WARNING - CAUTIONS AND WARNINGS
WARNING: Use an OSHA approved breathing filter when spraying paint or solvents in a confined area. Personal injury can result.
Avoid prolonged skin contact with petroleum or alcohol - based cleaning solvents. Personal injury can result. Do not stand under a hoisted vehicle that is not properly supported on safety stands. Personal injury can result.
CAUTION: When holes must be drilled or punched in an inner body panel, verify depth of space to the outer body panel, electrical wiring, or other components. Damage to vehicle can result.
Do not weld exterior panels unless combustible material on the interior of vehicle is removed from the repair area. Fire or hazardous conditions, can result. Always have a fire extinguisher ready for use when welding. Disconnect the negative (-) cable clamp from the battery when servicing electrical components that are live when the ignition is OFF. Damage to electrical 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 solvents on painted or upholstered surfaces. Damage to finish or color can result. Do not hammer or pound on plastic trim panel when servicing interior trim. Plastic panels can break.
WARNING - USE OF HEAT DURING REPAIR
WARNING: Chrysler Group engineering's position on the use of heat during collision repair is as follows:
Any body panel or frame component damaged which is to be repaired and reused, must be repaired using the "cold straightening" method. No heat may be used during the straightening process. During rough straightening prior to panel replacement, damaged panels or frame components may be heated to assist in body/frame
realignment. The application of heat must be constrained to the parts which will be replaced and not allowed to affect any other components.
This "no heat" recommendation is due to the extensive use of high strength and advanced high strength steels in Chrysler Group products. High-strength materials can be substantially and negatively affected from heat input which will not be obviously known to the repairer or consumer.
Ignoring these recommendations may lead to serious compromises in the ability to protect occupants in a future collision event, reduce the engineered qualities and attributes, or decrease the durability and reliability of the vehicle.
Failure to follow these instructions may result in serious or fatal injury.
This statement supersedes any previously released information by the Chrysler Group.
WATER LEAKS
Water leaks can be caused by poor sealing, improper body component alignment, body seam porosity, missing plugs, or blocked drain holes. Centrifugal and gravitational force can cause water to drip from a location away from the actual leak point, making leak detection difficult. All body sealing points should be water tight in normal wet-driving conditions. Water flowing downward from the front of the vehicle should not enter the passenger or luggage compartment. Moving sealing surfaces will not always seal water tight under all conditions. At times, side glass or door seals will allow water to enter the passenger compartment during high pressure washing or hard driving rain (severe) conditions. Overcompensating on door or glass adjustments to stop a water leak that occurs under severe conditions can cause premature seal wear and excessive closing or latching 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 floor and body plugs are in place, body drains are clear, and body components are properly aligned and sealed. If component alignment or sealing is necessary, refer to the appropriate information in this article for proper procedures.
WATER LEAK TESTS
WARNING: Do not use electric shop lights or tools in water test area. Personal injury can result.
When the conditions causing a water leak have been determined, simulate the conditions as closely as possible.
If a leak occurs with the vehicle parked in a steady light rain, flood the leak area with an open-ended garden hose. If a leak occurs while driving at highway speeds in a steady rain, test the leak area with a reasonable velocity stream or fan spray of water. Direct the spray in a direction comparable to actual conditions. If a leak occurs when the vehicle is parked on an incline, hoist the end or side of the vehicle to simulate this condition. This method can be used when the leak occurs when the vehicle accelerates, stops or turns. If the leak occurs on acceleration, hoist the front of the vehicle. If the leak occurs when braking, hoist the back of the vehicle. If the leak occurs on left turns, hoist the left side of the vehicle. If the leak occurs on right turns, hoist the right side of the vehicle. For hoisting recommendations. Refer to STANDARD
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water test and watch for water tracks or droplets forming on the inside of the vehicle. If necessary, remove interior trim covers or panels to gain visual access to the leak area. If the hose cannot be positioned without being held, have someone help do the water test.
Some water leaks must be tested for a considerable length of time to become apparent. When a leak appears, find the highest point of the water track or drop. The highest point usually will show the point of entry. After leak point has been found, repair the leak and water test to verify that the leak has stopped.
Locating the entry point of water that is leaking into a cavity between panels can be difficult. The trapped water may splash or run from the cavity, often at a distance from the entry point. Most water leaks of this type become apparent after accelerating, stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use a suitable mirror to gain visual access. A mirror can also be used to deflect light to a limited-access area to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can be detected without water testing. Position the vehicle in a brightly lit area. From inside the darkened luggage compartment inspect around seals and body seams. If necessary, have a helper direct a drop light over the suspected leak areas around the luggage compartment. If light is visible through a normally sealed location, water could enter through the opening.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compartment cannot be detected by water testing, pressurize the passenger compartment and soap test exterior of the vehicle. To pressurize the passenger compartment, close all doors and windows, start engine, and set heater control to high blower in HEAT position. If engine can not be started, connect a charger to the battery to ensure adequate voltage to the blower. With interior pressurized, apply dish detergent solution to suspected leak area on the exterior of the vehicle. Apply detergent solution with spray device or soft bristle brush. If soap bubbles occur at a body seam, joint, seal or gasket, the leak entry point could be at that location.
WIND NOISE
Wind noise is the result of most air leaks. Air leaks can be caused by poor sealing, improper body component alignment, body seam porosity, or missing plugs in the engine compartment or door hinge pillar areas. All body sealing points should be airtight in normal driving conditions. Moving sealing surfaces will not always seal airtight under all conditions. At times, side glass or door seals will allow wind noise to be noticed in the passenger compartment during high cross winds. Over compensating on door or glass adjustments to stop wind noise that occurs under severe conditions can cause premature seal wear and excessive closing or latching effort. After a repair procedure has been performed, test vehicle to verify noise has stopped before returning vehicle to use.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and body components are aligned and sealed. If component alignment or sealing is necessary, refer to the appropriate procedure of this article for proper procedures.
ROAD TESTING WIND NOISE
1. Drive the vehicle to verify the general location of the wind noise. 2. Apply 50 mm (2 in.) masking tape in 150 mm (6 in.) lengths along weatherstrips, weld seams or moldings. After each length is applied, drive the vehicle. If noise goes away after a piece of tape is applied, remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
Moldings standing away from body surface can catch wind and whistle. Gaps in sealed areas behind overhanging body flanges can cause wind-rushing sounds. Misaligned movable components. Missing or improperly installed plugs in pillars. Weld burn through holes.
BODY LUBRICATION
All mechanisms and linkages should be lubricated when necessary. This will maintain ease of operation and provide protection against rust and excessive wear. The weatherstrip seals should be lubricated to prolong their life as well as to improve door sealing.
All applicable exterior and interior vehicle operating mechanisms should be inspected and cleaned. Pivot/sliding contact areas on the mechanisms should then be lubricated.
1. When necessary, lubricate the operating mechanisms with the specified lubricants. 2. Apply silicone lubricant to a cloth and wipe it on door seals to avoid over-spray that can soil passenger's clothing. 3. Before applying lubricant, the component should be wiped clean. After lubrication, any excess lubricant
should be removed. 4. The hood latch, latch release mechanism, latch striker, and safety latch should be lubricated periodically. 5. The door lock cylinders should be lubricated twice each year (preferably autumn and spring). Spray a small amount of lock cylinder lubricant directly into the lock cylinder. Apply a small amount to the key and insert it into the lock cylinder. Rotate it to the locked position and then back to the unlocked position several times. Remove the key. Wipe the lubricant from it with a clean cloth to avoid soiling of clothing.
Component Fluid, Lubricant, and Genuine Part Hinges: Door & Hood Mopar® Engine Oil Lift Gate Mopar® Multi-Purpose Lube NLGI Grade 2 EP, GC-LB
Latches: Hood/Safety Catch Mopar® Multi-Purpose Lube NLGI Grade 2 EP, GC-LB Seat Regulator & Track Mopar® Multi-Purpose Lube NLGI Grade 2 EP, GC-LB Lock Cylinders Mopar® Lock Cylinder Lube
BUZZ, SQUEAK & RATTLE
Buzz, Squeak & Rattles (BSR) may be caused by any one or more of the following and may be corrected as indicated:
Loose fasteners should be tightened to specifications. Damaged or missing clips should be replaced. Damaged trim panels should be replaced. Incorrectly installed trim panels should be reinstalled properly.
Many BSR complaints such as loose trim, can be serviced using the Mopar® Parts BSR Noise Reduction Kit. This kit contains various tapes including foam, flock and anti-squeak used to eliminate noises caused by metal, plastic and vinyl components. Long life lubricants and greases can also be used on a variety of components. Refer to Buzz, Squeak & Rattle Kit table for material contents and usage.
Buzz, Squeak & Rattle Kit
ITEM FEATURES APPLICATIONS SERVICE TEMP
| Itch And Squeak | An abrasion resistant material Between metal and metal, | -40° to 225° | |
| Tape | thin enough to conform to | metal and plastic, metal and | Fahrenheit |
| most irregular surfaces. Stops vinyl, vinyl and plastic. | (-40° to 107° | ||
| most itches and squeaks. | Interior. | Celsius) |
Examples: Trim panels and bezels.
Black Nylon Flock Nylon Flock with an Between metal and metal, -40° to 180°
aggressive acrylic adhesive. metal and plastic, vinyl and Fahrenheit
Provides for cushioning and plastic. (-40° to 82° Celsius)compression fit, also isolates Examples: Pull cups, bezels,
components. Water-resistant. clips, ducts, top cover to glass, cowl panel.
| High Density | Tear resistant, highly resilient Between metal and metal, | -40° to 180° | |
| Urethane Foam | and durable. | metal and plastic. Water- | Fahrenheit |
| resistant. | (-40° to 82° Celsius) |
Examples: I/P, heavy metal rattles, isolating brackets.
| Open Cell Foam | Soft foam conforms to | Wire harness and connector | -40° to 180° |
| Tape | irregular surfaces. | wrap. | Fahrenheit |
| Examples: Seals, gasket, | (-40° to 82° Celsius) |
wiring, heat ducts.
| Closed Cell Low | Soft, conformable. Water- | Wherever bulk is needed. | -40° to 180° |
| Density Foam Tape resistant. | Prevents closing flutters and | Fahrenheit | |
| rattles when applied to door | (-40° to 82° Celsius) |
watershield. Examples: Door, I/P. NYE® Grease 880 Long life. Suspensions. -40° to 390° Examples: Strut busings, sway Fahrenheit bars. (-40° to 200° Celsius)
Krytox® Oil Long life. Will not dry out or When access is not possible, -30° to 400°
harm plastics or rubber. oil will migrate to condition. FahrenheitVinyl, rubber, plastic, metal. (-34° to 205° Examples: Convertible top Celsius) bushings, pull cups trim panel inserts.
Krytox® Grease Long life. Will not dry out or Vinyl, rubber, plastic, metal, -30° to 400°
harm plastics or rubber. glass. Fahrenheit
Examples: Weather-strips, (-34° to 205°
backlite and windshield Celsius)moldings.
HEAT STAKING
1. Remove trim panel. 2. Bend or move the trim panel components at the heat staked joints. Observe the heat staked locations and/or component seams for looseness. 3. Heat stake the components. If the heat staked or component seam location is loose, hold the two components tightly together and using a soldering gun with a flat tip, melt the material securing the components together. Do not over heat the affected area, damage to the exterior of the trim panel may occur. If the heat staked material is broken or missing, use a hot glue gun to apply new material to the area to be repaired. The panels that are being heat staked must be held together while the applying the glue. Once the new material is in place, it may be necessary to use a soldering gun to melt the newly applied material. Do not over heat the affected area, damage to the exterior of the trim panel may occur.
4. Allow the repaired area to cool and verify the repair. 5. Install trim panel.
PLASTIC BODY PANEL REPAIR
There are many different types of plastics used in today's automotive environment. Chrysler groups plastics in three different categories: Rigid, Semi-Rigid, and Flexible. Any of these plastics may require the use of an adhesion promoter for repair. These types of plastic are used extensively on DaimlerChrysler Motors vehicles. Always follow repair material manufacturer's plastic identification and repair procedures.
Rigid Plastics:
Examples of rigid plastic use: Fascias, Hoods, Doors, and other Body Panels, which include SMC, ABS, and Polycarbonates.
Semi-Rigid Plastics:
Examples of semi-rigid plastic use: Interior Panels, Under Hood Panels, and other Body Trim Panels.
Flexible Plastics:
Examples of flexible plastic use: Fascias, Body Moldings, and upper and lower Fascia Covers.
Repair Procedure:
The repair procedure for all three categories of plastics is basically the same. The one difference is the material used for the repair. The materials must be specific for each substrate, rigid repair material for rigid plastic repair, semi-rigid repair material for semi-rigid plastic repair and flexible repair material for flexible plastic repair.
Adhesion Promoter/Surface Modifier:
Adhesion Promoters/Surface Modifiers are required for certain plastics. All three categories may have plastics that require the use of adhesion promoter/surface modifiers. Always follow repair material manufacturer's plastic identification and repair procedures.
SAFETY PRECAUTION AND WARNINGS
WARNING: Eye protection should be used when servicing components. Personal injury can result. Use an OSHA approved breathing mask when mixing epoxy, grinding, and spraying paint or solvents in a confined area. Personal injury can result. Avoid prolonged skin contact with resin, petroleum, or alcohol based solvents. Personal injury can result. Do not venture under a hoisted vehicle that is not properly
supported on safety stands. Personal injury can result.
NOTE: When holes must be drilled or cut in body panels, verify locations of internal body components and electrical wiring. Damage to vehicle can result. Do not use abrasive chemicals or compounds on undamaged painted surfaces around repair areas. Damage to finish can result.
PE POLYETHYLENE ALATHON, DYLAN, -
PANEL SECTIONING
1 - EXISTING PANEL 2 - NEW PANEL 3 - PANEL ADHESIVE 4 - BONDING STRIP
If it is required to section a large panel for a plastic repair, it will be necessary to reinforce the panel. To bond
two plastic panels together, a reinforcement must overlap both panels. The panels must be "V'd" at a 20 degree angle. The area to be reinforced should be washed, then sanded. Be sure to wipe off any excess soap and water when finished. Lightly sand or abrade the plastic with an abrasive pad or sandpaper. Blow off any dust with compressed air or wipe with a clean dry rag.
When bonding plastic panels, follow repair material manufacturers recommendations. Be sure that enough adhesive has been applied to allow squeeze out and to fill the full bond line. Once the pieces have been brought together, do not move them until the adhesive is cured. The assembly can be held together with clamps, rivets, etc. A faster cure can be obtained by heating with a heat lamp or heat gun. After the parts have been bonded and have had time to cure, rough sand the seam and apply the final adhesive filler to the area being repaired. Smooth the filler with a spreader, wooden tongue depressor, or squeegee. For fine texturing, a small amount of water can be applied to the filler surface while smoothing. The cured filler can be sanded as necessary and, as a final step, cleanup can be done with soapy water. Wipe the surface clean with a dry cloth allowing time for the panel to dry before moving on with the repair.
PANEL REINFORCEMENT
1 - SOFTENED EDGES 2 - PANEL ADHESIVE 3 - BONDING STRIP
Structural repair procedures for rigid panels with large cracks and holes will require a reinforcement backing. Reinforcements can be made with several applications of glass cloth saturated with structural adhesive. Semi- rigid or flexible repair materials should be used for semi-rigid or flexible backing reinforcement and open meshed fiberglass dry wall tape can be used to form a reinforcement. The dry wall tape allows the resin to penetrate through and make a good bond between the panel and the adhesive. Structurally, the more dry wall tape used, the stronger the repair.
1 - PANEL ADHESIVE 2 - REINFORCEMENT
Another kind of repair that can be done to repair large cracks and holes is to use a scrap piece of similar plastic and bond with structural adhesive. The reinforcement should cover the entire break and should have a generous amount of overlap on either side of the cracked or broken area.
When repairing plastic, the damaged area is first "V'd" out, or beveled. Large bonding areas are desirable when repairing plastic because small repairs are less likely to hold permanently. Beveling the area around a crack at a 20° angle will increase the bonding surface for a repair. It is recommended that sharp edges be avoided because the joint may show through after the panel is refinished.
Panel repair for both flexible and rigid panels are basically the same. The primary difference between flexible panel repair and rigid panel repair is in the adhesive materials used.
The technician should first decide what needs to be done when working on any type of body panel. One should determine if it is possible to return the damage part to its original strength and appearance without exceeding the value of the replacement part.
When plastic repairs are required, it is recommended that the part be left on the vehicle when ever possible. That will save time, and the panel will remain stationary during the repair. Misalignment can cause stress in the repair areas and can result in future failure.
VISUAL INSPECTION
1 - PUNCTURE
Composite materials can mask the severity of an accident. Adhesive bond lines, interior structure of the doors, and steel structures need to be inspected carefully to get a true damage assessment. Close inspection may require partial removal of interior trim or inner panels.
Identify the type of repair: Puncture or Crack - Damage that has penetrated completely through the panel. Damage is confined to one general area; a panel section is not required. However, a backer panel, open fiberglass tape, or matted material must be bonded from behind.
PANEL SURFACE PREPARATION
If a body panel has been punctured, cracked, or crushed, the damaged area must be removed from the panel to achieve a successful repair. All spider web cracks leading away from a damaged area must be stopped or removed. To stop a running crack in a panel, drill a 6 mm (0.250 in.) hole at the end of the crack farthest away from the damage. If spider web cracks can not be stopped, the panel would require replacement. The surfaces around the damaged area should be stripped of paint and freed from wax and oil. Scuff surfaces around repair area with 360 grit wet/dry sandpaper, or equivalent, to assure adhesion of repair materials.
PATCHING PANELS
1 - CUTOUT 2 - DAMAGED BODY PANEL 3 - 4 MM (0.160 IN.) HOLES 4 - PATCH CUT TO SIZE
A panel that has extensive puncture type damage can be repaired by cutting out the damaged material. Use a suitable reciprocating saw or cut off wheel to remove the section of the panel that is damaged. The piece cut out can be used as a template to shape the new patch. It is not necessary to have access to the back of the panel to install a patch. Bevel edges of cutout at 20° to expose a larger bonding area on the outer side. This will allow for an increased reinforcement areas.
PANEL PATCH FABRICATIONS
1 - STRUCTURAL ADHESIVE 2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE 3 - WIDTH OF V-GROOVE 4 - WAXED PAPER
A patch can be fabricated from any rigid fiberglass panel that has comparable contour with the repair area. Lift gates and fenders can be used to supply patch material. If existing material is not available or compatible, a patch can be constructed with adhesive and reinforcement mesh (dry wall tape). Perform the following operation if required:
1. Cover waxed paper or plastic with adhesive backed nylon mesh (dry wall tape) larger than the patch required. 2. Tape waxed paper or plastic sheet with mesh to a surface that has a compatible contour to the repair area. 3. Apply a liberal coat of adhesive over the reinforcement mesh. If necessary apply a second or third coat of adhesive and mesh after first coat has cured. The thickness of the patch should be the same as the repair area. 4. After patch has cured, peel waxed paper or plastic from the back of the patch. 5. If desired, a thin film coat of adhesive can be applied to the back of the patch to cover mesh for added
strength.
PANEL PATCH INSTALLATION
1 - SUPPORT SQUARES 2 - SCREWS 3 - DAMAGED BODY PANEL
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 sustain the patch in the cutout. 5. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in from edge of cutout hole. 6. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) away from edge of patch across from holes drilled around cutout.
7. Drill 3 mm (0.125 in.) holes in the support squares 13 mm (0.5 in.) from the edge in the center of one side. 8. Scuff the backside of the body panel around the cutout hole with a scuff pad or sandpaper. 9. Mix enough adhesive to cover one side of all support squares. 10. Apply adhesive to cover one side of all support squares. 11. Using number 8 sheet metal screws, secure support squares to back side of body panel with adhesive sandwiched between the panel and squares.
1 - CUTOUT 2 - SUPPORT SQUARES
12. Position patch in cutout against support squares and adjust patch until the gap is equal along all sides. 13. Drill 3 mm (0.125 in.) holes in the support squares through the pre-drilled holes in the patch.
1 - APPLICATOR 2 - SUPPORT SQUARES 3 - ADHESIVE
14. Apply a coat of adhesive to the exposed ends of the support squares.
1 - PATCH 2 - GAP
15. Install screws to hold the patch to support squares. Tighten screws until patch surface is flush with panel surface. 16. Allow adhesive to cure, and remove all screws.
1 - PATCH 2 - GAP 3 - DISC GRINDER
17. Using a 125 mm (5 in.) 24 grit disc grinder, grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2 mm (0.080 in.) deep path across the gaps around the patch. With compressed air, blow dust from around patch.
1 - GROUND DOWN AREA 2 - PATCH 3 - MESH
18. Apply adhesive backed nylon mesh (dry wall tape) over gaps around patch. 19. Mix enough adhesive to cover the entire patch area.
1 - ADHESIVE 2 - MESH 3 - PATCH 4 - SPREADER
20. Apply adhesive over the mesh around patch, and smooth epoxy with a wide spreader to reduce finish grinding. Use two to three layers of mesh and adhesive to create a stronger repair.
PATCHED PANEL SURFACING
After patch panel is installed, the patch area can be finished using the same methods as finishing other types of body panels. If mesh material is exposed in the patched area, grind surface down, and apply a coat of high quality rigid plastic body filler. Prime, block sand, and paint as required.
SPECIFICATIONS - TORQUE
| DESCRIPTION | N.m | Ft. Lbs. | In. Lbs. |
| Close out panel bolts | 2.5 | - | 22 |
| Fender bolts | 9 | - | 80 |
| Front door carrier plate bolts | 5.5 | - | 50 |
| Front door exterior handle nuts | 4.5 | - | 40 |
| Front door hinge to A-pillar bolts | 26 | 19 | - |
| Front door hinge to door nuts | 36.5 | 27 | - |
| Front door latch adjustment screw | 4.5 | - | 40 |
| Front door latch bracket screw to door shut face | 7 | - | 60 |
| Front door latch screw to door shut face | 7 | - | 60 |
| Front door latch striker bolts | 26 | 19 | - |
| Front door module screws | 1.5 | - | 13 |
| Front door speaker screws | 1.5 | - | 13 |
| Front door window motor screws | 3.5 | - | 31 |
| Front seat back recliner bolts | 47.5 | 35 | - |
| Front seat belt bolt | 47.5 | 35 | - |
| Front seat bolts/nuts riser to floor | 62 | 46 | - |
| Front seat nuts riser to frame | 27.5 | 20 | - |
| Front seat riser nuts to seat frame (Domestic) | 47.5 | 35 | - |
| Front seat riser nuts to seat frame (Export) | 28 | 21 | - |
| Grille opening reinforcement | 10 | - | 85 |
| Hood hinge to body bolts | 20 | 15 | - |
| Hood hinge to hood nuts | 20 | 15 | - |
| Hood latch bolts | 13.5 | 10 | - |
| Hood latch support bolts | 8.5 | - | 75 |
| Hood release handle bolts | 4 | 3 | - |
| Instrument panel center support bracket bolts | 28 | 20.5 | - |
| Instrument panel HVAC nuts/bolts | 6 | - | 55 |
| Instrument panel lower bolts | 30.5 | 22.5 | - |
| Instrument panel lower nuts | 6 | - | 55 |
| Instrument panel upper bolts | 28 | 20.5 | - |
| Lift gate exterior handle | 8 | 6 | - |
| Lift gate hinge to body bolts | 28.5 | 21 | - |
| Lift gate hinge to body nuts | 28.5 | 21 | - |
| Lift gate hinge to lift gate bolts | 28.5 | 21 | - |
| Lift gate striker screws | 28 | 20.5 | - |
| Load floor nuts | 28 | 20.5 | - |
| Outside mirror nuts | 7 | - | 65 |
| Radiator crossmember bolts | 10 | - | 85 |
| Rear door carrier plate bolts | 5.5 | - | 50 |
| Rear door hinge to B-pillar bolts | 26 | 19 | - |
| Rear door hinge to door nuts | 36.5 | 27 | - |
| Rear door latch adjustment screw | 4.5 | - | 40 |
| Rear door latch bracket screw to door shut face | 7 | - | 60 |
| Rear door latch screw to door shut face | 7 | - | 60 |
| Rear door latch striker bolts | 26 | 19 | - |
| Rear door exterior handle nuts | 4.5 | - | 40 |
| Rear door speaker screws | 1.5 | - | 13 |
| Rear door window motor screws | 3.5 | - | 31 |
| Rear fascia support bolts | 7 | 5 | - |
| Rear seat belt anchor nut | 62 | 46 | - |
| Rear seat belt bolt | 44.5 | 33 | - |
| Rear seat 40 pivot bolt | 27.5 | 20 | - |
| Rear seat 40 power inverter screw | 3 | - | 26.5 |
| Rear seat 40 release lever | 7 | - | 62 |
| Rear seat 40 seat bolt | 27.5 | 20 | - |
| Rear seat 40 seat screw | 10 | - | 88.5 |
| Rear seat 40 shield screw | 3 | - | 26.5 |
| Rear seat 40 bracket bolts | 47.5 | 35 | - |
| Rear seat 60 bracket bolts | 47.5 | 35 | - |
| Rear seat hinge bolts | 47.5 | 35 | - |
| Rear seat recliner bolt | 7 | - | 62 |
| Rear seat riser bolts | 10 | - | 88.5 |
| Rear seat trim screws | 3 | - | 26.5 |
| Rear seat 60 belt attachment to seat back | 47.5 | 35 | - |
| Rear seat mounting bolts | 54 | 40 | - |
| Rear seat mounting nuts | 62 | 46 | - |
| Rear seat 60 release lever | 7 | - | 62 |
| Rear seat 60 seat bolt restraint | 55 | 40.5 | - |
| Rear seat 60 seat screw | 8 | - | 71 |
| Rear seat 60 seat screw | 10 | - | 88.5 |
| Rear seat 60 shield screw | 3 | - | 26.5 |
| Rear seat riser to seat frame bolts | 10 | 7 | - |
| Rear view mirror setscrew | 1 | - | 15 |
| Roof luggage rack bolts | 6.2 | - | 55 |
| Running boards bolts | - | - | - |
| Running boards nuts | 25 | 18.5 | - |
| Side step nuts/bolts | 23 | 17 | - |
Side view mirror nuts
| 7 | - | 65 | |
| Sunroof mounting bolts | 9 | - | 80 |
| Washer bottle bolt | 10 | - | 85 |
Special tools
CARRIER PLATE
SYMPTOM POSSIBLE CAUSES CORRECTION
Roof Completely Inoperative Inoperative control switch Perform sunroof switch diagnostics
Inoperative circuit between Check the condition of the circuit
FORR motor/ECU, control protection and inspect all wiring. Repair
switch, and body harness. as necessary.
Inoperative FORR Replace as necessary Motor/ECUmotor/ECU
Audible Whine When Switch Is Inoperative drive motor gear Replace drive motor
Depressed, Roof Does Not Re-initialize ECU:
Operate Refer to STANDARD PROCEDURE .
Broken or worn drive cable Replace cables left & right handSee REMOVAL. Re-initialize ECU: Refer to STANDARD PROCEDURE . Left & right hand cables need to be timed See REMOVAL. Cables out of calibration Re-initialize ECU: Refer to STANDARD PROCEDURE . Replace cable retainer clip
Cable retainer clip worn or See REMOVAL. Audible Clicking Or Ratcheting broken Re-initialize ECU: When Switch Is Pressed, FORR Refer to STANDARD PROCEDURE . Does Not Operate. Replace cables left & right hand
See REMOVAL. Broken or worn drive cable Re-initialize ECU: Refer to STANDARD PROCEDURE . Replace drive motor Inoperative drive motor gear Re-initialize ECU: Refer to STANDARD PROCEDURE . Remove debris from track, check cables for wear replace if necessary and reset timing. Debris in drive track See REMOVAL. Re-initialize ECU:
Front Header Bow Misaligned Refer to STANDARD PROCEDURE . To Frame Replace Drive Cables
See REMOVAL. Broken or worn drive cable Re-initialize ECU: Refer to STANDARD PROCEDURE .
Left & right hand cables need to be timed
See REMOVAL. Cables out of time Re-initialize ECU: Refer to STANDARD PROCEDURE . Replace the front drive assembly. See REMOVAL. Broken cap extension Re-initialize ECU: Refer to STANDARD PROCEDURE . Remove Debris from Track, check cables for wear replace if necessary and reset Timing. Debris in drive track See REMOVAL. Re-initialize ECU: Refer to STANDARD PROCEDURE . Replace cables left & right hand See REMOVAL. Broken or worn drive cable
Rear Header Bow Misaligned Re-initialize ECU: To Frame Refer to STANDARD PROCEDURE .
Left & right hand cables need to be timed See REMOVAL. Cables out of time Re-initialize ECU: Refer to STANDARD PROCEDURE . Replace the rear drive assembly. See REMOVAL. Broken cap extension Re-initialize ECU: Refer to STANDARD PROCEDURE . Repair or replace spring if necessary Spring disengaged from lift See REMOVAL. arm Re-initialize ECU: Refer to STANDARD PROCEDURE . Repair or replace nylon pin if necessary See REMOVAL. Pin disengaged or broken Front Lift Arm Not Lifting Re-initialize ECU: Refer to STANDARD PROCEDURE . Repair or replace front lift arm assembly if necessary Lift arm disengaged from cap See REMOVAL. extension or broken Re-initialize ECU: Refer to STANDARD PROCEDURE . Repair or replace spring if necessary See REMOVAL. Spring disengaged Re-initialize ECU: Floating Bows Not Lifting Refer to STANDARD PROCEDURE . Replace lift arm assembly if necessary Broken lift arm assembly See REMOVAL. Re-initialize ECU:
Refer to STANDARD PROCEDURE . Attach tension cable to front header
Tension cable not attach at See REMOVAL.
front header Re-initialize ECU:Refer to STANDARD PROCEDURE . Attach tension cable to rear header
Top Cover Loose In Side View Tension cable not attach at See REMOVAL. To Seal rear header Re-initialize ECU:
Refer to STANDARD PROCEDURE . Replace tension cable See REMOVAL. Tension cable broken Re-initialize ECU: Refer to STANDARD PROCEDURE . Clean track Debris in track Re-initialize ECU: Top Stops Moving Prior To Refer to STANDARD PROCEDURE . Full Close, Or Full Open
ECU lost normed "home" Re-initialize ECU:
position Refer to STANDARD PROCEDURE .Clean track Slider Chatter Debris in track Re-initialize ECU: Refer to STANDARD PROCEDURE .
PROCEDURE.
12. Position the rear of the cover down over the rear drive (1) and seat fully. 13. Install the five screws (2). 14. Line up the headliner (3) center notch with the center screw (2) and seat the headliner hook and loop strip (3) fully. 15. Position the front of the cover down over the front drive assembly and seat fully. 16. Install the five screws (2), and seat the headliner hook and loop strip (3) fully. 17. Re-initialize ECU, see STANDARD PROCEDURE.
DRIVE ASSEMBLY
PROCEDURE.
4. Remove the three screws (2) and separate the front motor (3) from the roof system.
NOTE: Discard the screws (2) and replace with service screws and washers.
5. Disconnect the electrical connector (1) and remove the motor.
6. Manually position the front bow and drive assembly (1) back about 300 mm (12 inches).
CAUTION: When moving the drive assemblies without the motors attached make sure that the assemblies are moved straight back.
7. Separate the headliner hook and loop strip (3) and expose the drive mechanism. 8. Remove the five screws (2) and separate the cover assembly from the drive (1).
9. Remove the wind deflector, see REMOVAL. 10. Remove the couplers (1).
11. Remove the front cam plates (2), see REMOVAL.
12. Move the front drive forward to gain access to the nylon pin (2). 13. Carefully remove the two nylon pins (2) and separate the cover assembly (1) from the drive assembly cap (3). 14. Remove the nylon push pins (2).
15. Disconnect the drive link (4) and remove the drive assembly (1). 16. Pull cables out slightly.
PROCEDURE.
17. Install the couplers (1). 18. Install the wind deflector, see INSTALLATION.
19. Position the front of the cover down over the front drive assembly and seat fully. 20. Install the five screws (2), and seat the headliner hook and loop strip (3) fully. 21. Connect the large ECU electrical connector. 22. Install the headliner, see INSTALLATION. 23. Re-initialize ECU, see STANDARD PROCEDURE.
DRIVE ASSEMBLY
PROCEDURE.
14. Position the rear of the cover down over the rear drive (1) and seat fully. 15. Install the five screws (2). 16. Line up the headliner (3) center notch with the center screw (2) and seat the headliner hook and loop strip (3) fully. 17. Install the front drive assembly, see INSTALLATION.
HEADLINER
PROCEDURE.
4. Separate the headliner hook and loop strip (3) and expose the drive mechanism. 5. Remove the five screws (2) and separate the cover assembly from the drive (1).
6. Remove the three screws (2) and separate the front motor (3) from the roof system.
NOTE: Discard the screws (2) and replace with service screws and washers.
7. Disconnect the electrical connector (1) and remove the motor. 8. Manually position the front bow and drive assembly (1) forward fully.
CAUTION: When moving the drive assemblies without the motors attached make sure that the assemblies are moved straight back.
9. Manually position the rear drive assembly about 300 mm (12 inches) open, see STANDARD
PROCEDURE.
10. Separate the headliner hook and loop strip (3) and expose the drive mechanism. 11. Remove the five screws (2) and separate the cover assembly from the drive (1).
12. Remove the three screws (2) and separate the rear motor (3) from the roof system.
NOTE: Discard the screws (2) and replace with service screws and washers.
13. Disconnect the electrical connector (1) and remove the motor. 14. Manually position the rear bow and drive assembly (1) rearward fully.
CAUTION: When moving the drive assemblies without the motors attached make sure that the assemblies are moved straight back.
15. Remove the rivets (3) and remove the motor mounting plates.
16. Using a magnet (3) draw out the remaining rivet pieces through the cable guide openings (1) in the rail (2).
PROCEDURE.
9. Position the rear of the cover down over the rear drive (1) and seat fully. 10. Install the five screws (2). 11. Line up the headliner (3) center notch with the center screw (2) and seat the headliner hook and loop strip (3) fully.
CAUTION: When moving the drive assemblies without the motors attached make sure that the assemblies are moved straight back.
12. Manually push the front drive assembly (1) fully forward. 13. Using a small screwdriver or equivalent, make sure the cable ends (3) are in contact with the frame (2).
14. Position the front drive motor (1) up onto the motor mounting plate.
CAUTION: Do not install the motor using any twisting motion. Always install the motor straight and use the screws to draw the drive gear into the drive cables.
NOTE: When ever the motors are removed, the screws (2) need to be discarded and replaced with new service screws and washers.
15. Install the motor screws (2) and draw the motor evenly using the motor screws. 16. Connect the electrical connector.
17. Manually position the front and rear drive assemblies about 300 mm (12 inches) open, see STANDARD
PROCEDURE.
18. Position the front of the cover down over the front drive assembly and seat fully. 19. Install the five screws (2), and seat the headliner hook and loop strip (3) fully. 20. Connect the large ECU electrical connector. 21. Install the headliner, see INSTALLATION. 22. Re-initialize ECU, see STANDARD PROCEDURE.
SLIDER ASSEMBLY
RESTRAINT SYSTEM
WARNING: To avoid personal injury or death, during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or inoperative buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or faulty seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar® parts catalog.
WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or
service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
WARNING: To avoid personal injury or death on vehicles equipped with airbags, before performing any welding operations disconnect and isolate the battery negative (ground) cable and disconnect all wire harness connectors from the airbag control module (ACM). Failure to take the proper precautions could result in accidental airbag deployment and other possible damage to the supplemental restraint system circuits and components.
WARNING: To avoid personal injury or death, do not attempt to dismantle an airbag unit or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). An airbag inflator unit may contain sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. An airbag inflator unit may also contain a gas canister pressurized to over 2500 psi.
WARNING: To avoid personal injury or death, when handling a seat belt tensioner retractor, proper care should be exercised to keep fingers out from under the retractor cover and away from the seat belt webbing where it exits from the retractor cover.
WARNING: To avoid personal injury or death, replace all restraint system components only with parts specified in the DaimlerChrysler Mopar® parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection.
WARNING: To avoid personal injury or death, the fasteners, screws, and bolts originally used for the restraint system components must never be replaced with any substitutes. These fasteners have special coatings and are specifically designed for the restraint system. Any time a new fastener is needed, replace it with the correct fasteners provided in the service package or specified in the DaimlerChrysler Mopar® parts catalog.
WARNING: To avoid personal injury or death, when a steering column has an airbag unit attached, never place the column on the floor or any other surface with the steering wheel or airbag unit face down.
BEZEL - CLUSTER
WARNING.
NOTE: Position the steering column to the lowest position to ease in the removal of the cluster bezel.
2. Using a trim stick C-4755 or equivalent, remove the cluster bezel from the instrument panel assembly.
WARNING.
2. Position and install the cluster bezel to the instrument panel, use hand pressure to seat the bezel clips.
BEZEL - INSTRUMENT PANEL CENTER
WARNING.
2. Set the park brake and move the transmission gear selector into the most rearward position. 3. Using a trim stick C-4755 or equivalent and starting at the top of the center bezel, pry the bezel away from the instrument panel far enough to disengage the snap clip retainers that secure it to the instrument panel. 4. Reach behind the bezel to access and disconnect all electrical connections. 5. Remove the center bezel from the instrument panel. 6. Remove all heating and air conditioning vents, control units and power outlets from the center bezel.
WARNING.
2. Install all heating and air conditioning vents, control units, power outlets to the center bezel. 3. Connect the electrical connectors. 4. Position the center bezel and seat the retaining clips starting with the lower clips first using hand pressure. 5. Place the transmission into park.
BEZEL - HVAC
WARNING.
2. Position the steering column into the highest position to ease in the removal of the steering column cover. Reach into the steering column opening at the top of the steering column cover and pull the top rearward to disengage cover blocker clips. 3. Gently swing the cover open. 4. While the cover is in a full down position, slide the cover to the left or outboard of the driver side, this will allow the claws of the cover to disengage from the trim panel hinges, and then pull the cover rearward to remove the steering column cover.
WARNING.
2. Align steering column cover's claws to instrument panel tabs. When claws are aligned with tabs, slide the cover to the right or inboard of the driver side to engage the claws over the instrument panels hinges. 3. Gently swing the steering column cover upward until the clips touch the corresponding slots in the instrument panel and use hand pressure to engage the clips.
END CAP - INSTRUMENT PANEL
WARNING.
2. Using a trim stick C-4755 or equivalent, remove the end cap bezel from the instrument panel assembly.
WARNING.
2. Position the end cap and seat the retaining clips using hand pressure.
GLOVE BOX - INSTRUMENT PANEL
WARNING.
2. Open the glove box. 3. Squeeze the stop tabs located on the sides of the box while and swing the glove box door open. 4. With box in the full down position slide the box to the right off of the hinges and remove.
WARNING.
2. Position the box on and slide the box to the left to engage the hinges. 3. Close the glove box.
GRILLE-DEFROSTER
WARNING.
2. Remove the glove box, see REMOVAL. 3. Remove the three screws and remove the glove box latch.
WARNING.
2. Position the latch to the glove box. 3. Install the three screws. 4. Install the glove box, see INSTALLATION.
PANEL - INSTRUMENT
WARNING.
2. Loosen the battery terminal nut and use a battery terminal removal tool (2) to disconnect the negative battery cable from the battery (1).
3. Remove the right and left A-pillar trim moldings using a small pry tool or equivalent, lift the A-pillar trim molding (3) from the A-pillar slots (2) releasing the clips on the molding.
4. Remove the fasteners and close out panels from the lower I/P.
5. Remove the floor console, see REMOVAL.
6. Remove the nuts and the instrument panel support bracket.
7. Reach into the steering column opening at the top of the knee blocker and pull the top rearward to disengage upper knee blocker clips. 8. Gently swing the knee blocker open. 9. While the cover is in a full down position, slide the cover to the left or outboard of the driver side, this will allow the claws of the cover to disengage from the trim panel hinges, and then pull the cover rearward to remove the steering column cover.
10. Remove the right and left cowl side panels, see REMOVAL.
11. Remove bolts (1) and the nuts (2) from the lower instrument panel mounts.
NOTE: Using a grease pencil or equivalent, mark the position of the steering wheel.
12. Remove the steering column from the vehicle, refer to REMOVAL .
CAUTION: Carefully disengage the retaining clips on the defroster grille. Make sure the tool does not scratch the instrument panel assembly while removing.
13. Using a trim stick C-4755 or equivalent, release the rearward edge clips, and secondly once the rearward
edge clips are released. Move in an upward and rearward direction to release the front edge clips of the instrument panel top cover. 14. Remove the defroster grille from the instrument panel.
15. Remove the bolts (2) attaching the instrument panel (1) to the body (3).
16. Disconnect the electrical connector at the inner side of the pedal support bracket. 17. Remove the two bolts at the front of the pedal support bracket. 18. Remove the two bolts from the bottom side of the pedal support bracket.
19. Remove the instrument panel center bezel. 20. Disconnect the following electrical connections: Control Head Lighter Switch Bank 21. Remove the fasteners from the center instrument panel attachment.
22. Remove the glove box, see REMOVAL. 23. Remove the fastener from the upper instrument panel attachment.
24. Remove the fastener from the lower instrument panel attachment.
25. Disconnect the two 40 way electrical connectors (1) and the Nag1 connector for the transmission if equipped. 26. Remove the electrical connections on the instrument panel harness. 27. Remove the instrument panel from the vehicle compartment.
+4 more figures in this topic
WARNING.
20. Align steering column cover's claws to instrument panel tabs. When claws are aligned with tabs, slide the cover to the right or inboard of the driver side to engage the claws over the instrument panels hinges. 21. Gently swing the steering column cover upward until the clips touch the corresponding slots in the instrument panel and use hand pressure to engage the clips.
22. Install the instrument panel support bracket and nuts and tighten to 28 N.m (20.5 ft. lbs.).
23. Install the floor console, see INSTALLATION.
24. Install the close out panels and the bolts to the lower I/P and tighten to 2.5 N.m (22 in. lbs.).
25. Align the right and left A-pillar trim tabs on the moldings (3) to the top cover slot of the instrument panel (1). 26. Align the two clips on the molding to the slots (2) on the A-pillar. Snap the A-pillar trim molding (3) into place using hand pressure. 27. Connect the negative battery cable to the battery.
STRIKER - GLOVE BOX DOOR LATCH
WARNING.
2. Open the glove box. 3. Remove the two striker screws and remove the latch striker.
WARNING.
2. Install the striker and install the two screws. 3. Loosen the screws to adjust if necessary.
BASE - FLOOR CONSOLE
SPECIFICATIONS - COLOR CODES
NOTE: Because of late model changes to the available paint colors. Refer to
EXTERIOR COLOR DAIMLERCHRYSLER CODE
Inferno Red Crystal Pearlcoat ARH
Light Graystone Pearlcoat EDA
Modern Blue Pearlcoat EBL
Bright Silver Metallic Clearcoat WS2
Brilliant Black Crystal Pearlcoat AXR
Stone White Clearcoat SW1
Red Rock Crystal Pearlcoat EEM
Jeep Green Metallic Clearcoat EGJINTERIOR COLOR DAIMLERCHRYSLER CODE
Slate Gray/Pastel Slate Gray DA
Dark Pebble Beige/Pastel Pebble Beige KAPAINT CODE
PAINT CODE
Exterior vehicle body colors are identified on the Vehicle Certification Label. Refer to DESCRIPTION . The first digit of the paint code listed on the vehicle indicates the sequence of application, i.e.: P = primary coat, Q = secondary coat. The color names provided in the Paint and Trim Code Description chart are the color names used on most repair product containers. . See SPECIFICATIONS.
BASE COAT/CLEAR COAT FINISH
RESTRAINT SYSTEM
WARNING: To avoid serious or fatal injury on vehicles equipped with the Supplemental Restraint System (SRS), never attempt to repair the electrically conductive circuits or wiring components related to the SRS. Such repairs can compromise the conductivity and current carrying capacity of those critical electrical circuits, which may cause SRS components not to deploy when required, or to deploy when not required. Any wire harness containing broken, cut, burned or otherwise damaged electrically conductive SRS wiring, terminals or connector components must be removed and replaced with an entire new wire harness. Only minor cuts or abrasions of wire and terminal insulation where the conductive material has not been damaged, or connector insulators where the integrity of the latching and locking mechanisms have not been compromised may be repaired using appropriate methods.
WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar® Parts Catalog.
WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side curtain airbags in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side curtain airbags will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment.
WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, Occupant Classification System (OCS), seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment.
WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, before performing any welding operations disconnect and isolate the battery negative (ground) cable and disconnect all wire harness connectors from the Occupant Restraint Controller (ORC). Failure to take the proper precautions could result in accidental airbag deployment and other possible damage to the Supplemental Restraint System (SRS) circuits and components.
WARNING: To avoid serious or fatal injury, do not attempt to dismantle an airbag unit or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). An airbag inflator unit may contain sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. An airbag inflator unit may also contain a gas canister pressurized to over 17.24 kPa (2500 psi).
WARNING: To avoid serious or fatal injury when handling a seat belt tensioner retractor, proper care should be exercised to keep fingers out from under the retractor cover and away from the seat belt webbing where it exits from the retractor cover.
WARNING: To avoid serious or fatal injury, replace all Supplemental Restraint System (SRS) components only with parts specified in the DaimlerChrysler Mopar® Parts Catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection.
WARNING: To avoid serious or fatal injury, the fasteners, screws, and bolts originally used for the Supplemental Restraint System (SRS) components must never be replaced with any substitutes. These fasteners have special coatings and are specifically designed for the SRS. Any time a new fastener is needed, replace it with the correct fasteners provided in the service package or specified in the DaimlerChrysler Mopar® Parts Catalog.
WARNING: To avoid serious or fatal injury when a steering column has an airbag unit attached, never place the column on the floor or any other surface with the steering wheel or airbag unit face down.
BUTTON
7 - CUSHION, SEAT 26 - RIVET 8 - PRETENSIONER, ASSEMBLY 27 - WIRE, SHIELD ATTACHMENT 9 - SHIELD, ASSEMBLY 28 - HARNESS, ASSEMBLY 10 - SCREW 29 - RISER, LH OUTBOARD
11 - SHIELD 30 - NUT 27.5 N.m (20 ft. lbs.) 12 - FRAME, SEAT 31 - RISER, LH INBOARD 13 - SCREW, M10 47.5 N.m (35 ft. lbs.) 32 - COVER, SEAT 14 - FRAME, SEAT BACK 33 - ELEMENT, HEATED SEAT 15 - PLATE, ROUTING 34 - ELEMENT, HEATED SEAT BACK 16 - PIN, PUSH 35 - COVER, SEAT BACK 17 - SCREW 36 - COVER, HEAD REST 18 - SHIELD 37 - SENSOR, SEAT TRACK POSITION 19 - SCREW, M10 47.5 N.m (35 ft. lbs.) -
1 - BAG, BSR 22 - PLATE, ROUTING 2 - CUSHION, BACK 23 - SCREW 3 - HEADREST, GUIDE WITHOUT BUTTON 24 - RIVET 4 - HEADREST, ASSEMBLY 25 - SHIELD 5 - HEADREST, GUIDE WITH LOCK 26 - SCREW 6 - BOLT, SEAT BELT 47.5 N.m (35 ft. lbs.) 27 - SHIELD 7 - CUSHION, SEAT 28 - SCREW 8 - PRETENSIONER, ASSEMBLY 29 - SHIELD, CLOSEOUT 9 - SHIELD, ASSEMBLY 30 - SHIELD, POWER SWITCH 10 - FRAME, SEAT 31 - SHIELD, POWER SEAT
11 - SCREW, M10 47.5 N.m (35 ft. lbs.) 32 - WIRE, SHIELD ATTACHMENT 12 - SHIELD 33 - HARNESS, 6 WAY POWER 13 - SCREW 34- RISER, LH OUTBOARD 14 - RISER, LH INBOARD 35 - NUT 27.5 N.m (20 ft. lbs.) 15 - SCREW 36 - COVER, SEAT 16 - FRAME, SEAT BACK 37 - ELEMENT, HEATED SEAT BACK 17 - PIN, PUSH 38 - ELEMENT, HEATED SEAT 18 - SHIELD 39 - COVER, SEAT BACK 19 - SHIELD 40 - COVER, HEAD REST 20 - RECLINER, HANDLE ASSEMBLY 41 - SENSOR, SEAT TRACK POSITION 21 - SCREW, M10 47.5 N.m (35 ft. lbs.) -
1 - BAG, BSR 26 - BOLT, SEAT BELT 2 - HEADREST, GUIDE WITHOUT BUTTON 27 - SCREW 3 - HEADREST, ASSEMBLY 28 - CABLE, RELEASE 4 - HEADREST, GUIDE WITH LOCK 29 - FRAME, SEAT 5 - SHIELD, CLOSEOUT 30 - SENSOR, SEAT TRACK POSITION 6 - SCREW 31 - HARNESS, ASSEMBLY 7 - SHIELD, ASSEMBLY 32 - GAGE, STRAIN TI 8 - SCREW 33 - NUT 27.5 N.m (20 ft. lbs.)
9 - RIVET 34 - RISER 10 - WIRE, SHIELD ATTACHMENT 35 - RIVET 11 - SCREW 36 - NUT 47.5 N.m (35 ft. lbs.) 12 - SHIELD 37 - RISER 13 - SHIELD 38 - SCREW 14 - RECLINER, HANDLE ASSEMBLY 39 - BRACKET, METAL MODULE 15 - SCREW, M10 47.5 N.m (35 ft. lbs.) 40 - MODULE, OCS 16 - FRAME, SEAT BACK 41 - NUT 27.5 N.m (20 ft. lbs.) 17 - PLATE, ROUTING 42 - MODULE, ASSEMBLY HEATED 18 - SCREW 43 - CUSHION, SEAT 19 - PANEL, BACK ASSEMBLY 44 - CUSHION, BACK 20 - SHIELD 45 - ELEMENT, HEATED BACK 21 - SHIELD 46 - ELEMENT, HEATED SEAT 22 - SCREW, M10 47.5 N.m (35 ft. lbs.) 47 - COVER, SEAT 23 - SHIELD, ASSEMBLY 48 - COVER, SEAT BACK 24 - SHIELD, SIDE 49 - COVER, HEAD REST 25 - PRETENSIONER, ASSEMBLY -
1 - BAG, BSR 21 - SCREW, M10 47.5 N.m (35 ft. lbs.) 2 - HEADREST, GUIDE WITHOUT BUTTON 22 - SHIELD, ASSEMBLY
3 - HEADREST, ASSEMBLY 23 - SHIELD, ASSEMBLY 4 - SHIELD, CLOSEOUT 24 - PRETENSIONER, ASSEMBLY 5 - HEADREST, GUIDE WITH LOCK 25 - BOLT, SEAT BELT 47.5 N.m (35 ft. lbs.) 6 - SHIELD, ASSEMBLY 26 - SCREW 7 - RECLINER, HANDLE ASSEMBLY 27 - CABLE, RELEASE 8 - SCREW 28 - FRAME, SEAT 9 - RIVET 29 - HARNESS, ASSEMBLY 10 - WIRE, SHIELD ATTACHMENT 30 - RISER 11 - SCREW 31 - NUT 27.5 N.m (20 ft. lbs.) 12 - SHIELD 32 - RISER 13 - SCREW, M10 47.5 N.m (35 ft. lbs.) 33 - MODULE, ASSEMBLY HEATED 14 - SHIELD 34 - CUSHION, SEAT 15 - FRAME, SEAT BACK 35 - CUSHION, BACK 16 - PLATE, ROUTING 36 - ELEMENT, HEATED BACK 17 - SCREW 37 - ELEMENT, HEATED SEAT 18 - PANEL, BACK ASSEMBLY 38 - COVER, SEAT 19 - SHIELD 39 - COVER, SEAT BACK 20 - SHIELD 40 - COVER, HEAD REST
GLASS - QUARTER WINDOW
1. Remove the quarter trim panel as necessary to gain access to the glass seal from the inside, see
Removal
2
Cut urethane bonding from around quarter glass (1) using a suitable sharp cold knife. A pneumatic cutting
device can be used if available.
3
Remove glass from vehicle.
GLASS - QUARTER WINDOW
CAUTION: Open a window before installing glass. This will avoid pressurizing the passenger compartment. If a door or swing gate flip-up glass is slammed before urethane is cured, water leaks can result.
The quarter glass fence should be cleaned of old urethane bonding material. Support spacers should be cleaned and properly installed onto the quarter glass.
1. Clean inside of glass with Mopar® Glass Cleaner and lint-free cloth. 2. Apply PVC (vinyl) primer 25 mm (1 in.) wide around edge of glass. Wipe with clean/dry lint-free cloth. 3. Apply fence primer around edge of fence. Allow at least eighteen minutes drying time. 4. Apply a 10 mm (0.4 in.) bead of urethane around window vinyl border location. 5. Install the adhesive backed spacers (2) to the upper part of the quarter glass (1). 6. Install the spacers (3) to the lower part of the quarter glass (1). 7. Position quarter glass (1) into window opening and lock clips into place. 8. Install the quarter trim panel if removed, see REMOVAL. 9. After urethane has cured, water test quarter glass to verify repair.
WINDSHIELD SAFETY PRECAUTIONS
WARNING: Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the windshield may not perform properly in an accident.
Urethane adhesives are applied as a system. Use glass cleaner, glass prep solvent, glass primer, PVC (vinyl) primer and pinch weld (fence) primer provided by the adhesive manufacturer. If not, structural integrity could be compromised. DaimlerChrysler does not recommend glass adhesive by brand. Technicians should review product labels and technical data sheets, and use only adhesives that their manufacturers warrant will restore a vehicle to the requirements of FMVSS 212. Technicians should also insure that primers and cleaners are compatible with the particular adhesive used. Be sure to refer to the urethane manufacturer's directions for curing time specifications, and do not use adhesive after its expiration date. Vapors that are emitted from the urethane adhesive or primer could cause personal injury. Use them in a well-ventilated area. Skin contact with urethane adhesive should be avoided. Personal injury may result. Always wear eye and hand protection when 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 when removing moldings or cutting urethane around windshield.
WARNING.
2. Remove inside rear view mirror, see REMOVAL. 3. Remove the wiper arms, refer to REMOVAL .
4. Remove the hood seal (3). 5. Use a trim stick C-4755 or equivalent, separate the cover assembly from the a-pillar. 6. Remove the four push pins (2) and remove the cowl grille (1) from the body (4).
7. Using a trim stick C-4755 or equivalent, remove the push pin (1). 8. Remove the windshield A-pillar molding (2) and clips (3) from the windshield A-pillar.
9. Cut urethane bonding from around windshield using a suitable sharp cold knife. A pneumatic cutting device can be used if available. 10. Remove windshield from vehicle.
- OPEN CLOSE VENT
Push and hold switch until Push and hold switch until glass stops in flush closed glass stops in flush closed position, the glass will then FULL express open position. No action
TESTING (POWER FULL OPEN RETRACTABLE ROOF - SERVICE INFORMATION). Refer to
DIAGNOSIS AND TESTING (POWER TOP - SUNROOF - SERVICE INFORMATION). Also refer to SYSTEM WIRING DIAGRAMS for circuit, splice and component descriptions.
Before beginning diagnosis for wind noise or water leaks, verify that the sunroof is in a fully closed position. A common problem is the sunroof is left in an open position, this can be caused by releasing the control switch before the sunroof was fully closed. The sunroof module is equipped with a water-management system. If however, the sunroof glass is in a partial closed position, high pressure water may be forced beyond the water management system boundaries and onto the headlining.
SYMPTOM POSSIBLE CAUSE
Sunroof water leak. Drain tubes clogged or kinked or disconnected from the sunroof. Glass panel improperly adjusted. Faulty glass panel seal.
Gurgling sound from sunroof. Low spot in drain hose routing, allowing water to stand. Wind noise from sunroof. Front of glass panel too high or rear too low.
Wind deflector not deploying. Glass not centered in opening. Faulty glass panel seal. Rattles from open sunroof while driving. Loose or broken attaching hardware. Worn or broken mechanism.
Sunroof does not stop in the fully closed Drive motor has lost position of glass, teach procedure position. required to reprogram drive motor. Refer to DRIVE
WATER DRAINAGE AND WIND NOISE DIAGNOSIS
Adequate drainage is provided by a drain trough in the sunroof housing which encircles the sliding glass panel and leads to drain hoses. If a wet headliner or other water leak complaints are encountered, before performing any adjustments, first ensure that the drainage system is not plugged or disconnected. Use a pint container to pour water into the sunroof housing drain trough. If water flow is restricted, use compressed air to blow out any material plugging the drain system. Retest system again.
To further check for a disconnected drain hose:
1. Lower headliner as necessary to gain access to sunroof housing drain tubes. See REMOVAL. 2. Repair as necessary. 3. Install headliner. See INSTALLATION.
The sliding glass panel is designed to seal water entry with a snug fit between the roof and the seal. The fit can be checked by inserting a piece of paper between the roof and the seal. The piece of paper should have some resistance when pulled out when the glass panel is in the closed position. The sunroof housing will drain off a minimum amount of water. Excessive wind noise could result if the gap clearances are exceeded. The sunroof glass panel may need to be adjusted. See ADJUSTMENTS for proper procedures.
DEFLECTOR - SUNROOF WIND
INFORMATION).
13. Remove the wire harness. 14. Remove the trough. 15. Remove the module side brackets. 16. Remove the deflector.
INFORMATION).
3. Install the sunshade, see INSTALLATION. 4. Install the trough. 5. Install the glass panel. 6. Raise rear end of sunroof module assembly (2) to the roof (1) and guide into position and start the rear fasteners (3). 7. Raise front end of sunroof module assembly (2) to the roof (1) and guide into position, start the remaining fasteners (3). 8. Visually line up the alignment guide holes with the guide holes in the roof of the vehicle. 9. Tighten the fasteners to 9 N.m (80 in. lbs.). 10. Tighten the nuts (4).
11. Connect the rear drain tube at the sunroof (1).
12. Connect the front drain tube (3) at the sunroof (2). 13. Install the wire harness. 14. Connect battery negative cable. 15. If equipped, install the overhead console, refer to INSTALLATION . 16. Perform the sunroof motor teach procedure, refer to STANDARD PROCEDURE . 17. Test sunroof operation, adjust glass as necessary, see ADJUSTMENTS. 18. Install the headliner, see INSTALLATION.
SUNSHADE - SUNROOF
BODY GAP AND FLUSH Fig. 747.
NOTE: All dimensions are in millimeters.
O/F = Over Flush U/F = Under Flush
U/D = Up/Down F/A = Fore/Aft
DIMENSION DESCRIPTION GAP FLUSH
3.0 +/- 2.0 1 Headlamp to Grille - Parallel within 2.0
8.0 +/- 2.0 O/F -2.0 +/- 2.0
2 Hood to Grille
Parallel within 2.0 Parallel within 2.0
7.0 +/- 1.5 O/F 1.0 +/- 1.5
3 Hood to Fender
Parallel within 1.5 Parallel within 1.5
Hood to Body Side 4.5 +/- 1.5 O/F 0.5 +/- 1.5
Aperture Parallel within 1.5 Parallel within 1.54.5 +/- 1.5
| Front Door to Body | Parallel within 1.0 | U/F -1.5 +/- 1.5 |
| Side Aperture | Except 7.25 +/- 1.25 @ A-pillar | Parallel within 1.5 |
U/D Rear Door to Body
4.5 +/- 1.5 U/F 1.5 +/- 1.5
6 Side Aperture
Parallel within 1.5 Parallel within 1.5(above belt) Rear Door to Body
4.5 +/- 1.5 0.0 +/- 1.5
7 Side Aperture
Parallel within 1.5 Parallel within 1.5(below belt)
| Fuel Door to Body Side | 3.25 +/- 1.0 | U/F 0.75 +/-1.0 |
| Aperture | Parallel within 1.0 | Parallel within 1.0 |
| Front Door to Rear | 4.5 +/- 1.5 | 0.0 +/- 1.5 |
| Door | Parallel within 1.5 | Parallel within 1.5 |
| 4.5 +/- 1.5 | O/F 1.0 +/- 1.5 | |
| 10 | Fender to Door | |
| Parallel within 1.5 | Parallel within 1.5 |
3.0 +/- 2.0 11 Fascia to Fender Flare Parallel within 2.0 - Centered within 2.0 12 Side Marker to Fender 3.0 +/- 2.0 - 5.5 +/- 2.0 U/F -1.0 +/- 2.0 13 Grille to Fender Parallel within 2.0 Parallel within 2.0 Centered within 2.0 4.0 +/- 2.0 14 Fascia to Grille - Parallel within 2.0
9.0 +/- 1.5 U/F -1.5 +/- 1.5
15 Lift Gate to Roof
Parallel within 1.5 Parallel within 1.5
Fascia to Rear Wheel 3.0+/- 2.0
16 -
Flare Centered within 2.0Fascia to Body Side 17 0.0 +/- 1.0 -0.0 - Aperture
2.0 +/- 1.5 U/F 0.75 +/-2.0
Parallel within 1.5 F/A Parallel within 2.0 Tail Lamp to Body 18 4.0 +/- 1.5 Centered within 2.0 Side Aperture Centered within 2.0 U/D 3.0 +/- 2.0 19 Tail Lamp to Fascia Parallel within 2.0 - Centered within 2.0 4.0 +/- 2.0 O/F 1.0 +/- 2.0 20 Tail Lamp to Lift Gate Parallel within 2.0 Parallel within 2.0 Centered within 2.0
| Lift Gate to Body Side | 4.0 +/- 1.0 | U/F 1.75 +/- 1.5 |
| Aperture | Parallel within 1.0 | Parallel within 1.5 |
Cross/Car: 4.0 +/- 2.0 Centered within 2.0 22 Fascia to Lift Gate - U/D: 8.0 +/- 2.0 Parallel within 2.0 4.0 +/- 2.0
Lift Gate Glass to Body U/F -2.5 +/- 2.0
23 Parallel within 2.0
Side Aperture Parallel within 2.0Centered within 2.0
OPENING DIMENSIONS
DESCRIPTION FIGURE
ENGINE BOX Fig. 748.
FRONT DOOR Fig. 749.
LIFTGATE Fig. 750.LIFTGATE WINDOW Fig. 751.
REAR DOOR Fig. 752.
REAR QUARTER WINDOW Fig. 753.
WINDSHIELD Fig. 754.
SEALER LOCATIONS
Specifications
STRUCTURAL ADHESIVE LOCATIONS
Specifications
WELD LOCATIONS
Specifications
FRONT WHEELHOUSE (3 OF 3) Fig. 808. DASH Fig. 809.
+177 more figures in this topic