) Align locating pins on backside of trim panel to

mating holes in B-pillar.(4) Push clips on trim panel into slots in B-pillar.(5) Install access cover to B-pillar trim.

Fig. 63 Side Cowl Trim1 – DOOR OPENING2 – COWL3 – SILL4 – COWL TRIM

PL BODY 23 - 53


(6) Install bolt attaching turning loop to beltadjuster.

(7) Move adjuster in to the lowest position.(8) Install shoulder belt height control knob.(9) Install bolt attaching lower seat belt anchor to

floor pan kick-up.

UPPER QUARTER TRIM

REMOVAL(1) Disengage clips attaching trim to upper quar-

ter panel (Fig. 66).(2) Remove upper trim panel from vehicle.

INSTALLATION(1) Check to ensure that electric rear window wir-

ing is positioned correctly in the roof channel pro-vided.

(2) Position trim panel in vehicle.(3) Align locating pins on backside of trim panel to

mating holes in upper quarter panel.(4) Push clips on trim panel into slots in upper

quarter panel.

LOWER QUARTER TRIM

REMOVAL(1) Remove upper quarter trim panel.(2) Remove rear seat cushion and back.

Fig. 66 Upper Quarter Trim1 – UPPER QUARTER TRIM PANEL2 – LOWER QUARTER TRIM PANEL3 – SEAT BELT

Fig. 64 B-pillar Trim1 – FRONT SEAT BELT ADJUSTER2 – UPPER B-PILLAR TRIM PANEL3 – ADJUSTER BUTTON4 – TURNING LOOP5 – SEAT BELT6 – SEAT BELT RETRACTOR7 – ANCHOR BOLT8 – LOWER B-PILLAR TRIM PANEL

Fig. 65 Turning Loop to Belt Adjuster1 – FRONT SHOULDER BELT ADJUSTER2 – TAB IS ON BOTTOM

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23 - 54 BODY PL


(3) Disengage clips attaching trim to lower quarteranel.(4) Remove seat belt from slot in trim panel.(5) Remove lower quarter trim from vehicle (Fig.

6).

NSTALLATION(1) Position lower quarter trim panel to vehicle.(2) Install seat belt to slot in trim panel.(3) Align locating pins on backside of trim panel toating holes in inner quarter panel.(4) Press clips on trim panel into slots in inner

uarter panel.(5) Install rear seat back and cushion.(6) Install upper quarter trim panel.

LOOR CONSOLE

EMOVAL(1) Fully apply parking brake.(2) Remove screw cover plugs over screws just

earward of cup holders.(3) Remove screws in cup holders attaching con-

ole to floor bracket.(4) Open console storage compartment lid, if so

quipped.(5) Remove screw cover plugs over screws near

ear of console.(6) Remove screws attaching console to floor

racket.(7) Remove shift lever knob, if vehicle is equippedith a manual transmission.(8) Lift console upward over gear selector and park

rake handle.(9) Remove console from vehicle.

NSTALLATION(1) Place floor console into position in vehicle.(2) Install screws attaching console to floor brack-

ts.(3) Install screw cover plugs.(4) Install shift lever knob, if vehicle is equippedith a manual transmission.(5) Release parking brake.

RONT SEAT BELT BUCKLE

AUTION: Front seat belt assemblies must beeplaced after a collision.

EMOVAL(1) Remove bolt attaching seat belt buckle from

eat anchor.(2) Remove seat belt buckle from seat.

INSTALLATION(1) Place seat belt buckle in position on seat

anchor.(2) Install bolt attaching seat belt buckle to seat

anchor. Tighten seat belt anchor bolt to 40 N·m (30ft. lbs.) torque.

FRONT SEAT BELT RETRACTOR

CAUTION: Front seat belt assemblies must bereplaced after a collision.

REMOVAL(1) Remove B-pillar trim.(2) Remove bolt attaching seat belt retractor to

B-pillar (Fig. 68).(3) Remove seat belt retractor from vehicle.

INSTALLATION(1) Install seat belt retractor into vehicle.(2) Install bolt attaching seat belt retractor to

B-pillar. Tighten seat belt anchor bolt to 40 N·m (30ft. lbs.) torque.

(3) Install B-pillar trim.

FRONT SHOULDER BELT ADJUSTER

CAUTION: Front seat belt assemblies must bereplaced after a collision.

REMOVAL(1) Remove B-pillar trim (Fig. 68).

Fig. 67 Floor Console1 – FLOOR CONSOLE WITH ARMREST2 – ATTACHING SCREWS

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PL BODY 23 - 55


(2) Remove the two bolts attaching shoulder beltdjuster to B-pillar (Fig. 69).(3) Remove shoulder belt adjuster from vehicle.

NSTALLATION

AUTION: Front seat belt adjuster must be in theowest position when Installing adjuster knob.

(1) Place into position the shoulder belt adjuster.(2) Install bolts attaching shoulder belt adjuster to-pillar. Tighten all seat belt bolts to 40 N·m (30 ft.

bs.) torque.(3) Install B-pillar trim.

EAR SEAT BELT BUCKLE

EMOVAL(1) Remove rear seat cushion.(2) Remove rear seat belt buckle bolt (Fig. 70).(3) Remove rear seat belt buckle from vehicle.

NSTALLATION(1) Install rear seat belt buckle. Tighten the seat

elt nut to 40 N·m (30 ft. lbs.) torque.

Fig. 68 Front Seat Belt Retractor1 – FRONT SEAT BELT ADJUSTER2 – UPPER B-PILLAR TRIM PANEL3 – ADJUSTER BUTTON4 – TURNING LOOP5 – SEAT BELT6 – SEAT BELT RETRACTOR7 – ANCHOR BOLT8 – LOWER B-PILLAR TRIM PANEL

(2) Install rear seat cushion.

REAR SEAT BELT RETRACTOR

REMOVAL(1) Remove rear seat cushion and back.(2) Remove seat belt bezel from parcel shelf cover.

Fig. 69 Front Shoulder Belt Adjuster1 – FRONT SHOULDER BELT ADJUSTER2 – TAB IS ON BOTTOM

Fig. 70 Rear Seat Belt Buckle1 – REAR SEAT CUSHION2 – CUSHION ATTACHING RETAINER

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23 - 56 BODY PL


(3) Remove rear seat closure panel silencer pad asecessary to gain access to retractor.(4) Remove bolt attaching seat belt lower anchor to

loor.(5) Remove bolt attaching retractor to rear seat

losure panel (Fig. 71).(6) Push seat belt bezel and buckle stab through

ccess hole in parcel shelf.(7) From in trunk compartment, remove rear seat

elt retractor from vehicle.

NSTALLATION(1) Position rear seat belt retractor in trunk com-

artment.(2) Push seat belt bezel and buckle stab through

ccess hole in rear shelf trim panel.(3) Install bolt attaching retractor to rear seat clo-

ure panel. Tighten the seat belt bolt to 40 N·m (30t. lbs.) torque.

(4) Install bolt attaching seat belt lower anchor toloor. Tighten the seat belt bolt to 40 N·m (30 ft. lbs.)orque.

(5) Install rear seat closure panel silencer pad.(6) Install seat belt bezel to the rear shelf trim

anel.(7) Install rear seat cushion and back.

ARPET

EMOVALFor removal of the carpet, the carpet will need to

e cut under the instrument panel.(1) Remove front seats.(2) Remove rear seat cushion.(3) Remove bolts attaching front seat belt lower

nchors to floor (Fig. 72).

Fig. 71 Rear Seat Belt Retractor1 – REAR RIGHT OUTER SEAT BELT2 – SEAT BELT RETRACTOR

(4) Remove door sill trim covers.(5) Remove cowl trim covers.(6) Remove center floor console.(7) Remove decklid release assist handle.(8) Remove lower fasteners from B-pillar trim

panel.(9) Pull carpet from behind trim panel.(10) Fold carpet in half toward rear seat.(11) Remove carpet through rear door opening.

INSTALLATIONThe new carpet must be cut for installation. The

area is mark on the reverse side of the carpet. Thelocation is in front of the tunnel area.

(1) Install carpet through rear door opening.(2) Unfold carpet.(3) Tuck carpet behind trim panel.(4) Install lower fasteners holding B-pillar trim

panel.(5) Install decklid release assist handle.(6) Install center floor console.(7) Install cowl trim covers.(8) Install door sill trim covers.(9) Install bolts attaching front seat belt lower

anchors to floor. Tighten all seat belts to 40 N·m (30ft. lbs.) torque.

(10) Install rear seat cushion.(11) Install front seats.

SUN VISORAll vehicles with driver and passenger side airbags

must have a colored coded five Bullet point airbag

Fig. 72 Carpet1 – FLOOR CARPET2 – TRUNK REAR END PANEL

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PL BODY 23 - 57


arning label applied to the sun visor, verify labelvailability and ensure the label is installed.

EMOVAL(1) Remove sun visor from center support.(2) Remove screws attaching sun visor to roof

eader.(3) Remove sun visor from header.(4) If equipped, disconnect wire connector from

ody harness.(5) Remove sun visor from vehicle.

NSTALLATION(1) Place sun visor in position.(2) If equipped, connect wire connector from body

arness.(3) Install screws attaching sun visor to header.(4) Install sun visor into center support.

EADLINER

EMOVAL(1) Remove screws attaching sun visors to roof

eader panel.(2) Disconnect wire connector from lighted vanityirror, if so equipped.(3) Remove sun visors from vehicle.(4) Remove A-pillar trim covers.(5) Remove B-pillar trim panels.(6) Remove (upper) quarter panel trim panels.(7) Remove assist handle, if so equipped.(8) Remove sun visor hooks.(9) Remove coat hooks, if so equipped.(10) Remove three push in fasteners at rear of

eadliner.(11) Disengage dome lamp wire connector, at rear

f headliner.(12) Remove push in fastener attaching wiring to-pillar.(13) Remove headliner through door opening (Fig.

3).

NSTALLATION(1) Position headliner in vehicle.(2) Install sun visor hooks, if so equipped.(3) Install coat hooks, if so equipped.(4) Install three push in fastener at rear of head-

iner.(5) Install assist handles, if so equipped.(6) Install push in fastener attaching headlineriring to C-pillar.(7) Connect dome lamp wire connector, at rear of

eadliner.(8) Install (upper) quarter panel trim panel.(9) Install B-pillar trim panels.(10) Install A-pillar trim covers.

(11) Install sun visors, lighted vanity mirror wireconnector, if so equipped, and screws attaching sunvisors to roof header panel.

INSIDE REAR VIEW MIRROR

REMOVAL(1) Loosen the mirror base set screw (Fig. 74).(2) Slide the mirror base upward and off the

bracket.

INSTALLATION(1) Position the mirror base at the bracket and

slide it downward onto the support bracket.(2) Tighten the setscrew 1 N·m (15 in. lbs.) torque.

REAR SHELF TRIM PANEL

REMOVAL(1) Remove quarter trim panels as necessary.(2) Remove rear seat cushion and back.(3) Disengage seat belt bezels from rear shelf trim

panel.(4) Remove rear seat shoulder belt from the shelf

by sliding belt through the slot.(5) Remove rear shelf trim panel from vehicle.

INSTALLATION(1) Place into position rear shelf trim panel.(2) Slide the rear seat shoulder belt through the

slot in the rear shelf trim panel.(3) Engage seat belt bezels to rear shelf trim

panel.

Fig. 73 Headliner1 – HEADLINER TO REAR HEADER FASTENERS2 – HEADLINER3 – VISORS

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(4) Install rear seat cushion and back.(5) Install quarter trim.

ODY VENT

EMOVAL(1) Hoist rear end of vehicle and support on safety

tands.

Fig. 74 Rear View Mirror1 – WINDSHIELD2 – MIRROR3 – LIGHTED MIRROR CONNECTOR

Fig. 75 Rear Shelf Trim Panel1 – REAR SHELF PANEL2 – SLOT3 – REAR SHELF MOLDING

(2) From behind rear bumper fascia below quarterpanel, disengage clips attaching body vent to trunkwell.

(3) Remove body vent from vehicle (Fig. 76).

INSTALLATION(1) Place body vent in vehicle.(2) From behind rear bumper fascia below quarter

panel, engage clips attaching body vent to trunk well.(3) Lower vehicle.

ADJUSTMENTS

FRONT DOOR LATCH ADJUSTMENT(1) Insert a hex-wrench through the elongated hole

in the door end frame near the latch striker opening.(2) Loosen socket head screw on the side of the

latch linkage.(3) Lift upward on outside door handle and release

it.(4) Tighten socket head screw on latch.(5) Verify latch operation.

REAR DOOR LATCH ADJUSTMENT(1) Insert a hex-wrench through the elongated hole

in the door end frame near the latch striker opening.(2) Loosen socket head screw on the side of the

latch linkage.(3) Lift upward on outside door handle and release

it.(4) Tighten socket head screw on latch.(5) Verify latch operation.

Fig. 76 Body Vent1 – BODY VENT2 – TRUNK WELL SIDE PANEL

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PL BODY 23 - 59

PECIFICATIONS

ODY LUBRICATION

UBRICATION REQUIREMENTSBody mechanisms and linkages should be

nspected, cleaned, and lubricated, as required, toaintain ease of operation and to provide protection

gainst rust and wear. When performing othernderhood services, the hood latch release mecha-ism and safety catch should be inspected, cleaned,nd lubricated. During the winter season, externaloor lock cylinders should be lubricated to assureroper operation when exposed to water and ice.Prior to the application of any lubricant, the parts

oncerned should be wiped clean to remove dust andrit. If necessary, a suitable solvent can be used tolean the item to be lubricated. After lubricating aomponent, any excess oil or grease should beemoved.

UBRICANT APPLICATION

OOR LOCK CYLINDERS(1) Apply a small amount of lubricant directly into

he lock cylinder.(2) Apply a small amount of lubricant to the key.(3) Insert key into lock cylinder and cycle theechanism from the locked to the unlocked position.

OTE: Do not add more lubricant.

(4) Cycle the lock cylinder mechanism severalimes to allow the lubricant to flow throughout theylinder.(5) Wipe all lubricant from exterior of lock cylinder

nd key.

LL OTHER BODY MECHANISMS
(1) Clean component as described above.
(2) Apply specified lubricant to all pivoting andsliding contact areas of component.

LUBRICANT USAGE

ENGINE OIL• Decklid Hinges

MOPART SPRAY WHITE LUBE OR EQUIVALENT• Ash Receiver• Fuel Filler Door Remote Control Latch Mecha-

nism• Parking Brake Mechanism• Sliding Seat Tracks• Decklid Latch

MOPART MULTIPURPOSE GREASE OREQUIVALENT

• All Other Hood Mechanisms

MOPART LOCK CYLINDER LUBRICANT OREQUIVALENT

• Door Lock Cylinders• Decklid Lock Cylinder

SPECIAL TOOLS

BODY

STICK, TRIM C 4755

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23 - 60 BODY PL

SPECIFICATIONS

TABLE OF CONTENTS

page page

PECIFICATIONSBODY LUBRICATION SPECIFICATIONS. . . . . . . . 60BODY GAP AND FLUSH MEASUREMENTS . . . . . 61
BODY OPENING DIMENSION . . . . . . . . . . . . . . . 62
nd key.

BODY SEALING LOCATIONS. . . . . . . . . . . . . . . . 64STRUCTURAL ADHESIVE LOCATIONS . . . . . . . . 74TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 76
WELD LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . 77
PECIFICATIONS

ODY LUBRICATION SPECIFICATIONS

UBRICATION REQUIREMENTSBody mechanisms and linkages should be

nspected, cleaned, and lubricated, as required, toaintain ease of operation and to provide protection

gainst rust and wear. When performing other underood services, the hood latch release mechanism andafety catch should be inspected, cleaned, and lubri-ated. During the winter season, external door lockylinders should be lubricated to assure proper oper-tion when exposed to water and ice.Prior to the application of any lubricant, the parts

oncerned should be wiped clean to remove dust andrit. If necessary, a suitable solvent can be used tolean the item to be lubricated. After lubricating aomponent, any excess oil or grease should beemoved.

UBRICANT APPLICATION

OOR LOCK CYLINDERS(1) Apply a small amount of lubricant directly into

he lock cylinder.(2) Apply a small amount of lubricant to the key.(3) Insert key into lock cylinder and cycle theechanism from the locked to the unlocked position.

OTE: Do not add more lubricant.

(4) Cycle the lock cylinder mechanism severalimes to allow the lubricant to flow throughout theylinder.(5) Wipe all lubricant from exterior of lock cylinder

ALL OTHER BODY MECHANISMS(1) Clean component as described above.(2) Apply specified lubricant to all pivoting and

sliding contact areas of component.

LUBRICANT USAGE

ENGINE OIL• Door Hinges – Hinge Pin and Pivot Contact

Areas• Hood Hinges – Pivot Points• Liftgate Hinges• Decklid Hinges

MOPART SPRAY WHITE CUBE OR EQUIVALENT• Door Check Straps• Liftgate Latches• Liftgate Prop Pivots• Ash Receiver• Fuel Filler Door Remote Control Latch Mecha-

nism• Parking Brake Mechanism• Sliding Seat Tracks• Decklid Latch

MOPART Multipurpose GREASE OR EQUIVALENT• All Other Hood Mechanisms

MOPART LOCK CYLINDER LUBRICANT OREQUIVALENT

• Door Lock Cylinders• Decklid Lock Cylinder

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PL BODY 23 - 61


ODY GAP AND FLUSH MEASUREMENTSBODY GAP

LOCATION

A Hood to Fender 4.0

B Hood to Fender (Fore & Aft) Flu

C Front Door to Fender 5.0

D Rear Door to Front Door 5.0

E Fuel Filler Door to Quarter Panel 3.0

F Fascia to Hood Pa

G Front & Rear Door to Roof 5.0

H Deck Lid to Quarter Panel 4.0

I Tail Lamp to Applique & Deck Lid 4.0

J Rear Door to Quarter Panel 4.0

K Front & Rear Door to Sill 5.0

NOTE: ALL MEASU

AND FLUSH

GAP FLUSH

6 1.0 // 1.0 6 1.0

sh w/in 6 1.5 N/A

6 1.0 // 1.0 6 1.0

6 1.0 // 1.0 6 1.0

6 0.75 conc. 6 0.5 0.5 6 0.5

rallel // w/in 2.0 N/A

6 1.5 // 1.0 0.0 6 1.5 // 1.0

1.5 // 1.0 1.0 6 1.0 // 1.0

6 1.5 // 1.0 1.0 6 1.0 // 1.0

6 1.0 // 1.0 0.0 6 1.0 // 1.0

6 1.5 // 1.5 6.4 6 1.5 / 1.5

REMENTS ARE IN mm

B

23 - 62 BODY PL


ODY OPENING DIMENSIONDOOR AND WIND
SHIELD OPENINGS

PL BODY 23 - 63


REAR WINDOW AND TRUNK OPENINGS

B

23 - 64 BODY PL


ODY SEALING LOCATIONSMETHODS OF APPLYIN
G AUTO BODY SEALANT

PL BODY 23 - 65


COWL SIDE AND PLENUM

23 - 66 BODY PL


COWL AND PLENUM

COWL AND PLENUM

PL BODY 23 - 67


COWL SIDE AND PLENUM

23 - 68 BODY PL


ROOF PANEL

PL BODY 23 - 69


FLOOR PAN, REAR INNER (RIGHT) WHEELHOUSE, AND REAR END PANEL

23 - 70 BODY PL


FLOOR PAN AND REAR INNER (LEFT) WHEELHOUSE

TAIL LAMP AREA

PL BODY 23 - 71


TRUN
K AREA

23 - 72 BODY PL


TRUNK AREA

PL BODY 23 - 73


TRUNK AREA

TRUNK AND REAR WHEELHOUSE AREA

S

23 - 74 BODY PL


TRUCTURAL ADHESIVE LOCATIONSRAIL TO FRO
NT FLOOR PAN

PL BODY 23 - 75


ROOF BOW TO ROOF PANEL

CENTER PILLAR TO EXTENSION

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23 - 76 BODY PL


ORQUE SPECIFICATIONS

ODY COMPONENTS

DESCRIPTION TORQUEAll seat belt anchor bolts . . . . . 40 N·m (30 ft. lbs.)All seat belt anchor nuts . . . . . . 40 N·m (30 ft. lbs.)All seat belt retractor bolts . . . . 40 N·m (30 ft. lbs.)Decklid latch striker . . . . . . . . . 22 N·m (16 ft. lbs.)Front seat track to floor pan bolts . . 55 N·m (40 ft.

lbs.)Front seat inboard pivot bolt . . . 40 N·m (30 ft. lbs.)Front seat recliner to seat cushion frame . . 12 N·m

(9 ft. lbs.)Front seat track to cushion frame bolt . . 12 N·m (9

ft. lbs.)Front seat back . . . . . . . . . . . . . 40 N·m (30 ft. lbs.)

RAIL TO REA

DESCRIPTION TORQUEFront seat back recliner to seat back . 12 N·m (9 ft.

lbs.)Front door hinge to hinge pillar bolt . 28 N·m (21 ft.

lbs.)Front door hinge to door nuts and bolt . 28 N·m (21

ft. lbs.)Front door latch striker . . . . . . . 28 N·m (20 ft. lbs.)Hood latch striker . . . . . . . . . 13.5 N·m (10 ft. lbs.)Rear door glass to regulator bolt . . 11 N·m (105 in.

lbs.)Rear door hinge to B-pillar bolt . 28 N·m (20 ft. lbs.)Rear door hinge to door bolt . . . 28 N·m (20 ft. lbs.)Rear door latch striker . . . . . . . 28 N·m (20 ft. lbs.)Rear seat back and seat belt buckle anchor nut . 57

N·m (42 ft. lbs.)

FLOOR PAN
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PL BODY 23 - 77


ELD LOCATIONSFRONT SUSPENSION STRUT TOW
ER TO SIDE COWL AND DASH PANEL

23 - 78 BODY PL


FRONT SIDE COWL AND FRONT RAIL ASSEMBLY TO RAIL EXTENSION

FRONT SUSPENSION STRUT TOWER, FENDER SIDE SHIELD, SIDE RAIL AND REINFORCEMENTS

PL BODY 23 - 79


FRONT SIDE RAIL ASSEMBLY, COWL SIDE TO DASH PANEL

FRONT SIDE RAIL TO REAR COWL SIDE

23 - 80 BODY PL


UPPER DASH PANEL TO DASH PANEL

PL BODY 23 - 81


COWL SIDE PANEL, PLENUM TO FRONT SIDE RAIL

23 - 82 BODY PL


RADIATOR CLOSURE ASSEMBLY TO FRONT SIDE RAIL

PL BODY 23 - 83


FRONT FENDER SIDE SHIELD, SIDE RAIL AND FRONT SUSPENSION STRUT TOWER

23 - 84 BODY PL


FRONT HINGE PILLAR ASSEMBLY

PL BODY 23 - 85


CENTER PILLAR ASSEMBLY

23 - 86 BODY PL


COWL PLENUM AND REINFORCEMENT TO COWL TOP PANEL

PL BODY 23 - 87


COWL PLENUM REINFORCEMENT GUSSET TO COWL PLENUM PANEL

23 - 88 BODY PL


COWL PLENUM A/C BRACKET TO COWL PLENUM PANEL

PL BODY 23 - 89


COWL PLENUM BRAKE PEDAL SUPPORT BRACKET AND REINFORCEMENT, TO COWL PLENUMPANEL AND REINFORCEMENT

23 - 90 BODY PL


WIPER MOTOR BRACKET TO COWL TOP PANEL

PL BODY 23 - 91


COWL TOP PANEL AND REINFORCEMENT TO COWL SIDE PANELS

23 - 92 BODY PL


INNER BODY SIDE TO OUTER BODY SIDE

PL BODY 23 - 93


INNER BODY SIDE TO OUTER BODY SIDE AND WHEELHOUSE

23 - 94 BODY PL


OUTER BODY SIDE TO INNER WINDSHIELD OPENING

OUTER BODY SIDE PANEL TO INNER WHEELHOUSE AND LOWER DECK REAR CLOSURE

PL BODY 23 - 95


REAR RAIL ASSEMBLY

FRONT CROSSMEMBER AND CONSOLE BRACKET

23 - 96 BODY PL


INNER QUARTER PANEL TO OUTER WHEELHOUSE AND REINFORCEMENT

PL BODY 23 - 97


QUARTER PANEL WHEELHOUSE TO UPPER QUARTER PANEL AND EXTENSION

23 - 98 BODY PL


REAR INNER WHEELHOUSE ASSEMBLY

PL BODY 23 - 99


TAIL LAMP PANEL LOWER DECK CLOSURE ASSEMBLY

BODY SILL INNER PANEL TO FRONT FLOOR REINFORCEMENT AND GUSSET

23 - 100 BODY PL


REAR FLOOR PAN TO BODY SIDE SILL EXTENSION AND REAR WHEELHOUSE

PL BODY 23 - 101


FENDER TO WELD BRACKET

23 - 102 BODY PL


DECK OPENING LOWER REINFORCEMENT TO REAR LOWER DECK CLOSURE PANEL

PL BODY 23 - 103


REAR FLOOR PAN TO REAR SUSPENSION CROSSMEMBER, SEAT AND SPARE TIRE ANCHOR

REAR FLOOR PAN TO REAR RAIL

23 - 104 BODY PL


SHELF PANEL SUPPORT TO SHELF REINFORCEMENT

DASH PANEL TO FRONT FLOOR PAN

PL BODY 23 - 105


FLOOR PAN TO RAIL – FRONT SIDE REAR TO COWL SIDE

INNER AND OUTER BODY SIDE APERTURE TO COWL AND FRONT FLOOR PAN

23 - 106 BODY PL


OUTER BODY SIDE APERTURE TO ROOF PANEL AND ROOF RAILS

FRONT FENDER SUPPORT TO COWL AND OUTER BODY SIDE APERTURE

PL BODY 23 - 107


OUTER BODY SIDE APERTURE TO SILL AND COWL SIDE PANEL

INNER AND OUTER BODY SIDE APERTURE TO SILL AND FLOOR PAN

23 - 108 BODY PL


OUTER BODY SIDE APERTURE TO ROOF PANEL AND REAR SHELF TO EXTENSION

LOWER DECK CLOSURE TO REAR FLOOR PAN

PL BODY 23 - 109


OUTER BODY SIDE APERTURE TO CENTER PILLAR

INNER WHEELHOUSE TO OUTER WHEELHOUSE

23 - 110 BODY PL


INNER WHEELHOUSE TO WHEELHOUSE EXTENSION

PANEL SHELF TO TROUGH AND WHEELHOUSE

PL BODY 23 - 111


RIGHT BODY SIDE APERTURE – FRONT

BODY SIDE APERTURE TO ROOF RAIL INNER AND REINFORCEMENT

23 - 112 BODY PL


FRONT UPPER LOAD BEAM BRACKET, WINDSHIELD FRAME AND PILLAR TO BODY SIDEAPERTURE

PL BODY 23 - 113


DRAIN TROUGH TO BODY SIDE APERTURE

23 - 114 BODY PL


FLOOR PAN EXTENSION, STRAP ASSEMBLY, REAR DOOR STRIKER RETAINER TO BODY SIDEAPERTURE

body · (6) apply molding to top of windshield. (7) apply glass prep adhesion promoter 25 mm (1...

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