98 voyager body
TRANSCRIPT
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BODY
CONTENTS
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BODY COMPONENT SERVICE . . . . . . . . . . . . . . 21GENERAL SERVICE INFORMATION . . . . . . . . . . . 1PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL SERVICE INFORMATION
INDEX
page
GENERAL INFORMATIONSAFETY PRECAUTIONS AND WARNINGS . . . . . 1
GENERAL INFORMATION
SAFETY PRECAUTIONS AND WARNINGS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-SONAL INJURY CAN RESULT.
USE A OSHA APPROVED BREATHING FILTERWHEN SPRAYING PAINT OR SOLVENTS IN A CON-FINED AREA. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITHPETROLEUM OR ALCOHOL BASED CLEANINGSOLVENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETYSTANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punchedin an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-nents. Damage to vehicle can result.
Do not weld exterior panels unless combustiblematerial on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, canresult.
Always have a fire extinguisher ready for usewhen welding.
Disconnect the negative (-) cable clamp from thebattery when servicing electrical components thatare live when the ignition is OFF. Damage to electri-cal system can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damageto finish or color can result.
Do not hammer or pound on plastic trim panelwhen servicing interior trim. Plastic panels can
break.
Chrysler Corporation uses many different types of
push-in fasteners to secure the interior and exterior
t r im t o t h e b od y. M os t of t h es e f a st en er s ca n b e
r eu s ed t o a s s em b le t h e t r i m d u r in g v a r i ou s r ep a ir
p r oced u r es. At t im e s, a p u sh-in f a st e n er ca n n ot be
r e m o ve d w it h o u t d a m a g in g t h e f a st e n e r o r t h e co m -
ponent it is holding. If it is not possible to remove a
fastener without damaging a component or body, cut
or br ea k t h e f a s ten er a n d u se a n ew on e w h e n
in st a l l in g t h e com p on e n t . N e ver p r y o r p ou n d on a
p la st ic or p r essed -boa r d t r im com p on e n t . U sin g a
su it a ble f o r k-t y p e p r y in g d e vice , p r y t h e f a st e n erfrom the retaining hole behind the component being
removed. When installing, verify fastener alignment
w it h t h e r e t a in in g h o le by h a n d . Pu sh d ir e ct ly o n o r
over t he fa stener unt il it seats. Apply a low-force pull
t o t h e p a n e l t o ve r i f y t h a t i t is se cu r e .
When it is necessary to remove components to ser-
v ice a n o t he r, i t s h ou ld n ot b e n ece ss a r y t o a p pl y
e xce ssive f o r ce or ben d a com p on e n t t o r e m ove i t .
B e f or e d a m a g i n g a t r i m com p on en t , v er i fy h i dd en
fast eners or captured edges holding the component in
place.
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PAINT
INDEX
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GENERAL INFORMATION
AFTERMARKET PAINT REPAIR PRODUCTS . . . 3BASE COAT/CLEAR COAT FINISH . . . . . . . . . . . 2
PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PAINTED SURFACE TOUCHUP . . . . . . . . . . . . . 2WET SANDING, BUFFING, AND POLISHING . . . 2
GENERAL INFORMATION
PAINT CODEA pa in t cod e is p r ovid ed on t h e bod y cod e p la t e
l oca t e d i n t h e en g in e com pa r t m en t . R ef er t o t h e
I n t r o d uct ion se ct ion a t t h e f r o n t o f t h is m a n u a l f o r
body code plat e description. The pa int an d trim codes
are also included on the Vehicle Safety Label locatedon the drivers door end frame.
BASE COAT/CLEAR COAT FINISHOn most vehicles a tw o-part paint applicat ion (base
coat /clear coat ) is used. C olor paint tha t is a pplied to
primer is called ba se coat . The clear coat protects th e
ba se co a t f r o m u lt r a vio le t l ig h t a n d p r o vid e s a d u r a -
ble high-gloss finish.
WET SANDING, BUFFING, AND POLISHINGMin or a cid e t ch in g , o r a n g e p ee l, or sm u d g in g in
cle a r coa t or sin gle-st a g e f in ish es ca n be r e d uced
w it h l ig h t w e t sa n d in g , h a n d bu f f in g , a n d p o lish in g .If the finish has been wet sanded in the past, itcannot 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 for
durability.
PAINTED SURFACE TOUCHUPW h e n a p a in t e d m e t a l su r f a ce h a s be e n scr a t ch e d
or chipped, it should be touched-up as soon as possi-
ble to a void corrosion. For best results, use Mopar
Scra tch Filler/P rimer, Touch-U p P a ints a nd Clea r Top
C oa t . Re fe r t o I n t r o d u ct ion g r ou p o f t h is m a n u a l f or
B o d y C od e P la t e in f or m a t ion .
TOUCHUP PROCEDURE
(1) S cr a p e loose p a in t a n d cor r osion f r om in sid e
scratch or chip.
(2) C le a n a f f e ct e d a r e a w it h Mo p a r Ta r/Roa d Oil
Remover, and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overla p prim er onto good sur-
f a ce f in is h . Th e a p pl ica t or b ru sh s h ou ld b e w e t
enough to puddle-fill the defect without running. Do
n ot st r ok e br u sh a p p lica t or on bod y su r f a ce . Allow
the filler/primer to dry ha rd.
(4) C over t h e f i ller /p r im e r w it h color t o u ch -u p
paint . Do not overlap touchup color onto the original
co lo r co a t a r o u n d t h e scr a t ch o r ch ip . B u t t t h e n e w
color to the original color, if possible. Do not stroke
a p pl ica t o r b r us h on b od y s u r fa c e. Al low t ou ch u p
p a i nt t o d r y h a r d .
(5) O n v eh i cl es w i t h ou t cl ea r coa t , t h e t ou ch u p
color ca n be l ig h t ly w e t sa n d e d (1500 g r i t ) a n d p ol-
ished with rubbing compound.
(6) On vehicles with clear coat , a pply clear top coat
t o t ou ch up pa in t w it h t he s a me t ech niq ue a s
described in Step 4. Allow clear top coat to dry hard.
If desired, Step 5 can be performed on clear top coat .
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AFTERMARKET PAINT REPAIR PRODUCTS
1997 EXTERIOR COLORS
EXTERIORCOLOR
CHRYCODE*
PPG BASF DUPONT
S-W
ACMEM-S
AKZO NOBELSIKKENS
Candy AppleRed Mt. TintClear Coat
RH2 4974 26098 B9616 51063 CHA95:RH2
5025 5106
Flame RedClear Coat
PR4 4679 23043 B9326 4691 CHA93:PR4
Dark RosewoodPearl Coat
REG 27558 25041 B9519 50266 CHA95:REG
Light Gold PearlCoat
SYL 83539 26097 B9618 51076 CHA95:SYL
Deep Hunter
Green Pearl
Coat
SG8 47439 26078 B9609 5106 CHA95:SG8
Light SilverfernPearl Coat
RJM 47383 25043 B9525 50269 CHA95:RJM
Island TealSatin Glow
SPJ 47425 26085 B9610 51065 CHA95:SPJ
Pale Iris Clear
Coat
SCP 18887 26093 B9625 51536 CHA96:SCP
Light Iris Pearl
Coat
PC5 4788 24078 B9455 48782 CHA94:PC5
Dark Iris Pearl
Coat
RCW 51844 26092 B9614 51061 CHA95:RCW
Medium BluePearl Coat
RBK 18757 25039 B9529 50264 CHA95:RBK
Bright WhiteClear Coat
GW7 4037 18238 B8833 37298 CHA88:GW
Golden WhitePearl Tri-Coat
SWP 83554 26095 B9623 51074 CHA96:SWP
83642 B9624 51075
Deep Amethyst
Pearl Coat
TCN 5246 27038 B9736 52566 CHA97:TCU
Taupe Frost
Pearl Coat
TTK 5244 27040 B9750 52567 CHA97:TTK
* H e r be r t s S t a n d o x a n d S p ie s H e ck e r u se t h e C h r y sle r p a in t co d e a s l ist e d o n t h e B o d y C o d e Pla t e .
1997 INTERIOR COLORS
INTERIORCOLOR
CHRYCODE
PPG BASF DUPONTS-W ACME
M-S
Mist Gray C3 35799/2-1576 25065 C9507 50508
Silver Fern JK 35798/2-1577 25066 C9509 50510
Camel K5 27731/2-1584 26120 C9603 51541
NS/GS BODY 23 - 3
GENERAL INFORMATION (Continued)
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STATIONARY GLASS
INDEX
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DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 4REMOVAL AND INSTALLATION
BODY SIDE/SLIDING DOOR STATIONARY
GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . 7WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLEWITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANEADHESIVE TO CURE. IF IT IS NOT CURED, THEWINDSHIELD MAY NOT PERFORM PROPERLY INAN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-TEM. USE GLASS CLEANER, GLASS PREP SOL-VENT, GLASS PRIMER, PVC (VINYL) PRIMER ANDPINCHWELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURALINTEGRITY COULD BE COMPROMISED.
BE SURE TO REFER TO THE URETHANE MANU-FACTURERS DIRECTIONS FOR CURING TIMESPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.VAPORS THAT ARE EMITTED FROM THE URE-THANE ADHESIVE OR PRIMER COULD CAUSEPERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAYRESULT.
ALWAYS WEAR EYE AND HAND PROTECTIONWHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.Be careful not to damage painted surfaces whenremoving moldings or cutting urethane aroundwindshield.
I t i s d i f fi cu lt t o s a l v a g e a w i n d sh i el d d u r i n g t h e
r em ov a l op er a t i on . Th e w i n d sh i el d i s p a r t of t h e
structura l support for the roof. The uretha ne bonding
used to secure the windshield to the fence is difficult
t o cu t o r cle a n f r o m a n y su r f a ce . I f t h e m o ld in g s a r e
se t in u r e t h a n e , i t w o u ld a lso be u n like ly t h e y cou ld
be sa lva g e d . B e f o r e r e m o vin g t h e w in d sh ie ld , ch e ck
t h e a va ila bil i t y o f t h e w in d sh ie ld a n d m o ld in g s f r o m
the parts supplier.
REMOVAL AND INSTALLATION
WINDSHIELD
Th e u r e t h a n e a d h e sive h old in g t h e w in d sh ield t ot h e op en in g p in ch w e ld (f en ce ) ca n be cu t u sin g a
s h a r p col d k n if e f r om t h e e xt e ri or of t h e v eh i cl e.
U sin g t h e co ld k n if e m e t h o d is e f f e ct ive i f t h e w in d -
s h iel d i s a l r ea d y b r ok en . I f t h e g l a s s m u s t b e s a l -
v a ged , cu tt in g t h e u ret h a ne a d hes iv e f rom t h e
interior of the vehicle using a reciprocating or oscil-
lat ing power knife is recommended.
RECOMMENDED TOOLS AND ADHESIVE
POWER KNIFE
Fein Power Cut-out Knife
Eq u a liz e r M a g nu m , I n t er ior Au t o G l a s s C u tO u t K n if e
ADHESIVE, PRIMER AND CLEANER
Mopar Win d sh ie ld G la ss P oly u r et h a n e p a cka g e ,
o r e q u iva le n t , m u st be u se d in o r d e r t o e n su r e t h a t
t h e v eh i cl e w i ll con f or m t o t h e F M VS S 212 w i n d -
sh ield r e t e n t ion st a n d a r d a n d t h e F MV S S 216 r oof
cr u sh st a n d a r d .
WINDSHIELD REMOVALEXTERIOR METHOD
(1) R emove inside rea r view mirror.
(2) Remove windshield wiper arms.
(3) Remove cowl cover.(4) Remove A-pillar trim panels.
(5) D i sen ga g e w i re con n ect or s t o w i nd sh iel d
defroster grid.
(6) Pla ce protective covers over instrument panel
and hood.
(7) Remove w indshield molding (Fig. 1). Using pli-
ers, pull outward on molding at the bottom of A-pil-
la r s.
(8) U s in g a s h a r p col d k n if e, cu t u r et h a n e a d h e -
s i ve h ol di n g t h e w i n d sh i el d t o t h e A-p il la r s , r oof
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header and cowl pinch weld fences (Fig. 2). A power
cutting device can be used if available.
(9) Separate windshield from vehicle.
WINDSHIELD REMOVALINTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Rem ove in st r u m en t p a n e l t o p cover . Re fe r t o
G r o u p 8E, I n st r u m e n t Pa n e l .
(3) Remove A-pillar trim covers.
(4) D i sen ga g e w i re con n ect or s t o w i nd sh iel d
defroster grid.
(5) Pla ce protective covers over instrument panel
and hood.
(6) U s i n g a r eci pr oca t i n g or os ci ll a t i ng p ow e r
k n ife , cu t u r et h a n e a d h e sive h old in g t h e w in d sh ield
t o t h e A-p il la r s , r oof h ea d e r a n d cow l p in ch w e ldfences. Refer to instructions provided with the equip-
ment being used.
(7) Separate 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 before
urethane bonding is cured, water leaks can result.
Allow the urethane at least 24 hours to cure
before returning the vehicle to use.To avoid stressing the replacement windshield,
the urethane bonding material on the windshieldfence should be smooth and consistent to the
shape of the replacement windshield. The support
spacers should be cleaned and properly installedon weld studs or repair screws at bottom of wind-shield opening.
(1) P la ce r e pla cem e n t w in d sh ield in t o w in d sh ield
opening and posit ion glass in the center of the open-
in g a g a in st t h e su p p o r t sp a ce r s.
(2) V e r if y t h e g la ss la y s e ve n ly a g a in st t h e p in ch
w el d fen ce a t t h e s id es , t op a n d b ot t om of t h e
replacement windshield. If not , the pinch weld fence
m u st be f o r m e d t o t h e sh a p e o f t h e n e w g la ss.
( 3 ) M a r k t h e g l a s s a t t h e s u p p o r t s p a c e r s w i t h a
g r e a se p e n cil o r p ie ce s o f m a sk in g t a p e a n d in k p e n
to use as a reference for installat ion (Fig. 3).(4) Re m ove r e pla cem e n t w in d sh ield f r om w in d -
shield opening.
(5) Posit ion the windshield inside up on a suitable
w o r k su r f a ce w it h t w o p a d d ed , w ood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft .) apart (Fig. 4).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFOREAPPLYING GLASS PREP AND PRIMER. POORADHESION CAN RESULT.
(6) Clean inside of windshield with ammonia basedglass cleaner and lint-free cloth.
(7) Install molding to perimeter of windshield.
(8) Apply Glass Prep adhesion promoter 25 mm (1
in .) w id e a r o u n d p e r im e t er of w in d sh ield a n d w ip e
with clean/dry lint-free cloth until no str eaks ar e vis-
ible.
(9) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying t ime.
(10) U sin g a r a z o r k n if e, r e m ove a s m u ch or ig in a l
u r e t h a n e a s p o ssible . D o n o t d a m a g e p a in t o n w in d -
shield fence.
(11) Apply pinch weld primer 15 mm (.75 in.) widea r ou n d t h e w i n d sh i el d f en ce. Al low a t l ea s t t h r ee
m in u t es d r y in g t im e .
(12) I f a low viscosit y u r et h a n e a d h e sive is u sed ,
in st a l l com p r ession sp a ce r s on t h e f en ce a r ou n d t h e
windshield opening (Fig. 5).
(13) Apply a 10 mm (0.4 in.) bead of uretha ne on
centerline of windshield fence.
(14) Wit h t h e a id of a h e lp er, p osit ion t h e w in d -
shield over the windshield opening. Align the refer-
en ce m a r k s a t t h e b ot t om of t h e w i n ds h ie ld t o t h e
support spacers.
Fig. 1 Windshield Molding
MOLDINGFENDERCOWL WINDSHIELDSUPPORTSPACER
Fig. 2 Cut Urethane Around Windshield
COLD KNIFEWINDSHIELD
NS/GS BODY 23 - 5
REMOVAL AND INSTALLATION (Continued)
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(15) S lo w ly low e r w in d sh ield g la ss t o w in d sh ield
opening fence. Guide the molding into proper position
a s n e ce ssa r y . Pu sh w in d sh ie ld in w a r d u n t i l m o ld in g
is flush to roof line and A-pillars (Fig. 5).
(16) C l ea n a c ce ss u r et h a n e f r om e xt e ri or w i t h
Mopar Super Kleen or equivalent.
(17) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)m a sk in g t a p e sp a ce d 250 m m (10 in .) a p a r t t o h o ld
molding in place until urethane cures.
(18) E n ga g e w i re con nect or s t o w in ds hield
defroster grid.
(19) Install A-pillar tr im panels.
(20) Install cowl cover and wipers.
(21) Install inside rear view mirror.
(22) After urethane has cured, remove tape strips
a n d w a t e r t e st w in d sh ie ld t o ve r i f y r e p a ir .
BODY SIDE/SLIDING DOOR STATIONARY GLASST h e t e m p e r a t u r e o f t h e ve h icle sh o u ld be a t le a st
21 C (70 F) before removing the stat ionary quarter/
sliding door glass. Butyl sealer becomes more pliable
a t h ig h t e m p e r a t u r e s.
REMOVAL
(1) Rem ov e i nt er ior t r im a s n eces sa r y t o g a in
access at taching locations on back of glass.
(2) Remove nuts holding stat ionary glass to fence.
(3) U s in g r a z or k n if e, cu t b ut y l s ea l er h ol di n g
glass to fence from between the mounting studs (Fig.
6).
(4) Push glass from opening.
INSTALLATION
The stat ionary glass fence should be cleaned of all
old butyl sealer.
(1) Ap pl y a 6 m m (0. 25 i n .) b u t yl t a p e a r ou n d
p er im et e r of g la s s a s s em b ly en ca p s ul a t i on t r a c k.
E n s ur e t h a t t h e b u t yl t a p e i s w r a p ped a r ou n d t h e
mounting studs.
(2) P l a c e t h e g la s s i nt o t h e open in g a n d i ns er t
mounting studs through holes in fence.
Fig. 3 Center Windshield and Mark atSupportSpacers
A-PILLAR WINDSHIELDMARKS SUPPORTSPACERCOWL
Fig. 4 Work Surface Set up and Molding Installation
WINDSHIELD AND MOLD-INGSBLOCKS
Fig. 5 Lower Windshield Into Position
BREAK TAB OFFFLUSH AFTERINSTALLATION WINDSHIELD WITHMOLDING REFER-ENCEMARKSSEE VIEW AADHESIVESUPPORTSPACER* = COMPRESSI ONSPACERVIEW A
Fig. 6 Sliding Door StationaryGlass
NUMBERS INDICATE THETIGHTENING SEQUENCE6mm BEAD OF BUTYL TAPEBODY SIDE/SLIDING DOORGLASS
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(3) I n s t a l l n u t s t o h o ld s t a t i on a r y g la s s t o f en ce
(Fig. 6).
NOTE: Torque nuts to 3.4 Nm (30 in. lbs.) in thesequence indicated. Do not overtorque, or glassbreakage may result.
(4) Install interior tr im.
REAR WINDOWRe fe r t o t h e Win d sh ie ld p a r a g r a p h of t h is sect ion
for description of tools and adhesive systems that are
recommended for use in this procedure.
REAR WINDOW REMOVALEXTERIOR
METHOD
(1) Remove rear window wiper arm, if equipped.
(2) Re m ove scr e w s h old in g m o ld in g s t o l if t g a t e a t
the sides of the rear window (Fig. 7).
(3) U s i ng p li er s , p ul l ou t w a r d on m ol di n g a t t h e
t o p a n d bot t o m of l i ft g a t e .
(4) U s i ng a s h a r p col d k n if e, cu t u r et h a n e a d h e -
sive holding the rear window to the liftgate. A power
cutting device can be used if available.
(5) Separate rear window from vehicle.
REAR WINDOW REMOVALINTERIOR
METHOD
(1) Remove rear window wiper arm, if equipped.
(2) Re m ove scr e w s h old in g m o ld in g s t o l if t g a t e a t
the sides of the rear window (Fig. 7).
(3) Remove liftgate inside lamps and trim covers.
(4) Remove center high mounted stop lamp.
(5) U s i n g a r eci pr oca t i n g or os ci ll a t i ng p ow e r
knife, cut urethane adhesive holding the rear window
t o t h e l if t g a t e . Re fe r t o in st r u ct ion s p r ovid ed w it h
the equipment being used.
(6) Separate rear window from vehicle.
REAR WINDOW INSTALLATION
CAUTION: Open the left front door glass before
installing rear window to avoid pressurizing thepassenger compartment. If a door is slammedbefore urethane bonding is cured, water leaks canresult.
Allow the urethane at least 24 hours to cure
before returning the vehicle to use.To avoid stressing the replacement rear window,
the urethane bonding material on the rear windowfence should be smooth and consistent to the
shape of the replacement glass.
(1) Place replacement glass into rear window open-
ing.
(2) V e r if y t h e g la ss la y s e ve n ly a g a in st t h e p in ch
w el d fen ce a t t h e s id es , t op a n d b ot t om of t h e
r e pla cem e n t r e a r w in d ow . I f n ot , t h e f e n ce m u st be
f o r m e d t o t h e sh a p e o f t h e n e w g la ss.(3) U sin g a g r e a se p e n cil , m a r k t h e g la ss a n d l i f t -
g a t e in se ve r a l lo ca t io n s t o a id in st a l la t io n .
(4) Remove replacement gla ss from liftga te open-
ing.
(5) P osit ion t h e r e a r w in d ow in sid e u p o n a su it -
a b l e w o r k s u r fa c e w i t h t w o p a d d ed , w o od 10 c m b y
10 cm b y 50 c m (4 i n . b y 4 i n . b y 20 i n . ) b lock s,
placed parallel 75 cm (2.5 ft .) apart .
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN REAR WINDOW BEFOREAPPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(6) C lea n i ns id e of r ea r w i nd ow w i t h a m m on ia
based glass cleaner and lint-free cloth.
(7) Ap p ly m o ld in g t o t o p a n d bo t t o m o f r e a r w in -
dow.
(8) Apply Glass Prep adhesion promoter 25 mm (1
in .) w id e a r o u n d p e r im e t e r o f r e a r w in d o w a n d w ip e
with clean/dry lint-free cloth until no str eaks ar e vis-
ible.
(9) Apply Glass Primer 25 mm (1 in.) wide around
p er im et e r of r e a r w in d ow . Allow a t lea st t h r e e m in -
u t e s d r y in g t im e .
(10) Apply P inchweld P rimer 15 mm (.75 in.) widea r o u n d t h e r e a r w in d ow f en ce. Allow a t lea st t h r e e
m in u t es d r y in g t im e .
(11) I f a low viscosit y u r e t h a n e a d h e sive is u sed ,
in st a l l com p r ession sp a ce r s on t h e f en ce a r ou n d t h e
rear window opening (Fig. 8).
(12) Ap pl y a 10 m m (0. 4 i n .) b ea d of u r et h a n e
along centerline of rear window fence.
(13) Wi t h t h e a i d of a h el pe r, p os it i on t h e r ea r
w in d o w o ve r t h e r e a r w in d o w o p e n in g a n d a l ig n t h e
reference ma rks.Fig. 7 Rear Window Side Moldings
MOLDINGLIFTGATE
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(14) Slowly lower the glass to rear window opening
fence. Guide the molding into proper posit ion as nec-
e s s a r y . P u s h g l a s s i n w a r d u n t i l m o l d i n g i s f l u s h t o
liftgate surface (Fig. 8).
(15) C l ea n e xce ss u r et h a n e f r om e xt e ri or w i t h
Mopar Super Kleen, or equivalent.
(16) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)m a sk in g t a p e sp a ce d 250 m m (10 in .) a p a r t t o h o ld
molding in place until urethane cures.
(17) I n st a l l r e a r w in d o w sid e m o ld in g s a n d w ip e r
arm (Fig. 7).
(18) Install interior tr im.
(19) After urethane has cured, remove tape strips
a n d w a t e r t e st r e a r w in d o w t o ve r i f y r e p a ir .
Fig. 8 Lower Rear Window Into Position
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SEATS
INDEX
page page
REMOVAL AND INSTALLATION
ARM REST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9BENCH SEAT BACK COVER . . . . . . . . . . . . . . . 17BENCH SEAT BACK HINGE COVERS . . . . . . . . 17BENCH SEAT BACK HINGE . . . . . . . . . . . . . . . 18
BENCH SEAT RISER1st REAR . . . . . . . . . . . 17BENCH SEAT RISER2nd REAR . . . . . . . . . . . 16BENCH SEAT TRACK2nd REAR . . . . . . . . . . 16BUCKET SEAT BACK ASSIST STRAP . . . . . . . . 10BUCKET SEAT BACK . . . . . . . . . . . . . . . . . . . . 13
BUCKET SEAT CUSHION PAN . . . . . . . . . . . . . 13BUCKET SEAT CUSHION SIDE COVER . . . . . . 11BUCKET SEAT RECLINERMANUAL . . . . . . . . 14BUCKET SEAT RECLINERPOWER . . . . . . . . 15
BUCKET SEAT RISERMANUAL TRACK . . . . . 14
BUCKET SEAT TRACK FRONT
COVERPOWER . . . . . . . . . . . . . . . . . . . . . 12BUCKET SEAT TRACK REAR
COVERPOWER . . . . . . . . . . . . . . . . . . . . . 12BUCKET SEAT TRACKMANUAL . . . . . . . . . . 15
CHILD RESTRAINT SEAT MODULE . . . . . . . . . 19HEAD RESTRAINT SLEEVE . . . . . . . . . . . . . . . 10HEAD RESTRAINTBENCH SEAT . . . . . . . . . . 10HEAD RESTRAINTBUCKET SEAT . . . . . . . . . . 9POWER SEAT SWITCH . . . . . . . . . . . . . . . . . . . 11
RECLINER HANDLEMANUAL . . . . . . . . . . . . . 11SEAT TRACKPOWER . . . . . . . . . . . . . . . . . . 16UNDER SEAT STORAGE BIN GUIDE . . . . . . . . 14UNDER SEAT STORAGE BIN LOCK/LATCH . . . 14
UNDER SEAT STORAGE BIN . . . . . . . . . . . . . . 13
REMOVAL AND INSTALLATION
ARM REST
REMOVAL
(1) Using a screw driver, pry cap from side of arm
rest (Fig. 1).
(2) Remove bolt holding arm rest to seat back.
(3) S e p a r a t e a r m r e st f r o m se a t .
INSTALLATION
(1) Pla ce a r m r e st in p o sit io n o n se a t .
(2) I n st a l l bo lt t o h o ld a r m r e st t o se a t ba ck .
(3) Insert cap into side of arm rest (Fig. 1).
HEAD RESTRAINT BUCKET SEAT
REMOVAL
(1) L if t h e a d r e st r a in t t o t o p o f t r a ve l .
(2) Depress lock button on side of sleeve at top of
seat back (Fig. 2).
(3) Pu ll h e a d r e st r a in t f r o m t o p o f se a t ba ck .
INSTALLATION
Reverse the preceding operation.
Fig. 1 Arm Rest
SEAT BACK ARM RESTSHOULDERBOLT CAPWASHERSTOP SCREW
Fig. 2 Head RestraintBucket Seat
HEADRESTRAINT SLEEVESLOCK BUTTON
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HEAD RESTRAINT BENCH SEAT
REMOVAL
(1) L if t h e a d r e st r a in t t o t o p o f t r a ve l .
(2) Remove escutcheon from head restraint sleeve.
(3) U sin g a sm a ll scr e w d r ive r, d e pr e ss r e t a in er
in w a r d t o r e lea se h e a d r e st r a in t (F ig . 3).(4) Pu ll h e a d r e st r a in t f r o m t o p o f se a t ba ck (F ig .
4).
INSTALLATION
(1) I n ser t r et a i n er a n d es cu t ch eon i nt o h ea d
restra int sleeve (Fig. 5).
(2) Insert head restraint into sleeve.
BUCKET SEAT BACK ASSIST STRAP
REMOVAL
(1) U s i n g a s m a l l s cr ew d r iv er, p ry s cr ew p lu g s
from ends of assist strap (Fig. 6).
(2) R em ov e s cr ew s h ol d in g a s s i st s t r a p t o s ea t
back.
(3) S e pa r a t e a ssist s t r a p f r om veh icle.
INSTALLATION(1) Place assist strap in posit ion on vehicle.
(2) I n st a l l scr ew s t o h old a ssist s t r a p t o se a t ba ck.
(3) I n ser t s cr ew p lu g s i n t o e n ds of a s s i st s t r a p
(Fig. 6).
HEAD RESTRAINT SLEEVE
REMOVAL
(1) Remove head restraint .
(2) Disengage closure holding bottom of tr im cover
together.
(3) R ea c h u n d er t r i m cov er t h r ou g h op en i ng a t
bottom of seat back.(4) Pin ch r e t a in e r ba r bs o n e n d o f h e a d r e st r a in t
sleeve together (Fig. 7).
(5) Pu ll h e a d r e st r a in t s le e ve u p w a r d a n d o u t t h e
t o p of t h e se a t ba ck f r a m e g u id e t u be (F ig . 8).
INSTALLATION
(1) I n se r t h e a d r e st r a in t s le e ve in t o g u id e t u be a t
t o p o f se a t ba ck .
(2) P u s h h ea d r es t ra i n t s leev e d ow n w a r d u n ti l
retainer clicks into lock posit ion.
Fig. 3 Head Restraint Sleeve Escutcheon
REAR SEATBACK HEADRESTRAINTESCUTCHEONSLEEVE
Fig. 4 Release Retainer
HEAD RESTRAINTSCREW DRIVERSLEEVE
Fig. 5 Install Retainerand Escutcheon
RETAINERESCUTCHEONHEAD RESTRAINT SLEEVE
Fig. 6 Bucket Seat Back Assist Strap
ASSIST STRAP SCREW PLUGSEAT BACK
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(3) En g a g e closu r e t o h old bot t o m of t r im cove r
together.
(4) I n st a l l h e a d r e st r a in t .
RECLINER HANDLE MANUAL
REMOVAL
(1) R em ov e s cr ew h ol di ng r ecl in er h a n d le t o
recliner spline sha ft (Fig. 9).
(2) Separate recliner handle from spline shaft .
INSTALLATION
(1) P l a c e r ecl in er h a n d l e i n p os it i on on s pl in e
sh a f t .
(2) Install screw to hold recliner handle to recliner
spline shaft (Fig. 9).
BUCKET SEAT CUSHION SIDE COVER
REMOVAL
(1) Remove screws holding seat cushion side cover
to bucket seat (Fig. 10).
(2) S l id e se a t cu sh io n r e a r l ist in g t o w a r d t h e ce n -
t e r o f t h e se a t t o g a in a cce ss t o r e a r scr e w .
(3) Remove screw h olding r ear of side cover to seat
cushion frame.
(4) Separate side cover from seat cushion.
(5) I f e q u ip pe d , d isen g a g e w ir e con n e ct o r f r om
power seat switch (Fig. 11).
INSTALLATION
(1) Place side cover in posit ion on seat cushion.
(2) I f e q u ip pe d , in ser t w ir e con n e ct o r in t o p ow e r
se a t sw it ch .
(3) I n st a l l scr e w t o h o ld r e a r of s id e cover t o se a t
cushion frame.
(4) Insta ll screws to hold seat cushion side cover to
bucket seat (Fig. 10).
POWER SEAT SWITCHD i a g n os t i c i n f or m a t i on f or p ow e r s ea t s w i t ch i s
lo ca t e d in G r o u p 8R, Po w e r S e a t s .
Fig. 7 Head Restraint Sleeve Retainer
GUIDE TUBE PINCH RETAINER TORELEASESEAT BACK FRAME
Fig. 8 Head Restraint Sleeve
S EAT BAC K F RAM E H EA D R ES TR AI NT SL EEV E R ETAI NE RGUIDETUBE
Fig. 9 Recliner HandleManual
CUSHION SIDECOVER RECLINER SPINE SCREWRECLINER HANDLE
Fig. 10 Bucket Seat Cushion Side Cover
SIDE COVERSEATCUSHIONTRACK COVER
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REMOVAL
(1) Remove seat cushion side cover.
(2) D i s en g a g e w i r e con n ect or f r om p ow e r s ea t
switch.
(3) Pry power seat switch knobs straight off switch
(Fig. 12).
(4) Re m ove scr e w s h old in g p ow e r se a t sw it ch t o
side cover (Fig. 13).
(5) Separate power seat switch from side cover.
INSTALLATION
(1) P l a c e p ow e r s ea t s w i t ch i n p os i t ion on s id e
cover.
(2) Install screws to hold power seat switch to side
cover (Fig. 13).
(3) P u s h pow e r s ea t s w it ch k nob s s t ra i gh t on
switch (Fig. 12).
(4) Engage wire connector into power seat switch.
(5) Install seat cushion side cover.
BUCKET SEAT TRACK FRONT COVER POWER
REMOVAL
(1) Re mov e s cr ew s h ol di n g f r on t cov er t o s ea t
track (Fig. 14).
(2) Separate front cover from vehicle.
INSTALLATION
(1) Place front cover in posit ion on seat .
(2) I n st a l l scr e w s t o h o ld f r o n t co ve r t o se a t t r a ck
(Fig. 14).
BUCKET SEAT TRACK REAR COVER POWER
REMOVAL
(1) D isen g a g e a r r o w h e a d r e t a in er f r om loop st r ip
holding rear cover to power seat track crossbar (Fig.
15).
(2) Disengage fasteners holding rear cover to slots
o n p o w e r se a t t r a ck .
(3) Separate rear cover from seat .
Fig. 11 Power Seat Switch Wire Connector
SEAT CUSHION SIDECOVERPOWER SEAT SWITCHWIRE CONNECTOR
Fig. 12 Power Seat Switch Knobs
POWER SEAT 6-WAYSWITCH POWER RECLINER SWITCHKNOBS
Fig. 13 Power Seat Switch
POWER SEATSWITCHSEAT CUSHION SIDECOVER
Fig. 14 Bucket Seat Track Front CoverPower
SEAT CUSHIONPOWER SEAT TRACKFRONT COVER
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INSTALLATION
(1) Place rear cover in posit ion on seat .
(2) Engage fasteners to hold rear cover to slots on
p o w e r se a t t r a ck .
(3) E n g a g e a r r ow h e a d r et a i n er i n t o l oop s t r ip t o
hold rear cover to power seat track crossbar (Fig. 15).
BUCKET SEAT CUSHION PAN
REMOVAL
(1) Remove bucket seat from vehicle.
(2) Remove seat cushion side covers.
(3) If equipped, remove power seat track front andrear cover.
(4) If equipped, remove stowage bin.
(5) Remove bolts holding seat cushion pan to seat
t r a ck .
(6) S e p a r a t e se a t cu sh io n p a n f r o m se a t .
(7) D isengage J -strip retainers holding seat cover
to cushion pan.
(8) S e pa r a t e se a t cu sh ion p a n f r om cover a n d p a d .
INSTALLATION
(1) Place seat cushion pan in posit ion in seat cover
a n d p a d .
(2) En g a g e J -st r ip r e t a in er s t o h old se a t cover t ocushion pan.
(3) Place seat cushion pan in posit ion on seat .
(4) I n s t a l l b ol t s t o h o ld s ea t cu s hi on p a n t o s e a t
t r a ck .
(5) If equipped, install stowage bin.
(6) I f e q u ip p e d , in st a l l p o w e r se a t t r a ck f r o n t a n d
rear cover.
(7) Install seat cushion side covers.
(8) Install bucket seat in vehicle.
BUCKET SEAT BACK
REMOVAL
(1) Remove seat cushion pan.
(2) Remove nut holding recliner to seat back fra me
(Fig. 16).
(3) Remove pivot bolts holding seat back frame tose a t t r a ck .
(4) Separate seat back from recliner.
INSTALLATION
(1) Place seat back mounting stud into recliner.
(2) I n s t a l l p iv ot b ol t s t o h ol d s ea t b a ck f r a m e t o
se a t t r a ck .
(3) I n st a l l n u t t o h o ld r e clin e r t o se a t ba ck f r a m e
(Fig. 16).
(4) I n st a l l se a t cush ion p a n .
UNDER SEAT STORAGE BIN
REMOVAL
(1) Re le a se u n d e r se a t s t o r a g e bin la t ch a n d o p e n
bin.
(2) D e pr e ss lock t a bs a t t h e r e a r /t o p e d g e o f t h e
storage bin (Fig. 17).
(3) Pull storage bin from bucket seat r iser.
Fig. 15 Bucket Seat Track Rear CoverPower
Fig. 16 Bucket Seat Back
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INSTALLATION
(1) En g a g e st o r a g e bin t r a ck s in t o g u id e s o n e a ch
side of seat r iser.
( 2 ) P u s h s t o r a g e b i n i n w a r d u n t i l l o c k t a b s s n a p
p a st r e t a in in g r id g e o n t r a ck s
(3) Verify storage bin latch operation.
UNDER SEAT STORAGE BIN GUIDE
REMOVAL
(1) Remove under seat storage bin.
(2) Remove screws holding storage bin track guide
to seat r iser (Fig. 18).
(3) Separate track guide from vehicle.
INSTALLATION(1) Place track guide in posit ion on seat r iser.
(2) Install screws to hold storage bin track guide to
seat riser (Fig. 18).
(3) I n st a l l u n d e r se a t s t o r a g e bin .
UNDER SEAT STORAGE BIN LOCK/LATCH
REMOVAL
(1) Open under seat storage bin.
(2) Remove screws holding under seat storage bin
lock/lat ch to stora ge bin (Fig. 19).
(3) S epara te lock/lat ch from bin.
INSTALLATION
(1) P lace lock/la tch in position on s tora ge bin.
(2) In sta ll screws to h old lock/latch to st orage bin
(Fig. 19).
(3) Verify under seat storage bin latch operation.
BUCKET SEAT RISER MANUAL TRACK
REMOVAL
(1) Remove seat from vehicle.
(2) If equipped, remove storage bin from riser.
(3) Rem ov e n u t s h ol di ng r is er t o m a n u a l s ea t
track (Fig. 20).
(4) S e pa r a t e r ise r f r o m se a t .
INSTALLATION
(1) Place riser in posit ion on seat .
(2) I n s t a l l n u t s t o h ol d r i s er t o m a n u a l s ea t t r a c k
(Fig. 20).
(3) If equipped, install storage bin into riser.
(4) Install seat into vehicle.
BUCKET SEAT RECLINER MANUAL
REMOVAL
(1) Remove bucket seat cushion pan.
(2) Remove E-clip holding pin in seat track.
(3) R e m ov e p in h ol di n g m a n u a l r ecl in er t o s ea t
track (Fig. 21).
(4) R em ov e n ut h ol di ng r ecl in er t o s ea t b a ck
f r a m e .
(5) Separate recliner from seat .
Fig. 17 Storage Bin
PASS. SI DEBUCKET SEATUNDER SEAT STORAGE BINRISER LOCK TAB
Fig. 18 Under Seat Storage Bin Guide
STORAGE BINTRACK GUIDERISER
Fig. 19 Under Seat Storage Bin Lock/Latch
UNDER SEAT STORAGE BIN LOCK/LATCH
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INSTALLATION
(1) Place recliner in posit ion on seat .
(2) I n ser t s tu d on s ea t b a ck t h rou gh h ole i n
recliner.
(3) I n st a l l n u t t o h o ld r e clin er t o se a t ba ck f r a m e .
(4) I n st a l l r o l l p in t o h o ld m a n u a l r e cl in e r t o se a t
track (Fig. 21).
(5) I n st a l l E-clip t o h old p in in se a t t r a ck .
(6) Install bucket seat cushion pan.
BUCKET SEAT RECLINER POWERREMOVAL
(1) Remove seat cushion pan.
(2) R em ov e n ut h old in g s ea t ba ck fr a me t o
recliner.
(3) Using a suita ble punch, remove roll pin holding
recliner to seat track (Fig. 22).
(4) Separate recliner from seat track.
(5) Separate recliner from stud on seat back frame.
(6) Disengage wire connector from power recliner.
(7) Separate power recliner from seat .
INSTALLATION
(1) Place power recliner in posit ion on seat .
(2) Enga ge w ire connector into power recliner.
(3) I n ser t s t ud on s ea t b a ck t h rou gh h ole in
recliner.
(4) Place recliner in posit ion on seat track.
(5) I n s t a l l r ol l p in t o h ol d r ecl in er t o s ea t t r a c k(Fig. 22).
(6) I n st a l l n u t t o h o ld se a t ba ck f r a m e t o r e clin e r.
(7) I n st a l l se a t cush ion p a n .
BUCKET SEAT TRACK MANUAL
REMOVAL
(1) Remove seat from vehicle.
(2) Remove seat cushion pan.(3) Remove riser.
(4) On inboard track, remove nut holding recliner
t o se a t ba ck f r a m e .
(5) Re m ove bo lt h old in g sea t ba ck f r a m e t o se a t
track (Fig. 23).
(6) S e p a r a t e se a t t r a ck f r o m se a t a d ju st e r h a n d le
(Fig. 24).
(7) S e p a r a t e se a t t r a ck f r o m se a t .
INSTALLATION
(1) P la ce sea t t r a ck in p osit ion on se a t .
(2) P la ce a d ju st e r h a n d le in p osit ion on se a t t r a ck
(Fig. 24).(3) Insert stud on seat back frame into recliner.
(4) I n st a l l b ol t t o h ol d s ea t b a ck f ra m e t o s ea t
track (Fig. 23).
(5) On inboard track, install nut to hold recliner to
se a t ba ck f r a m e .
(6) Install r iser.
(7) I n st a l l se a t cush ion p a n .
(8) Install seat in vehicle.
Fig. 20 Bucket Seat RiserManual Track
RISER SEAT TRACK
Fig. 21 Bucket Seat ReclinerManual
MANUAL RECLINERPINSEAT TRACKE-CLIPNUTSEAT BACK
Fig. 22 Bucket Seat Reclinerpower
POWER SEATTRACKROLL PINPOWER RECLINER
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SEAT TRACK POWERTh e p ow e r se a t t r a ck a n d m ot o r s a r e se r vice d a s
an assembly.
REMOVAL
(1) Remove seat from vehicle.
(2) Remove seat cushion pan.
(3) R em ov e n u t h ol di ng r ecl in er t o s ea t b a ck
frame.
(4) Re m ove bo lt s h old in g se a t ba ck f r a m e t o sea t
t r a ck .(5) Separate stud on seat back frame from recliner.
(6) Separate seat back from recliner.
INSTALLATION
I f pow e r s ea t t r a ck i s b ei ng r ep la ced , t r a n sf er
pow e r r ecl in er, w i re h a r n es s a n d t r im cov er s t o
replacement seat track.
(1) Insert stud on seat back frame into recliner.
(2) I n s t a l l b o lt s t o h o ld s ea t b a ck f r a m e t o s ea t
t r a ck .
(3) I n st a l l n u t t o h o ld r e clin er t o se a t ba ck f r a m e .
(4) I n st a l l se a t cush ion p a n .
(5) Install seat in vehicle.
BENCH SEAT TRACK 2nd REAR
REMOVAL
(1) Re m ove 2n d r e a r se a t f r om ve h icle. Re fe r t o
Owners Manual for proper procedure.
(2) P la ce se a t on cle a n cove re d w o r k su r f a ce bo t -
tom side up.
(3) D ise n ga g e se a t t r a ck a d ju st er l in k w ir e f r om
track being removed.
(4) Re m ove n u t s h old in g t r a ck t o se a t r iser (F ig .
25).
(5) S e pa r a t e t r a ck f r om se a t r iser.
INSTALLATION
(1) Place track in posit ion on seat r iser.
(2) I n s t a l l n u t s t o h ol d t r a c k t o s ea t r i se r. (F i g.
25).(3) En g a g e se a t t r a ck a d ju st e r l in k w ir e on t o t r a ck
being installed.
(4) Install 2nd rear seat from vehicle.
BENCH SEAT RISER 2nd REAR
REMOVAL
(1) Remove seat track.
(2) R em ov e b ol t s h ol d in g r i se r t o s ea t cu s h ion
frame (Fig. 26).
(3) S e pa r a t e r ise r f r o m se a t .
INSTALLATION
(1) Place riser in posit ion on seat .
Fig. 23 Bucket Seat TrackManual
SHOULDER BOLTRECLINERMANUAL SEAT TRACK
Fig. 24 Seat Track Adjuster Handle
RECLINERSEAT ADJUSTER HANDLEMANUAL SEAT TRACK
Fig. 25 Bench Seat Track2nd Rear
3-PASS 2ND REAR SEATRISER
TRACK
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(2) Install bolts to hold riser to seat cushion frame
(Fig. 26).
(3) I n st a l l se a t t r a ck .
BENCH SEAT RISER 1st REAR
REMOVAL
(1) R e m ov e 1s t r ea r s ea t f r om v eh i cl e. R ef er t o
Owners Manual for proper procedures.
(2) Pla ce se a t bot t o m sid e u p o n a cle a n cover e dwork surface.
(3) Remove bolts holding seat r iser to seat cushion
frame (Fig. 27).
(4) S e p a r a t e r ise r f r o m se a t .
INSTALLATION
(1) Place riser in posit ion on seat .
(2) I n st a l l bo lt s t o h o ld se a t r ise r t o se a t cu sh io n
frame (Fig. 27).
(3) I n st a l l 1st r e a r se a t in t o ve h icle.
BENCH SEAT BACK COVER
REMOVAL
(1) U sin g a f or k t y p e p r y in g t o ol (C 4829), d isen -
g a g e p u sh -in f a st e n er s h old in g bot t o m of se a t ba ck
cover to seat back frame (Fig. 28).
(2) Disengage hooks holding top of seat back cover
t o se a t ba ck f r a m e .
(3) S e pa r a t e se a t ba ck cover f r om se a t .
INSTALLATION
(1) Place seat back cover in posit ion on seat .
(2) Engage hooks to hold top of seat back cover to
se a t ba ck f r a m e .
(3) Enga ge push-in fa steners to hold bottom of seat
back cover to seat back frame (Fig. 28).
BENCH SEAT BACK HINGE COVERS
REMOVAL
(1) If necessary, remove seat from vehicle. Refer to
Owners Manual for proper procedures.
(2) R em ov e s cr ew s h ol d in g l ow e r cov er t o s ea t
back hinge (Fig. 29).
(3) Separate lower cover from hinge.
(4) Re m ove scr e w s h old in g u p pe r h in g e cover t o
se a t ba ck h in g e .
(5) Separate upper cover from seat back hinge.
Fig. 26 Bench Seat Riser2nd Rear
RISER3PASS 2ND REAR SEAT
Fig. 27 Bench Seat Riser1st Rear
2-PASS 1ST REAR SEATRISER
Fig. 28 Bench Seat Back Cover
SEAT BACK REAR COVER1ST REAR CHILDRESTRAINT SEAT
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INSTALLATION
(1) P l a ce u pp er cov er i n p os i t ion on s ea t b a ck
hinge.
(2) Install screws to hold upper hinge cover to seat
back hinge.
(3) Place lower cover in posit ion on hinge.
(4) I n st a l l scr e w s t o h o ld lo w er cover t o se a t ba ckhinge (Fig. 29).
(5) If necessary, install seat in vehicle.
BENCH SEAT BACK HINGEB e n ch s ea t s e q ui pp ed w i t h ch i ld r es t r a i n t s ea t s
h a ve a n in t e r lo ck f e a t u r e t h a t w il l n o t a l lo w t h e se a t
ba ck t o f o ld f o r w a r d w it h t h e ch ild se a t o p e n .
REMOVAL(1) Remove bench seat back hinge covers.
(2) Remove shoulder bolts holding seat back hinge
to seat back frame (Fig. 30).
(3) Re m ove bo lt s h old in g se a t ba ck h in g e t o se a t
cushion frame.
(4) S e p a r a t e se a t ba ck h in g e f r o m se a t .
(5) D ise n ga g e sy n ch r on iz in g ca ble h ou sin g f r om
se a t ba ck h in g e.
(6) Disengage synchronizing cable end from (clip
on lef t s id e) h in g e la t ch r e le a se a r m .
(7) S e p a r a t e h in g e f r o m se a t .
INSTALLATION(1) Place hinge in posit ion on seat .
(2) En g a g e sy n ch r on iz in g ca ble e n d in t o (cl ip on
lef t s id e) h in g e la t ch r e le a se a r m .
(3) En g a g e sy n ch r on iz in g ca ble h ou sin g in t o se a t
back hinge.
(4) Pla ce se a t ba ck h in g e in p o sit io n o n se a t .
(5) I n s t a l l b ol t s t o h ol d s ea t b a ck h i ng e t o s ea t
cushion frame.
(6) Install shoulder bolts to hold seat back hinge to
seat back frame (Fig. 30).
(7) Install bench seat back hinge covers.
(8) Verify seat back hinge operation.
SYNCHRONIZING CABLE ADJUSTMENT
I f t h e s e a t b a ck h i n g es d o n ot r el ea s e a t t h e s a m e
t im e t h e sy n ch r on iz in g ca ble m u st be a d ju st e d .
(1) Re m ove se a t f r om veh icle. Re fe r t o O w n e r s
Manual for proper procedures (Fig. 31).
(2) U sin g a a w l , p r y sy n ch r on iz in g ca ble e n d f r om
clip on left seat back hinge.
(3) P u ll ca ble ou t of h ou sin g u n t i l ca ble is t ig h t .(4) Pu sh r e t a in in g cl ip o n h in g e la t ch r e le a se a r m
r e a r w a r d t o t a k e u p p la y in h in g e m e ch a n ism .
(5) Engage cable end into retaining clip on hinge.
Fig. 29 Bench Seat Back Hinge Covers
SEAT BACKHINGE HINGE COVERSREAR SEAT
Fig. 30 Bench Seat Back Hinge
SHOULDER BOLTREAR SEATHINGE
Fig. 31 SYNCHRONIZING CABLE ADJUSTMENT
REAR SEATCUSHIONAWLHINGE COVERCABLE ENDCLIP
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CHILD RESTRAINT SEAT MODULE
REMOVAL
(1) Close child restraint seat .
(2) Remove seat back cover.
(3) R em ov e s cr ew s h ol di n g ch i ld r es t r a i n t s ea t
module hinges t o seat back fra me lower ra il (Fig. 32).
(4) Return seat back to upright posit ion.
(5) Disengage push-in fast eners holding upper bol-
ster to child restraint seat module (Fig. 33).
(6) Re m ove scr e w s h old in g t o p o f m od u le t o se a t
back frame upper rail (Fig. 34).
(7) S e pa r a t e ch ild r e st r a in t sea t m od u le f r om sea t
back (Fig. 35).
INSTALLATION
(1) Place child restraint seat module in posit ion on
seat back (Fig. 35).
Fig. 32 Child Restraint Seat Lower Hinge
CHILD RESTRAINT SEATMODULE LOWER HINGE
Fig. 33 Child Restraint Seat Upper Bolster
UPPER BOLSTERCHILDRESTRAINTSEAT MODULEPUSH-IN FAS-TENER
Fig. 34 Child Restraint Seat Upper Screws
U PPE R BO L-STERCHILD RESTRAINT SEATMODULE
Fig. 35 Child Restraint Seat Module
1ST REAR SEAT BACKCHILD RESTRAINTSEAT MODULESEAT BACK HINGEINTERLOCK LEVER
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(2) Po sit ion sea t ba ck h in g e in t e rlock leve r over
t h e t op of t h e ou t b oa r d ch i ld r es t r a i n t s ea t h i ng e
(Fig. 36).
(3) I n st a l l scr e w s t o h o ld ch ild r e st r a in t se a t m od -
ule hinges to seat back frame lower rail (Fig. 32).
(4) I n s t a l l s cr ew s t o h ol d t op of m od u le t o s ea t
back frame upper rail (Fig. 34).(5) Engage push-in fasteners to hold upper bolster
to child restraint seat module (Fig. 33).
(6) Return seat back to folded posit ion.
(7) Install seat back cover.
(8) Verify child restraint seat operation.
Fig. 36 Interlock Lever
CHILD RESTRAINT SEATHINGE SEAT BACK HINGEINTERLOCK LEVER1 ST R EA R S EATBACKSEAT BACK FRAME RAIL
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BODY COMPONENT SERVICE
INDEX
page page
DIAGNOSIS AND TESTINGWATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . 22
WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . 23REMOVAL AND INSTALLATION
A-PILLAR LOWER EXTENSION TRIM . . . . . . . . 54A-PILLAR TRIM PANEL . . . . . . . . . . . . . . . . . . . 54
COWL COVER . . . . . . . . . . . . . . . . . . . . . . . . . 27COWL TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . 54FLOOR CARPET . . . . . . . . . . . . . . . . . . . . . . . . 69FRONT DOOR APPLIQUE . . . . . . . . . . . . . . . . . 37FRONT DOOR CHECK STRAP . . . . . . . . . . . . . 31
FRONT DOOR FRAME CLOSEOUTMOLDINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 36
FRONT DOOR GLASS RUN WEATHERSTRIP . . 37FRONT DOOR GLASS . . . . . . . . . . . . . . . . . . . 35
FRONT DOOR HINGE . . . . . . . . . . . . . . . . . . . . 31FRONT DOOR INNER BELT MOLDING . . . . . . . 34FRONT DOOR LATCH STRIKER . . . . . . . . . . . . 34FRONT DOOR LATCH . . . . . . . . . . . . . . . . . . . . 33
FRONT DOOR LOCK CYLINDER . . . . . . . . . . . 32FRONT DOOR OUTER BELT MOLDING . . . . . . 34FRONT DOOR OUTSIDE HANDLE . . . . . . . . . . 31FRONT DOOR REFLECTOR . . . . . . . . . . . . . . . 30
FRONT DOOR SILL PLATE . . . . . . . . . . . . . . . . 54FRONT DOOR TRIM PANEL . . . . . . . . . . . . . . . 28
FRONT DOOR WEATHERSTRIP . . . . . . . . . . . . 38FRONT DOOR WINDOW CRANK . . . . . . . . . . . 28
FRONT DOOR WINDOW REGULATOR . . . . . . . 36FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 30FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . 69FRONT WHEELHOUSE SPLASH SHIELD . . . . . 27FUEL FILL DOOR BLOCKER LATCH STRIKER . 50
FUEL FILL DOOR BLOCKER LATCH . . . . . . . . . 49FUEL FILL DOOR BLOCKER LOCKOUT LINK . . 49FUEL FILLER HOUSINGWITH BLOCKER
LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23HEADLINING . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . 25HOOD LATCH STRIKER . . . . . . . . . . . . . . . . . . 25
HOOD LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . 25HOOD RELEASE CABLE . . . . . . . . . . . . . . . . . 26HOOD RELEASE HANDLE . . . . . . . . . . . . . . . . 26HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
JACK STORAGE COVER . . . . . . . . . . . . . . . . . 57LEFT D-PILLAR TRIM PANEL . . . . . . . . . . . . . . 58LEFT QUARTER TRIM PANEL . . . . . . . . . . . . . . 61LIFTGATE CHMSL ACCESS PANEL . . . . . . . . . 75LIFTGATE HINGE . . . . . . . . . . . . . . . . . . . . . . . 73
LIFTGATE LATCH STRIKER . . . . . . . . . . . . . . . 76
LIFTGATE LATCH . . . . . . . . . . . . . . . . . . . . . . . 75LIFTGATE LOCK CYLINDER . . . . . . . . . . . . . . . 76
LIFTGATE OUTSIDE HANDLE . . . . . . . . . . . . . . 75LIFTGATE PROP ASSEMBLY . . . . . . . . . . . . . . 73LIFTGATE SILL PLATE . . . . . . . . . . . . . . . . . . . 55LIFTGATE STABILIZER WEDGE STRIKER . . . . 77
LIFTGATE STABILIZER WEDGE . . . . . . . . . . . . 76LIFTGATE TRIM PANEL . . . . . . . . . . . . . . . . . . 74LIFTGATE UPPER FRAME MOLDING . . . . . . . . 74LIFTGATE UPPER FRAME SIDE MOLDINGS . . 74LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
LOWER B-PILLAR TRIM COVER . . . . . . . . . . . . 56LUGGAGE RACK CROSSBAR . . . . . . . . . . . . . 78LUGGAGE RACK RISER COVER . . . . . . . . . . . 78LUGGAGE RACK SIDE RAIL . . . . . . . . . . . . . . . 78
OVERHEAD GRAB-HANDLES . . . . . . . . . . . . . . 55QUARTER GLASS . . . . . . . . . . . . . . . . . . . . . . . 77QUARTER TRIM BOLSTER . . . . . . . . . . . . . . . . 56RADIATOR CLOSURE PANEL
CROSSMEMBER . . . . . . . . . . . . . . . . . . . . . . 23RAIL LAMP MODULE . . . . . . . . . . . . . . . . . . . . 70REAR HEADER TRIM . . . . . . . . . . . . . . . . . . . . 55REAR HEVAC LOUVER AND BEZEL . . . . . . . . . 71
RIGHT D-PILLAR TRIM PANEL . . . . . . . . . . . . . 59RIGHT QUARTER TRIM PANEL . . . . . . . . . . . . 60
ROOF APERTURE (RAP) MOLDING . . . . . . . . . 77SEAT BELT BUCKLE FIRST REAR QUAD
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66SEAT BELT BUCKLE FIRST REAR2
PASSENGER BENCH . . . . . . . . . . . . . . . . . . . 66SEAT BELT BUCKLE SECOND REAR3
PASSENGER BENCH . . . . . . . . . . . . . . . . . . . 67
SEAT BELT BUCKLEFRONT INBOARD . . . . . 63SEAT BELT FIRST REAR ANCHOR BRACKET
LWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66SEAT BELT FIRST REAR OUTBOARD SWB4
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64SEAT BELT FIRST REAR OUTBOARDLWB4
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65SEAT BELT LEFT FIRST REAR OUTBOARD
SWB3 DOOR . . . . . . . . . . . . . . . . . . . . . . 65SEAT BELT LEFT FIRST REAR OUTBOARD
LWB3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . 66SEAT BELT SECOND REAR
OUTBOARDSWB . . . . . . . . . . . . . . . . . . . . 69SEAT BELTOUTBOARD FRONT . . . . . . . . . . . 63SECOND RIGHT REAR OUTBOARD SEAT
BELTLWB W/REAR HEVAC . . . . . . . . . . . . . 68SECOND RIGHT REAR OUTBOARD SEAT
BELTLWB . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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SHOULDER BELT HEIGHT ADJUSTER KNOB . . 64
SHOULDER BELT HEIGHT ADJUSTERB ORC-PILLAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . . . . . 28SLIDING DOOR CENTER HINGE . . . . . . . . . . . 42
SLIDING DOOR CENTER STABILIZER . . . . . . . 48SLIDING DOOR CENTER STOP TRIM COVER . 40
SLIDING DOOR HOLD OPEN LATCHTRIKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43SLIDING DOOR HOLD OPEN LATCH . . . . . . . . 43
SLIDING DOOR INSIDE LATCH HANDLEBELLCRANK . . . . . . . . . . . . . . . . . . . . . . . . . 42
SLIDING DOOR INSIDE LATCH HANDLE . . . . . 40SLIDING DOOR INSIDE LATCH RELEASE
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . 41SLIDING DOOR LATCH / LOCK CONTROL . . . . 45SLIDING DOOR LATCH STRIKER . . . . . . . . . . . 47SLIDING DOOR LOWER ROLLER ARM
BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SLIDING DOOR LOWER ROLLER ARM . . . . . . 44
SLIDING DOOR OUTSIDE LATCH RELEASEHANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SLIDING DOOR REAR LATCH . . . . . . . . . . . . . 47SLIDING DOOR SILL PLATE . . . . . . . . . . . . . . . 55
SLIDING DOOR STABILIZER SOCKET . . . . . . . 48SLIDING DOOR STABILIZER . . . . . . . . . . . . . . . 48
SLIDING DOOR STOP BUMPER . . . . . . . . . . . . 44SLIDING DOOR TRIM PANEL . . . . . . . . . . . . . . 40SLIDING DOOR UPPER ROLLER . . . . . . . . . . . 42
SLIDING DOOR WEATHERSTRIP . . . . . . . . . . . 49SLIDING DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 38STICK-ON BODY SIDE MOLDING . . . . . . . . . . . 50SUN VISOR SUPPORT . . . . . . . . . . . . . . . . . . . 71
SUN VISOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 71UPPER B-PILLAR TRIM COVER . . . . . . . . . . . . 55UPPER C-PILLAR TRIM . . . . . . . . . . . . . . . . . . 57
ADJUSTMENTS
SLIDING DOOR ADJUSTMENTS . . . . . . . . . . . . 79
DIAGNOSIS AND TESTING
WATER LEAKSWa t er l ea k s ca n b e ca u sed b y poor s ea l in g,
i m pr op er b od y com p on en t a l i gn m en t , b od y s ea m
porosity, missing plugs, or blocked drain holes. Cen-
t r i fu g a l a n d g r a v it a t i on a l f or ce ca n ca u s e w a t e r t o
d r ip f r om a loca t ion a w a y f r o m t h e a ct u a l lea k p oin t ,
m a k i ng l ea k d et e ct i on d if fi cu lt . Al l b od y s ea l i ng
p oin t s sh ou ld be w a t e r t ig h t in n o r m a l w e t -d r ivin g
conditions. Wat er flowing downwa rd from the front of
the vehicle should not enter t he passenger or luggage
com pa r t m en t . M ov in g s ea l in g s ur fa c es w i ll n ot
a l w a y s s ea l w a t e r t i gh t u n der a l l con d it ion s . At
t i m es , s i d e g l a s s o r d oor s ea l s w i l l a l l ow w a t e r t o
e n t er t h e p a ssen g e r com p a r t m e n t d u r in g h ig h p r es-
s u r e w a s h i n g or h a r d d r iv in g r a i n (s ev er e) con d i-
t ion s. Over com pen sa t in g on door or gla ss
a d ju s t m en t s t o s t o p a w a t e r l ea k t h a t occu r s u n d e r
severe conditions can cause premature seal wear and
excessive closing or lat ching effort . After completing
a repair , water-test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK
TESTS
Verify that f loor and body plugs are in place, body
d r a in s a r e cle a r, a n d bod y com p on e n t s a r e p r op er ly
a l ig n ed a n d sea le d . I f com p on e n t a l ig n m en t or se a l-
in g is n e ce ssa r y , r e f er t o t h e a p p r op r ia t e sect ion of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONALINJURY CAN RESULT.
Wh en t h e con d it i on s ca u s i ng a w a t er l ea k h a v ebeen determined, simulate the conditions a s closely
as possible.
I f a l ea k occu r s w i t h t h e v e hi cl e p a r ked i n a
s t ea d y l ig h t r a i n , f l ood t h e l e a k a r ea w i t h a n op en -
ended garden hose.
I f a lea k occur s w h ile d r ivin g a t h ig h w a y sp ee d s
in a st e a d y r a in , t e st t h e le a k a r e a w it h a r e a so n a ble
v el oci t y s t rea m or f a n s pr a y of w a t e r. D i rect t h e
spray in a direction comparable to actual conditions.
If a leak occurs when the vehicle is parked on an
in cline , h o ist t h e e n d o r sid e o f t h e ve hicle t o sim u -
la t e t h is con d it ion . Th is m e t h od ca n be u se d w h e n
the leak occurs when the vehicle a ccelera tes, st ops ort u r n s. I f t h e lea k occur s on a cce le r a t ion , h oist t h e
front of the vehicle. If the leak occurs when braking,
hoist the back of th e vehicle. If t he leak occurs on left
t u r n s, h oi st t h e l ef t s id e o f t h e v eh i cl e. I f t h e l ea k
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations refer to Group 0,
L u br ica t ion a n d Ma in t e n a n ce, G e n e r a l I n f or m a t ion
section.
WATER LEAK DETECTION
To d e t ect a w a t e r lea k p oin t -of -e n t r y, d o a w a t e r
t e st a n d w a t ch f o r w a t e r t r a ck s o r d r o p le t s f o r m in g
on the inside of the vehicle. If necessary, remove inte-
rior tr im covers or panels to gain visual access to the
lea k a r e a . I f t h e h ose ca n n o t be p osit ion e d w it h ou t
bein g h e ld , h a ve so m eon e h e lp d o t h e w a t e r t e st .
Some water leaks must be tested for a considerable
l en g t h of t i m e t o b ecom e a p pa r e n t . Wh en a l ea k
a p p e a r s, f in d t h e h ig h e st p o in t o f t h e w a t e r t r a ck o r
drop. The highest point usually will show the point of
e nt r y. Af t er l ea k p oi n t h a s b ee n f ou n d , r ep a ir t h e
lea k a n d w a t er t es t t o ver ify t ha t t he lea k h a s
stopped.
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L oca t i n g t h e e n t r y p oi n t of w a t e r t h a t i s l e a k in g
i n t o a ca v i t y b et w e en p a n el s ca n b e d if fi cu lt . Th e
t r a pped w a t e r m a y s pl a sh or r u n f rom t h e ca v it y,
o f t e n a t a d ist a n ce f r o m t h e e n t r y p o in t . Mo st w a t e r
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
Wh e n a lea k p oin t a r e a is visu a lly o bst r u ct e d , u se
a su it a ble m ir r or t o g a in visu a l a cce ss. A m ir r or ca n
a lso be u sed t o d e flect l igh t t o a l im it e d-a cce ss a r e a
t o a ssist in lo ca t in g a le a k p o in t .
BRIGHT LIGHT LEAK TEST METHOD
S o m e w a t e r le a k s in t h e lu g g a g e co m p a r t m e n t ca n
be d e t ect ed w it h o u t w a t e r t e st in g. P osit ion t h e veh i-
cle in a br ig h t ly l i t a r e a . F r o m in sid e t h e d a r k e n ed
lu g ga g e com p a r t m e n t in spe ct a r o u n d se a ls a n d bod y
seams. If necessary, have a helper direct a drop light
ov er t h e s u sp ect e d l ea k a r e a s a r ou n d t h e l ug g a g ecom p a r t m e n t . I f l ig h t is visible t h r o u gh a n or m a lly
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST M ETHOD
Wh en a w a t er l ea k i n t o t h e p a s se ng er com p a r t -
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
t h e veh icle. To p r essu r iz e t h e p a ssen g er com p a r t -
m e n t , clo se a l l d o o r s a n d w in d o w s, st a r t e n g in e , a n d
set heater control t o high blower in H EAT posit ion. I f
e n gin e ca n n o t be st a r t e d , con n e ct a ch a r g er t o t h e
b a t t e r y t o e ns u re a d e q ua t e v ol t a g e t o t h e b low e r.With interior pressurized, apply dish detergent solu-
t i on t o s u sp ect e d l ea k a r e a on t h e e xt e ri or of t h e
vehicle. Apply detergent solution with spray device or
s of t b r is t l e b r u sh . I f s oa p b u bb les occu r a t a b od y
seam, joint , seal or gasket, the leak entry point could
be a t t h a t lo ca t io n .
WIND NOISEWind noise is t he result of most a ir leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in th e engine compart ment or door hinge pillar a reas.
All bo d y se a l in g p o in t s sh o u ld be a ir t ig h t in n o r m a ldriving conditions. Moving sealing sur faces w ill not
a l w a y s s ea l a i r t i gh t u n d er a l l con d it i on s . A t t i m es ,
sid e g la ss or d oor sea ls w il l a l low w in d n oise t o be
n ot ice d in t h e p a ssen g er com p a r t m e n t d u r in g h ig h
cr os s w i nd s . O ve r com p en s a t i n g on d oor or g la s s
a d ju s t m en t s t o s t op w i n d n oi se t h a t occu r s u n d er
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
ce du r e h a s b ee n p er f or m ed , t e st v eh i cl e t o v er i fy
noise has stopped before returning vehicle to use.
Wind noise can also be caused by improperly fit ted
ex t er i or m ol d in g s or b od y or n a m en t a t i on . L oos e
moldings can flutter, creating a buzzing or chattering
noise. An open cavity or protruding edge can creat e a
whistling or howling noise. In spect t he exterior of the
vehicle to verify that these conditions do not exist .
VISUAL INSPECTION BEFORE TESTS
V e r if y t h a t f lo o r a n d bo d y p lu g s a r e in p la ce a n d
bod y com p on e n t s a r e a l ig n ed a n d se a led . I f com p o-
n e n t a l ig n m en t or se a l in g is n e cessa r y, r e f er t o t h e
a p p r op r ia t e se ct ion of t h is g r ou p f or p r op er p r oce-
dures.
ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of t h e w in d n oise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 i n .) l en g t h s a l on g w e a t h e rs t r ip s, w e ld s ea m s or
moldings. After ea ch length is a pplied, drive the vehi-cle. If noise goes aw ay aft er a piece of ta pe is applied,
remove tape, locate, and repair defect .
POSSIBLE CAUSE OF WIND NOISE
Mo ld in g s st a n d in g a w a y f r o m bo d y su r f a ce ca n
ca t ch w in d a n d w h ist le .
G a p s i n s ea l ed a r e a s b eh i nd ov er h a n g in g b od y
flanges can cause wind-rushing sounds.
Misaligned movable components.
Missing or improperly installed plugs in pillars.
Weld burn through holes.
REMOVAL AND INSTALLATION
GRILLE
REMOVAL
(1) Remove front fascia. Refer to Group 13, Frame
and Bumpers, for proper procedures.
(2) D ise n ga g e clips h old in g g r i lle t o f r on t f a scia
(Fig. 1).
(3) Remove plastic r ivets holding grille to fascia.
(4) Separate grille from fascia.
INSTALLATION
(1) Posit ion grille on fascia.
(2) I n st a l l p la st ic r ive t s t o h o ld g r i lle t o f a scia .
(3) I n st a l l c lips t o h o ld g r i l le t o f a scia a lon g bot -
tom of grille.
(4) I n st a l l f r o n t f a scia . Re f e r t o G r o u p 13, F r a m e
and Bumpers, for proper procedure.
RADIATOR CLOSURE PANEL CROSSMEMBER
REMOVAL
(1) Release hood latch and open hood.
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(2) Mark outline of hood latch on crossmember to
a id in st a l la t io n .
(3) Remove bolts holding hood latch to crossmem-be r a n d p o sit io n la t ch o u t o f t h e w a y .
(4) Remove radiator sight shield.
(5) Remove engine air inlet resonator.
(6) R em ov e b ol t h ol di n g a i r cl ea n e r h ou s in g t o
crossmember.
(7) Remove screw holding coolan t recovery bott le
to crossmember.
(8) R em ov e b ol t s h ol di n g r a d i a t or i sol a t or s t o
crossmember.
(9) Remove bolts holding ends of crossmember t o
radiator closure panel (Fig. 2).
(10) L if t cr os sm em ber u pw a r d a n d a w a y f rom
radiator closure panel.
(11) Separate crossmember from vehicle.
INSTALLATION
(1) P la ce r a d ia t o r closu r e p a n e l cr ossm em ber in
position on vehicle.
(2) I n se r t e n d s of cr ossm em ber bet w e e n la y e r ed
m e t a l se ct io n s o f r a d ia t o r clo su r e p a n e l a t e a ch sid e
of radiator.
(3) I n s t a l l b ol t s t o h ol d e nd s of cr os s m em b er t o
radiator closure panel (Fig. 2).
(4) I n st a l l bolt s t o h o ld r a d ia t o r iso la t or s t o cr oss-
member.(5) Install screw to hold coolant recovery bott le to
crossmember.
(6) Insta ll bolt t o hold a ir clean er housing to cross-
member.
(7) Install engine air inlet resonator.
(8) I n st a l l r a d ia t o r sig h t sh ie ld .
(9) Align hood latch to marks on crossmember.
(10) I n st a l l bo lt s t o h o ld h o o d la t ch t o cr o ssm e m -
ber.
(11) Ve r if y h ood la t ch op er a t io n a n d h ood a l ig n -
ment.
HOOD
REMOVAL
(1) Raise hood to full up posit ion.
(2) Ma r k a l l bolt a n d h in g e a t t a ch m en t loca t ion s
w it h a g r ea se p en cil or ot h e r su it a ble d e vice t o p r o-
vide reference marks for installat ion.
(3) Remove the top bolts holding hood to hinge a nd
loosen the bottom bolts until they can be removed by
hand (Fig. 3).
(4) Wit h a ssist a n ce f r o m a h e lp er a t t h e op posit e
side of th e vehicle to support t he h ood, remove bot-
tom bolts holding hood to hinge.
(5) Separate the hood from the vehicle.
INSTALLATION
(1) P lace hood in posit ion on vehicle. With assis-
ta nce from a helper a t the opposite side of the vehicle
to support the hood, inst all bottom bolts to hold hood
t o h in g e f in g er t ig h t .
Fig. 1 Grille
GRILLE
FRONT BUMPER FASCIA
Fig. 2 Radiator Closure Panel Crossmember
RADIATOR CLOSURE PANELCROSSMEMBERFRONT FASCIA
Fig. 3 Hood
HOOD
HOOD LATCH STRIKERH OOD HA LF OF H OODHINGE
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(2) I n st a l l t o p bolt s t o h old h ood t o h in g e f in g er
t ig h t .
(3) Po sit io n bo lt s a t m a r k s a n d t ig h t e n bo lt s . T h e
hood sh ould be a ligned t o 4 mm (0.160 in.) gap t o the
f r on t f en d e rs a n d f lush a cr oss t h e t op su r f a ces a lo n g
fenders.
(4) Verify hood operation and alignment.
HOOD HINGE
REMOVAL
(1) Remove hood.
(2) Remove wiper unit . Refer to Group 8K, Wind-
shield Wipers a nd Wa shers, for procedure.
(3) Ma r k a l l bolt a n d h in g e a t t a ch m e n t lo ca t ion s
w it h a g r ea se p en cil o r ot h e r su it a ble d e vice t o p r o-
vide reference marks for installat ion.
(4) Remove bolts holding body ha lf of hood hinge
t o f r o n t f e n d e r f la n g e a n d se p a r a t e h in g e f r o m ve h i-
cle (Fig. 4).
INSTALLATION
(1) I f n e ce ssa r y , p a in t n e w h in g e be for e in st a l la -
tion.
(2) Pla ce bod y h a lf of h ood h in g e in p osit ion on
vehicle.
(3) Install bolts to hold hood hinge to front fender
flange.
(4) I n st a l l w ip er u n it . Re fe r t o G r o u p 8K , Win d -shield Wipers a nd Wa shers, for procedure.
(5) Install hood.
(6) Al ig n a l l m a r k s a n d s ecu r e b ol t s. Th e h ood
should be a ligned to 4 mm (0.160 in.) gap t o the front
fenders and flush across the top surfaces along fend-
er s . S h im s ca n b e a d d ed or r em ov ed u n der h ood
hinge to achieve proper hood height.
HOOD LATCH STRIKER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts holding striker to inside of hood
(Fig. 3).
(3) Separate hood latch striker from vehicle.
INSTALLATION
(1) Posit ion hood latch striker on vehicle.
(2) Install bolts to hold hood latch striker to hood.
(3) Alig n h ood la t ch st r ik er t o e n ga g e sm oot h ly
into hood latch.
(4) Verify hood opera tion a nd alignment. Adjust as
necessary.
(5) Torque bolts to 100 140 in. lbs.
HOOD LATCH
REMOVAL
(1) Release hood latch and open hood.
(2) Mark perimeter outline of latch on crossmem-
be r t o a id in st a l la t io n .
(3) Remove bolts holding hood latch to radiator clo-
sure panel crossmember (Fig. 5).
(4) Separate hood latch from crossmember.
(5) D isconnect hood release cable from hood lat ch
(Fig. 7).
(6) Separate hood latch from vehicle.
INSTALLATION
(1) Position hood latch on vehicle.
(2) Connect hood release cable from hood latch.
(3) Position hood latch on crossmember.
(4) Alig n h ood la t ch t o ou t l in e o f la t ch on cr oss-
member.
(5) I n st a l l bolt s t o h o ld h o od la t ch t o r a d ia t o r clo-
sure panel crossmember.
(6) Verify hood opera tion a nd alignment. Adjust as
necessary.
(7) Torque bolts to 100 140 in. lbs.
Fig. 4 Hood Hinge
HOOD
Fig. 5 Hood Latch
HOOD RELEASE CABLE
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HOOD RELEASE CABLE
REMOVAL
(1) Remove hood latch.
(2) D isen g a g e ca ble e n d f r om h ood la t ch lock in g
mechanism.
(3) Slide cable case end sideways in keyhole slot ofhood latch while pinching barb on cable case closed.
(4) Separate cable from latch (Fig. 7).
(5) Re m ove h ood r e le a se h a n d le f r om in st r u m en t
panel.
(6) D i s en g a g e r u bb er g r om m et ca b l e i n su la t o r
f r o m h o le in d a sh p a n e l .
(7) At t a ch a su it a ble len g t h of m e ch a n ics w ir e t o
la t ch e n d of ca ble t o a ssist ca ble in st a l la t io n .
(8) R ou t e ca b l e b a ck f r om l a t ch t h r ou g h e ng in e
com pa r t m e n t t ow a r d d a s h p a n el n ea r p ow e r b r a k e
booster (Fig. 6).
(9) Remove attaching clips from cable case.
(10) F rom inside vehicle, pull cable t hrough da shpanel until mechanics wire is exposed.
(11) Disconnect cable from mechanics wire.
(12) Separate hood release cable from vehicle.
INSTALLATION
(1) P l a ce h ood r el ea s e ca b l e i n p os it i on u n d er
instrument panel.
(2) At t a ch l a t ch en d of h ood r el ea s e ca b le t o
mechanics wire protruding through dash panel.
(3) Ro u t e ca ble f or w a r d t h r o ug h e n gin e com p a r t -
m e nt t ow a r d l a t ch b y p ul li n g on m ech a n i cs w i r e(Fig. 6).
(4) Disconnect mecha nics wire from cable.
(5) E n g a g e r u bb er g r om m et ca b l e i n su la t o r i n t o
h o le in d a sh p a n e l .
(6) Install hood release handle into instrument panel.
(7) Place cable in posit ion on latch.
(8) Slide cable case end sideways into keyhole slot
of hood latch.
(9) Enga ge cable end int o hood la tch locking mech-
a n ism .
(10) Install hood latch.
(11) Install at taching clips to cable case and install
clips into original holes in strut tower, fender, head-la m p a r e a , a n d r a d ia t o r closu r e p a n e l crossm em ber .
HOOD RELEASE HANDLE
REMOVAL
(1) Remove lower steering column cover and knee
blocker reinforcement.
(2) Remove h ood la tch cable.
(3) Remove screws holding hood latch release han-
dle to instrument panel brace (Fig. 8).
(4) S e p a r a t e h o o d la t ch r e le a se h a n d le f r o m ve h i-
cle.
INSTALLATION
(1) Posit ion hood latch release handle on vehicle.
(2) Install screws to hold hood latch release handle
t o in st r u m e n t p a n e l br a ce.
(3) Install hood latch cable.
(4) I n st a l l low e r st e er in g colu m n cover a n d k n ee
blocker reinforcement.
Fig. 6 Hood Release Cable Routing
GROMMETHOOD RELEASE CABLERADIATOR CLOSURE PANELCROSSMEMBER
Fig. 7 Hood Release Cable End Attachment
RELEASE CABLE CASEHOOD LATCHRELEASE CABLE END
Fig. 8 Hood Release Handle
INSTRUMENT PANEL BRACEHOOD RELEASE HANDLE
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COWL COVER
REMOVAL
(1) Remove wiper arms. Refer to Group 8K, Wind-
shield Wipers a nd Wa shers.
(2) Remove screws holding lower area of cowl cover
to wiper module (Fig. 9).(3) Disengage quarter turn fasteners holding outer
ends of cowl cover to wiper module.
(4) Release hood latch and open hood.
(5) Remove w ing n uts holding front of cowl cover
to wiper module.
(6) C l os e h ood . D o n ot l a t ch . R em ov e ou t b oa r d
screws. (Fig. 10).
(7) Lift cowl cover upwa rd enough to ga in a ccess to
r ig h t w a sh e r h o se .
(8) D ise n g a g e w a sh e r h o se f r o m r ig h t w a sh e r n o z -
zle.
(9) Close hood. Do not latch.
(10) Separate cowl cover from vehicle.
INSTALLATION
Reverse the preceding operation.
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Remove front wheel. Refer to Group 22, Wheelsand Tires, for proper procedures.
(3) Remove push-in fasteners holding splash shield
t o f r a m e r a i l f o rw a r d of su spe n sion .
(4) Remove push-in fasteners holding splash shield
t o f r a m e r a i l r e a r w a r d o f su sp e n sio n .
(5) R em ov e s cr ew s h ol d in g w h e el h ou s e s pl a s h
shield to front fender.
(6) Separate splash shield from vehicle (Fig. 11).
INSTALLATION
(1) Place splash shield in posit ion on vehicle (Fig.11).
(2) Install screws to hold wheelhouse splash shield
to front fender.
(3) I n st a l l p u sh - in f a st e n e r s t o h o ld sp la sh sh ie ld
t o f r a m e r a i l r e a r w a r d o f su sp e n sio n .
(4) I n st a l l p u sh - in f a st e n e r s t o h o ld sp la sh sh ie ld
t o f r a m e r a i l f or w a r d of su spe n sion .
(5) Install front wheel. Refer to Group 22, Wheels
and Tires, for proper procedures.
(6) Lower vehicle.
Fig. 9 Cowl Cover
Fig. 10 Cowl Cover Retainers
SCREW
Fig. 11 Front Wheelhouse Splash Shield
BUMPER FAS-CIA FRONT WHEELHOUSESPLASH SHIELDFRONTFENDER
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SIDE VIEW MI RROR
REMOVAL
(1) Release front door latch and open door.
(2) Remove screw holding molding t o base of side
view mirror (Fig. 12).
(3) Separate molding from mirror.(4) Remove bolts holding bottom of side view mir-
ror to A-pillar.
(5) Remove bolt holding top of side view mirror to
A-pillar (Fig. 12).
(6) If equipped, disengage power side view mirror
wire connector from instrument panel harness.
(7) Separate side view mirror from vehicle.
INSTALLATION(1) E ngage power side view m irror wire connector
into instrument panel harness, if equipped.
(2) Pla ce sid e vie w m ir r or in p osit ion on ve hicle
(Fig. 12).
(3) I n st a l l bolt t o h o ld t o p o f s id e vie w m ir r or t o
A-pillar.
(4) Install bolts to hold bottom of side view mirror
to A-pilla r.
(5) Place molding in posit ion on mirror.
(6) I n s t a l l s cr ew t o h ol d m ol d in g t o b a s e of s i de
view mirror.
FRONT DOOR WINDOW CRANK
REMOVAL
(1) U sin g a su it a ble t ool , d isen g a g e cl ip h o ldin g
window crank to regulator shaft (Fig. 13).
(2) Pu ll w in d o w cr a n k f r o m r e g u la t o r sh a f t .
INSTALLATION
(1) P osit ion w in d ow cr a n k t o r e g u la t o r sh a f t .
(2) P u sh w i n dow cr a n k on t o r eg ul a t or s h a ft t o
engage retaining clip.
FRONT DOOR TRIM PANEL
REMOVAL(1) Using a tr im stick (C-4755), pry courtesy lamp
from door tr im.
(2) Disengage wire connector from courtesy lamp.
(3) If equipped, remove screws holding door assist
handle to inner door panel.
(4) I f e q u ip pe d , r e m ove scr e w h old in g d oor p u ll
cup to inner door panel.
(5) If equipped, remove screws holding tr im panel
to door from below map pocket.
(6) If equipped, remove window crank.
(7) U sin g a t r im st ick , r e m ove scr ew cover f r om
switch panel.
(8) Re m ove scr e w s h old in g sw it ch p a n e l t o d oor
t r im .
(9) S ep a r a t e p ow e r a c ce ss a r y s w i t ch f r om d oor
trim (Fig. 14).
(10) Disengage power switch from wire connector.
(11) I f e q ui pp ed , u s in g a s m a l l, f la t b la d e d p ry
tool, remove memory sea t/mirror sw itch a nd disen-
gage wire connector (Fig. 15).
(12) I f equipped, remove screw holding door tr im
t o d o o r p a n e l f r o m be h in d in sid e la t ch r e le a se h a n -
dle.
(13) D i se ng a g e cl ip s h ol d in g d oor t r i m t o d oor
frame around perimeter of panel (Fig. 16).(14) L i ft t r i m p a n el u pw a r d t o d is en g a g e f la n g e
from inner belt molding at top of door.
(15) Tilt top of tr im panel a wa y from door t o gain
access to latch linkage.
(16) D ise n ga g e clip h old in g l in k a g e r od t o in sid e
latch release handle (Fig. 17).
(17) S e pa r a t e l in ka g e r od f r om la t ch h a n d le .
(18) Separate front door tr im panel from vehicle.
Fig. 12 Side View Mirror
SIDE VIEW MIRROR
MOLDING
Fig. 13 Window Crank
DOOR HANDLEREMOVAL TOOL WINDOWCRANK
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INSTALLATION
(1) H o ld t o p o f t r im p a n e l a w a y f r o m d o o r t o g a in
access to latch linkage.
(2) Place linkage rod in posit ion on latch handle.
(3) En g a g e cl ip t o h o ld l in k a g e r o d t