Dodge Charger 1973, Body Service Manual

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Page 3: ...ticular section Example M T S C 72 3 may be called out in the beginning of the subject matter This refers to the year 1972 and the session issue number 3 The Master Technician Service Conference is a training supplement available wherever Chrysler Cor DD o DDDDDDD DD CHRYSLER CORPORATION o VEHICLE IDENTIFICATION NUMBER PLATE INSTRUMENT PANEL LOCATED NR464 Fig I Vehicle Identification Number Plate ...

Page 4: ... designate build date and the last four numerals designate the engine sequence number All 198 and 225 cubic inch engines have the serial numbers stamped on the joint face at right corner adjacent to number one cylinder bore Fig 8 All 318 340 and 360 cubic inch engines have the serial numbers stamped on the front of the block just below the left cylinder head Fig 9 All 400 and 440 cubic inch engine...

Page 5: ...g or left side of upper radiator support TIRE PRESSURE A decal showing the recom mended tire pressure is located on the body pillar at the rear of the left front door opening B post PF366 Fig 7 TorqueFlite Transmission Vehicle Number Pad Location PF248i Fig 8 198 and 225 Cubic Inch Engine Identification Number Location Fig 9 318 340 and 360 Cubic Inch Engine Identification Number Location Fig ì 0 ...

Page 6: ... 55 6 203 8 69 6 CHALLENGER Challenger 110 0 60 2 60 7 198 2 76 4 CHARGER CORONET Charger Charger Charger SE Coronet Coronet Custom Coronet Coronet Custom Coronet Crestwood Coronet Custom Coronet Crestwood H5 0 2 DR H7 5 4 DR 117 5 61 9 62 0 Charger 212 7 Coronet 212 9 217 6 Charger 77 0 Coronet 77 8 72 1 Front 75 6 Rear P0LARA M0NAC0 Polara Special Polara Polara Custom Monaco Polara Special Polar...

Page 7: ...1 2 8 3 4 9 9 1 4 9 1 4 9 1 2 9 3 4 10 10 1 4 10 1 2 10 1 2 10 3 4 11 1 4 11 3 4 12 15 15 1 2 16 16 1 2 16 3 4 17 17 1 2 18 18 1 2 19 19 1 2 20 20 1 2 21 21 1 2 22 22 1 2 23 23 1 2 24 24 1 2 25 25 1 2 26 26 1 2 27 27 1 2 28 29 30 12 1 2 13 13 1 4 13 3 4 14 14 1 4 14 1 2 15 15 1 2 15 3 4 16 1 4 16 3 4 17 17 1 2 18 18 1 4 18 3 4 19 1 4 19 1 2 20 20 1 2 20 3 4 21 1 4 21 3 4 22 22 1 2 23 23 1 4 24 1 4...

Page 8: ... 2 54 5 08 7 62 10 16 12 70 15 24 17 78 20 32 22 86 25 4 50 8 76 2 101 6 127 0 152 4 177 8 203 2 228 6 254 0 279 4 304 8 330 2 355 6 381 0 406 4 431 8 457 2 482 6 508 0 533 4 558 8 584 2 609 6 635 0 660 4 690 6 MILLIMETRES TO INCHES m ms 0 001 0 002 0 003 0 004 0 005 0 006 0 007 0 008 0 009 0 01 0 02 0 03 0 04 0 05 0 06 0 07 0 08 0 09 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 9: ...tion to the hexagon The manu facturer s trade mark shall be legible in the center of the bolt head and not cover more than one third of the bolt circle SAE CLASSIFICATION HEAD MARKINGS GRADE 3 0 180 GRADE 5 O 120 GRADE 8 60 PB283 inches to liters multiply cubic inches times 0 01639 to obtain liters Cubic Inch 0 01639 Liters CUBIC CENTIMETERS TO LITERS When chang ing centimeters to liters divide by...

Page 10: ...ggage Compartments with Rubber or Vinyl Mats 2 Nylon Upholstery 1 Package Shelf Restoration 2 Rubber and Vinyl Mat Restoration 2 _ Splatter Painted Luggage Compartments 3 H Station Wagons 2 Tires 3 Tools and Spare Tire 3 Useful General Hints 3 Vinyl Roof Covering 1 Cloth Seat Inserts or Carpeting Prior to shampooing cloth seat inserts or carpeting obvious spots should be removed with spot remover ...

Page 11: ... stronger if re quired Apply Cleaner solution with a natural sponge and agitate suds with a scrub brush Rubber and Vinyl Mat Restoration Shampoo thoroughly using Multi Purpose Cleaner as required Package Shelf Restoration More frequently than not the package shelf pre sents a dusty soiled or shabby appearance and must be reconditioned It is best and usually easier to re move the fiber board type p...

Page 12: ... and rinse with clear water Scuff marks can be dressed down by sanding lightly with 400 sandpaper Glass Do not use putty knifes razor blades steel wool or other metal objects to remove deposits from glass Interior glass surfaces should be thoroughly cleaned weekly to remove all traces of smoke and other films Exterior glass surfaces are best cleaned with the use of a commercially made cleaner Do n...

Page 13: ...arpet 9 NEVER leave wet rags with laquer thinner on 7 Overspray from Nylon and Leather and Vinyl paint surfaces Dye can be removed from upholstery with a water 10 When tinting seats never leave tinted seat in dampened cloth dipped in lacquer thinner direct sunlight Sun may bleach the dye before it is 8 In many cases the back side of a damaged fiber set board panel may be reversed from right to lef...

Page 14: ...TACT AREAS RELEASE LEVER SLIDING ONTACT PIVOT AREA PIVOT AREA SAFETY CATCH LOCK Page Fuel Tank Access Door Hinge 5 Hood Hinges 1 Hood Lock and Safety Catch 1 Lock Cylinders 2 Tail Gate Door 4 Tail Gate Wiper Linkage 5 Window Regulators 2 to assure ease of operation and freedom from binding All Models Apply Multi Purpose Lubricant NLGI grade 2 EP such as Multi Mileage Lubricant Part Number 2525035 ...

Page 15: ... to contact area of striker bolt PIVOT AREA STRIKER LOCK ASSEMBLY SLIDING CONTACT AREAS Door Locks and Locking Control Linkage All Models If necessary to inspect operation of and relubricate these parts remove door trim panel Apply a film of Lubriplate or equivalent to all pivot and sliding contact areas Fig 11 Door Remote Control Link All Models If necessary to inspect operation of and relubricat...

Page 16: ... Lubriplate or equivalent sparingly to all torsion bar support bearing areas and interior svr PIN ENDS PIN ENDS FRONT DOOR UPPER PIVOT A N D ROLLER CONTACT AREAS REAR DOOR UPPER PIN ENDS TORSION SPRING CONTACT POINTS JORSION SPRING CONTACT POINTS FRONT DOOR LOWER REAR DOOR LOWER DOOR HINGE LUBRICATION p Y 8 1 3 Fig 7 Door Hinge Lubrication Dart Challenger Models FRONT DOOR UPPER POINTS REAR DOOR U...

Page 17: ... to support links check strap links link contact areas and inner pivot or sliding contact surfaces of tailgate and door lock Lubricate torsion bar and check arm mechanism with a Multi Purpose Lubricant NLGI grade 2 EP such as Multi Mileage Lubricant Part Number 2525035 or equivalent Apply stainless wax type stick lubri GLASS REFERENCE PIVOT AND SLIDING CONTACT AREAS ASSIST SPRING AND PIVOTS GLASS ...

Page 18: ...Lubriplate or equivalent sparingly to the sliding contact areas between the actuator arm and pin and between the actuating arm and regula tor sector gear Do not contaminate wiper blades with lubricant Fuel Tank Access Door Hinge All Station Wagon Models Apply Automotive Multi Purpose Lubricant NLGI LUBRICATION AREAS TORSION BAR HINGE LUBRICATE SLIDING CONTACT AREA LUBRICATE BAR SLIDE PB98 Fig 76 D...

Page 19: ... IN DIRECTION OF ARROW W PB100A WEDGE LOCKING PINS TAILGATE WINDOW CHANNEL UPPER HINGE PIVOT A N D ROLLER TORSION BAR SLIDE LUBRICATION POINTS RELEASE CAM AND BRACKET TORSION BAR CENTER BEARING SUPPORT TAILGATE GLASS LUBRICATION POINT LOWER SUPPORT AREA GLASS STABILIZER SLIDE LOWER HINGE PIVOT AREA LUBRICATION POINTS VIEW IN DIRECTION VIEW IN DIRECTION STRIKER PLATE VIEW IN CIRCLE Z LUBRICATION PO...

Page 20: ... Panel 15 Torsion Bar 15 Weatherstrips 16 SERVICE PROCEDURES COWL TOP PANEL SEAL The cowl top panel seal Fig 1 is fastened to the panel by retainers moulded into the seal SIDE COWL TRIM PANEL The side cowl trim panel Fig 2 is attached to the panel with screws and at the rear lower edge under the floor sill step plate A silencer pad is used be tween the trim panel and cowl panel Build Up and Instal...

Page 21: ...ent is controlled by the cable housing attachment at the door bracket Fig 3 Loosen clip screw attaching the housing to the door bracket and push control cable knob to the fully closed position Holding vent door closed pull cable housing slack out of door flange Tighten clip screw and test operation of cable and door SIDE COWL ASSEMBLY VENT SCREW CLIP PAPER BACKING SEAL MUST COVER ALL MOUNTING HOLE...

Page 22: ...or bracket 6 Adjust vent door cable housing and install trim panel and silencer HOOD ALIGNMENT Prior to making any adjustment inspect clearances and alignment of hood sides in relation to cowl fen ders and grille The cowl adjustment must be made first Elongated holes in the hinge Fig 4 permit the hood to be moved up down fore and aft REPLACEMENT Removaf 1 Place a protective covering over cowl and ...

Page 23: ...nforcement by means of a retainer clip The cable is placed on the latch and activated by hand in the interior of the vehicle A handle mounted on the reinforcement of the instrument panel activates the remote system when pulled When the hood is closed the latch closes by a spring return load SHIMS FRONT FENDER FRONT TYPICAL ROUTING RELEASE HANDLE VIEW IN CIRCLE Y VIEW IN DIRECTION OF Fig 5 Remote C...

Page 24: ...ngine compartment RADIATOR YOKE SUPPORT Removal 1 Remove radiator assembly 2 Remove hood lock striker bar horn and head lamp wiring from yoke support 3 From under the fenders remove wheelhouse to yoke support screws Fig 8 4 Remove support to frame screws and support Installation 1 Position yoke support on frame and install frame to support screws finger tight 2 From under the fenders install splas...

Page 25: ...ELD CROSSMEMBER NU86 Fig 8 Air Shield and Cross Bar SUPPORT BRACE y BRACKET BUMPER SUPPORT CUSHION CUSHION SUPPORT FRONT MONACO GUARD FRONT POLARA BUMPER BRACE PLATE BRACE SUPPUKI f m 7 r REINFORCEMENT BUM ER STATION WAGON REAR CUSHION Fig 9 Front and Rear Bumper Attachment REAR EXCEPT STAT ON WAGON SHIELD MyMopar com ...

Page 26: ...osition Lowering lower part of door moves lower part forward when in closed position In and Out Adjustment is made at the door hinge half Adjust only one hinge at a time HINGE REPLACEMENT The door hinges Fig 11 are attached to the doors by screws accessible from outside The front door hinges are each attached to the A post by three screws The rear door upper hinges on hardtop and sta tion wagon mo...

Page 27: ...dded jack under door near the hinges 2 Remove door interior trim and hardware 3 Scribe aligning marks around hinge plates on door frame On vehicles with electric window lifts disconnect wires from motor and switch and remove from door 4 Remove the hinge screws from door and re move door Installation On vehicles with electric window lift attach wiring to motor and switch prior to installation of tr...

Page 28: ...al 1 Raise door glass 2 Remove remote control base to door panel screws Fig 14 3 Remove link from remote control lever 4 Remove control through large opening in door Installation 1 Apply lubriplate to sliding and contact areas 2 Install assembly through door opening and connect link to control lever 3 Install attaching screw and test operation of control LATCH REPLACEMENT Removal 1 Disconnect hand...

Page 29: ...nnect cylinder link to cylinder arm and to clip on lock lever Latch Push Rod The latch push rod Fig 18 is positioned through an opening in the door belt area approximately at the front end of the arm rest position on 2 door models On 4 door models the push rod is located approx imately above the latch Fig 18 ELECTRIC DOOR LOCKS Adjustment 1 Loosen solenoid to mounting bracket screws Fig 19 CYLINDE...

Page 30: ...ont doors only is attached to the door inner face with one screw The remote control push rod is attached to the switch with a push on type retainer OUTSIDE HANDLE FRONT DOOR Removal 1 With door glass in up position remove handle attaching nuts from mounting studs Fig 20 and link from handle to lock 2 Lift handle up and remove from door Installation 1 Position handle into door opening and engage ha...

Page 31: ...e of lock pillar seal and install seal on lock pillar Hardtop Hear Door 1 Index and install weatherstrip on door by in serting fasteners in door and install from top of hinge pillar side of door completely around to lock pillar 2 Make sure lip of weatherstrip dovetails into groove of hinge pillar seal and install seal 3 Make sure lip of weatherstrip dovetails into groove of door upper ornament sea...

Page 32: ...nd striker so that the plate screws and striker plate can be moved up or down B Tighten plate and striker at desired position BOTH THE UPPER AND LOWER STRIKERS SHOULD BE ADJUSTED TO CARRY EQUAL WEIGHT OF THE TAILGATE In and Out Adjustment 1 Loosen the three lower hinge attaching nuts and adjust the tailgate to the desired position by remov ing or installing the necessary shims and then tighten bol...

Page 33: ... KNOB BOOT LOCKING KNOB CHANNEL VIEW IN DIRECTION OF ARROW Y WEDGE VIEW IN DIRECTION OF ARROW Z O o o c o o 30 SHIMS LOCK CYLINDER RETAINER HINGE REGULATOR PB28O Fig 23 Tailgate Assembly Typical ö MyMopar com ...

Page 34: ...posts and locate hinge plates in relation to previous marked positions 3 Tighten attaching bolts firmly enough to hold position and inspect alignment 4 Close tailgate and center in opening 5 Attach torsion bar bracket to pillar post 6 Open tailgate and tighten locking screws on hinge pivot pin 7 Connect electrical leads and install trim panel 8 Operate tailgate window and inspect align ment TRIM P...

Page 35: ...es it to the retainer Trim the ends of the seal flush with the retainer Pillar Weatherstrip Retainer and Seal The tailgate upper pillar retainer seal with weatherstrip is retained on the pillar with screws Fig 27 The seal has adhesive applied to one side which attaches it to the retainer The outer weather NU294 Fig 27 Pillar Weatherstrip Retainer and Seal strip and clip assembly is held in positio...

Page 36: ...en re placing lid to prevent it sliding rearward and damag ing paint also to aid in aligning of hinge screw holes when installing LOCK REPLACEMENT The deck lid lock Fig 30 is attached to the deck lid by two screws Scribe location of lock mounting flang TAPPING PLATE HINGE NU68 Fig 29 Deck Lid Hinge and Latch es to aid in installation On vacuum actuated units disconnect vacuum hose Adjustment Verti...

Page 37: ...osition hinge on bracket pin and install a new spring nut 2 Install deck lid connect torsion bar and inspect alignment TORSION BAR Removal Use care when removing torsion bar as it is under a load Release load from torsion bar slowly and re move from support bracket 1 Remove torsion bar Fig 32 from adjustment slot Fig 32 Deck Lid Torsion Bar WEATHERSTRIP 1 4 INCH í DRAIN TROUGH VIEW IN CIRCLE Y VIE...

Page 38: ...ip and screw Fig 2 The right cable looped end is positioned on the air door control crank arm Fig 2 The left cable is held on the crank arm with a spring type retainer Fig 3 Routing with Heater Route cables rearward of heater support brace under heater control cables and defroster hoses to the instrument panel attaching points on right side of steering column Fig 3 With Air Conditioning Left door ...

Page 39: ... securing with nuts With Heater The right duct part of the heater housing is at tached to the plenum with a single hook type rod positioned over the plenum flange and secured to the Prior to making any hood adjustment inspect clearances and alignment of hood sides in relation to cowl fenders and grille The cowl adjustment must be made first REPLACEMENT Removal 1 Place a protective covering over co...

Page 40: ...ting with Air Condition ing 2 Mark outline of hinges on hood to aid in instal lation Fig 6 3 With an assistant remove hinge to hood at HOOD Fig 5 Outs de Air Duct taching bolts and remove hood assembly Use ex treme care not to permit hood to slide rearward and damage painted surfaces of the cowl and fender areas HOOD PANEL J Jf i L VIEW IN DIRECTION OF ARROW Z YOKE STRIKER FENDER SHIELD PB272 Fig ...

Page 41: ...EW IN CIRCLE C VIEW IN CIRCLE C ADJUSTMENT SCREW PY98A RELEASE HANDLE WITH REMOTE CABLE SAFETY CATCH PF543 Fig 7 Hood Leveling Adjustment Fig 8 Hood Lock and Striker top edge Alignment should be made at bottom of floor sill panel front of hood and door outer panel upper edge REPLACEMENT Removal 1 Disconnect battery ground strap 2 Tape leading edge of front door and cowl to fender area to avoid dam...

Page 42: ... FENDER YOKE FENDER BRACE VIEW IN DIRECTION OF ARROW Y X VIEW IN CIRCLE V SIDE SILL FENDER O o so o o m I m 3 IMPACT PAD LATCH VIEW IN CIRCLE X SUPPORT AIR SHIELD Fig 9 Sedan Fender Attachment CROSS MEMBER PB385 o o o s CO MyMopar com ...

Page 43: ...FENDER BRACE VIEW IN DIRECTION OF ARROWS RELEASE SUPPORT HANDLE O o 73 O 73 O O o o 73 in AIR SHIELD Fig 10 Hardtop Fender Attachment HOOD LOCK SUPPORT PB386 O MyMopar com ...

Page 44: ...aks AIR SHIELD AND CROSS BAR Refer to Fig 10 for air shield and cross bar at taching points FENDER BUMPERS ATTACHMENT Refer to Fig 11 and 12 for bumper attaching points GRILLE ALIGNMENT AND REPLACEMENT Refer to Figs 13 and 14 for grille attaching points The grille must be held against the front face of the fenders at the outer edges to avoid stressing or fracturing the grille Care must be taken to...

Page 45: ...s made at the door hinge half Adjust only one hinge at a time Raising outer end of door moves upper part of door forward when in closed position Lowering lower part of door moves lower part foward when in closed position Fore and Aft Adjustment is made at the pillar hinge half Adjust HEADLAMP BEZEL Front Door All Models Removal On vehicles with electric windows disconnect the wires from window reg...

Page 46: ...n attaching screws 4 Complete door aligning procedure and install door interior trim and hardware REAR DOOR All Models Removal On vehicles with electric window lifts disconnect wires from motor and control switch and remove from door prior to door removal 1 Open rear door and place a padded jack under door near the hinges 2 Remove door interior trim and hardware 3 Scribe aligning marks around hing...

Page 47: ...Remote Control Handle 2 Remove screws attaching trim panel to door inner panel 3 Insert a wide blade screw driver between trim panel and door frame next to retaining clips and snap retaining clips out of door panel Remove trim panel 4 Before installing door trim panel inspect con dition of watershield 5 Be certain the escutcheon spring is placed on the regulator shafts 6 Align trim panel retaining...

Page 48: ...EEVE I LINK ANTI RATTLER VIEW A Fig 19 Rear Door Remote Control LOCK NN546 SEAL REMOTE CONTROL LINK LATCH NR193 Fig 20 Rear Door Remote Control and Latch Installation 1 Position cylinder in door and install retainer on cylinder body 2 Connect the cylinder link to cylinder arm and to clip on lock lever 4 door models 3 On 2 door models connect cylinder link to cylinder position link bracket on door ...

Page 49: ...1 Apply lower half of weatherstrip starting at hinge face at belt line working fasteners into holes in shut face of doors 2 Apply a 1 8 inch bead of cement to weather strip seating area on door upper and lower areas 3 Install upper half of weatherstrip on door in dexing at the upper corners 4 Work weatherstrip from index points to a point midway between them Avoid puckering or stretching of weathe...

Page 50: ...ass in the raised or lowered position The tailgate can be opened in the conventional tail gate manner The sequence of adjusting the linkage should be followed as outlined in this manual to ascertain cor rect locking and releasing operations Weatherstrip Vertical Adjustment 1 Hinge pin adjustment Fig 25 A On the lower left side loosen the pin lock nut B Adjust the pin to proper height Proper ad jus...

Page 51: ...ds 3 Loosen hinge pivot pin locking screws Fig 25 4 Use a pencil and outline hinge plate position on pillar post for future assembly 5 Remove hinge plate attaching bolts from pillar post 6 Slide hinge plate and torsion bar in through guide toward center of tailgate 7 Lower tailgate down and out of body opening Installation 1 With torsion bar and hinge plates pushed in toward center of tailgate eng...

Page 52: ...HANDLE KNOB BOOT LOCKING KNOB CHANNEL VIEW IN DIRECTION O F A R R Q W Y WEDGE O o o o 1 o SHIMS HINGE k m o o z REGULATOR PB28O Fig 25 Tailgate Application MyMopar com ...

Page 53: ...se regulator mechanism and upper left latch remote lever clip 7 Install link into lock remote lever 8 Take up all play in latch remote lever and release regulator mechanism arm and adjust link threaded end to this point 9 Install link into upper right lock remote lever and test operation of tailgate and door assembly TAILGATE WEATHERSTRIPS The Roof Header Seal Fig 27 is cemented to the header and ...

Page 54: ...n installing LOCK REPLACEMENT The deck lid lock Fig 30 is attached to the deck lid by two screws Scribe location of lock mounting ñanges to aid in installation Adjustment Vertical adjustment of lock is made at the at taching screws and side adjustment is made at the striker attaching bolt HINGE Removal 1 Remove deck lid assembly and disengage tor sion bar from hinge Fig 31 being removed 2 Remove h...

Page 55: ...upport and insert end into roller in hinge arm 2 Hook torsion bar into support bracket 3 Wind bar and insert end into center adjusting slot 4 Place lid in various open positions and test tension 5 Adjust bars until deck lid stays in open posi tion LATCH VIEW IN DIRECTION OF ARROW Z SCREW STRIKER LATCH ASSEMBLY ELECTRIC TAPPING PLATE HINGE VIEW IN DIRECTION OF ARROW Y PANEL DECK OPENING VIEW IN DIR...

Page 56: ...andles 43 Remote Control 43 DECK LID Alignment 44 Deck Lid Lock Cylinder 47 Deck Lid Weatherstrip 47 Hinge Replacement 46 Page Installation 46 Removal 46 Torsion Bar 46 FENDERS Alignment 39 Installation 40 Removal 40 Replacement 40 GRILLE 41 HOOD 38 Alignment 38 Installation 39 Lock 39 Removal 38 Replacement 38 OUTSIDE AIR VENT 37 QUARTER PANEL AIRSHIELD 44 QUARTER PANEL TRIM 44 RADIATOR YOKE SUPP...

Page 57: ...owl Seal to Cowl Panel Fig 5 Position seal assembly to hood panel and fasteners align fasteners to holes in cowl top panel and secure by inserting fasteners into holes Cowl Side Trim Panel Fig 6 1 Assemble spring nut to cowl trim panel 2 Apply cement to felt side of silencer and cowl side trim rear 3 Position cemented surface of silencer to panel cowl side trim assembly Press down firmly to obtain...

Page 58: ...rim Panel 2 Align scribe markings on hood with hinge and tighten screws to hold in position 3 Close hood and inspect alignment 4 Adjust alignment Fig 7 tighten bolts and re move protective coverings LOCK AND HOOD BUMPERS To adjust lock Fig 8 loosen attaching screws and raise or lower until correct adjustment has been ob tained After making any adjustment that requires shifting of hood always inspe...

Page 59: ...r screws and nuts 2 With fender correctly positioned tighten screws and nuts securely 3 Connect head lamp wires and install grille to fender nuts Connect battery ground strap RADIATOR YOKE SUPPORT REPLACEMENT Removal 1 Drain and remove radiator 2 Remove hood lock striker horn and head lamp wiring from yoke support 3 From under fenders remove splash shield to yoke support screws 4 Remove support to...

Page 60: ...4 1 REINFORCEMENT GUARD CUSHION PF468 Fig ì I Rear Bumper Attachment BUMPERS FRONT AND REAR BUMPER Refer to Figures 10 and 11 for front and rear bumper attaching points GRILLE Refer to Fig 12 for installation of grille assem bly to car Care should be taken to protect textured grilles from high temperature during repairs DOORS The service procedures for internal door com U NUT PANEL SCREW AND WASHE...

Page 61: ...er relation to locks Fit and readjust as follows 2 Open doors 3 Loosen door latch striker Fig 14 4 Loosen the necessary hinge bolts to suit each door as follows Fig 13 a For front door upper and lower hinge body half forward most bolt b For front door upper and lower hinge body half rear most bolt c For front door upper and lower hinge door TAPPING PLATE WASHER STRIKER FRONT DOOR LATCH PY458 Fig I...

Page 62: ...NT DOOR LATCH LOCKING CONTROL Fig 20 1 Position front door latch to front door inside panel thru access hole 2 Secure with screw and washer DOOR TRIM PANEL INSTALLATION Fig 21 1 Position and hook door trim panel to inner HANDLE ASSEMBLY CYLINDER SCREW SPACER Fig 17 Lock Cylinder Door Lock PY464 REMOTE CONTROL SCREW AND WASHER ACCESS HOLE SEAL Fig 18 Remote Control NUT PY459 HANDLE AND LINK PY46l F...

Page 63: ... Door VIEW IN DIRECTION OF ARROW A PY677 Fig 23 Door Locking Control Knob QUARTER PANEL TRIM QUARTER TRIM PANEL INSTALLATION Fig 26 1 Position quarter trim panel align holes to quarter inner panel 2 Secure top with screws 3 Secure bottom to floor pan with screw For jobs with electric window lift thread wire thru trim panel before positioning to inner panel STONE DEFLECTOR Fig 27 1 Assemble rear st...

Page 64: ...E V MANUAL WINDOW REGULATOR VIEW IN CIRCLE Y ADHESIVE REGULATOR Fig 24 Door Air Shield QUARTER PANEL AIR SHIELD AIR SHIELD PY53 EXTENSION ADHESIVE AIR SHIELD ADHESIVE BRACE VIEW IN CIRCLE P MANUAL WINDOW REGULATOR r V I E W IN Ba a DIRECTION OF ARROW Y QUARTER j PANEL TAPE S I D E SILL QUARTER PANEL ADHESIVE VIEW IN CIRCLE Z ELECTRIC VIEW IN CIRCLE X PD482 Fig 25 Quarfer Panel Air Shield MyMopar c...

Page 65: ...tall hinge 2 Install deck lid and connect torsion bars 3 Test deck lid adjustment TORSION BAR REPLACEMENT Removal 1 Remove torsion bar under spring load from adjustable slot Fig 29 2 Unwind torsion bar and remove from support bracket STONE DEFLECTOR SUPPORT SCREW QUARTER PANEL TAB PY678 Fig 27 Stone Deflector Installation HINGE SPRING NUT SLIDE CAM TORSION BARS NR101 Fig 28 Deck Lid Hinge and Tors...

Page 66: ... VIEW IN DIRECTION OF ARROW Z WEATHERSTRIP ADHESIVE VIEW IN CIRCLE Y PY448 Fig 32 Deck Lid Weatherstrip attaching hole in deck lid opening lower panel 3 Install and tighten retainer nut 4 Install release lever on end of cylinder with re tainer nut and hook up link DECK LID WEATHERSTRIP Fig 32 1 Apply a coat of adhesive to weatherstrip con tact surfaces 2 Install weatherstrip so that joint will be ...

Page 67: ...s are attached to the plenum opening The right duct is retained by two hook type rods positioned over the plenum opening flange and held to brackets on the base of the duct with screws Fig 1 The left duct assembly is attached directly to the plenum by positioning the duct over the plenum weld studs and securing with nuts With Heater The right duct part of the heater housing is at CLIP MOUNTING ROD...

Page 68: ...ect adjust ment has been obtained After making any adjust ment that requires a shifting of the hood always inspect the hood striker and the lock plate assembly for alignment HINGE REPLACEMENT 1 Remove dash panel to fender shield 2 Scribe hinge location on hood and remove hinge to hood screws 3 Support hood at hinge and front area 4 From under side of fender remove hinge stud spring nuts from studs...

Page 69: ...mbly 4 Disconnect head lamp wires and remove nuts attaching grille extension to fender 5 Remove nuts and screws attaching fender to cowl floor sill wheelhouse or splash shields and radi ator yoke Fig 5 6 Remove fender assembly and if necessary re move fender mouldings ornamentation and head light assemblies Installation 1 Install head lamps mouldings and ornamenta tion if removed 2 Carefully posit...

Page 70: ...hing screws 5 Remove support to frame attaching screws and remove radiator yoke support from engine com partment Installation 1 Position yoke support into the engine com partment Install the frame to core support screws finger tight FENDER U NUT U NUT CROSS BAR VERTICLE SUPPORT FRAME AIR SHIELD U NUT BOLT Fig 6 Air Shield and Cross Bar PY615 CUSHION PF469 Fig 7 Front Bumper Attachment 2 From under...

Page 71: ...r hinge half Adjust only one hinge at a time Raising outer end of door moves upper part of door into door opening Lower ing outer end of door moves lower part of door into door opening LATCH AND STRIKER PIN The silent type door latch Fig 11 features a rubber isolation of the round striker pin on the door frame and those surfaces acting as stops inside the latch The latch assembly is built into a s...

Page 72: ... screw at the rear inner end Remote Control Handle Special 1 Remove door handle trim bezel and carefully work bezel out over handle 2 Remove necessary hardware to remove trim panel then remove panel 3 Lower glass to full down position DART SHEET METAL DOORS 3 53 REMOTE CONTROL NN6O5A Fig Ï2 Remote Control Handle 4 Remove remote handle link from door latch 5 Remove remote link anti rattle bracket 6...

Page 73: ...lock assembly 2 Position lock assembly in door and connect PY271A Door Locking Mechanism remote control link to lock lever 3 Install lock retaining screws 4 Connect handle to lock link 5 Connect locking lever rod front door only to lock assembly 6 Connect locking lever rod and remote control link to lock LOCK CYLINDER Removal 1 With window in the up position disconnect cylinder link Fig 14 from cl...

Page 74: ...ge face at belt line working fasteners into holes in shut face of doors 2 Apply a 1 8 inch bead of cement to weather strip seating area on door upper and lower areas 3 Install upper half of weatherstrip on door in dexing at the upper corners 4 Work weatherstrip from index points to a point midway between them Avoid puckering or stretching of weatherstrip ALL MODELS Except Sedan 1 Apply a coat of c...

Page 75: ...of glass OUTER BELT WEATHERSTRIP The door outer belt weatherstrips are retained in the door panel with spring type retainers DECK LID Alignment The deck lid hinges Fig 17 permit only a very slight adjustment at the deck lid to hinge attaching points Replacement The deck lid is attached to the hinges by two screws on each side An assistant s aid is recommend ed when replacing the deck lid to preven...

Page 76: ...anges to aid in installation LOCK ADJUSTMENT Vertical adjustment of the deck lid lock is made at the lock attaching screws The side adjustment is made at the striker attaching bolts LOCK CYLINDER The deck lid lock cylinder is retained in the body by a nut from within the body WEATHERSTRIP Apply an even continuous coat of cement to entire weatherstrip contact surface of deck lid opening Fig 19 and ...

Page 77: ...eat assembly and the rear seat cushion The front seat mounting brackets are positioned on top of both front and rear floor covers The rear floor covering is positioned under the front covering On units equipped with consoles the carpet must be assembled over the floor pan mounting brackets and or shifting lever The body wiring is positioned through the holes in the carpet The front edge of carpet ...

Page 78: ...rior to installing lock cylinder make sure tumbler VIEW FROM FRONT N u l g 9 Fig 3 Glove Box Rear Removal D PF34O Fig 4 Glove Box Door L is in a retracted position and key is fully inserted Removal 1 Open glove box door and put latch lever into lock position insert key and turn to lock position Fig 8 2 Remove key and with a small pointed tool or screw driver depress tab located in lock housing slo...

Page 79: ...ing wires gently forcing material up and off of retainers and while maintaining pressure on fabric pull down and out Work only small areas at a time 5 Remove headlining at the windshield header and from fasteners at rear window area 6 Remove listing wires from side rail retainers and support wire from rear listing wire Figs 9 10 and 11 7 Remove all foreign material and cement from windshield heade...

Page 80: ...step 5 7 Apply cement to windshield header area and when cement becomes tacky start at centerline area of windshield and position headlining on cemented area 8 Using a dull putty knife secure liner on barbs at header area do not install material at top of wind INNER ROOF RAIL QUARTER PANEL INSIDE HEADLINING HEADLINING UPPER QUARTER TRIM SUPPORT REAR WINDOW LISTING WIRE PPER FRAME CUP EXTENT OF ADH...

Page 81: ...EAMS 50 INCH TYPICAL VIEW IN CIRCLE Y 2 DOOR SPECIAL LISTING WIRES DRIVE NAIL RETAINER UPPER QUARTER PANEL INSIDE QUARTER PANEL LANCED TABS UPPER QUARTER PANEL CLIP SIDE DRAIN TROUGH VIEW IN CIRCLE X 4 DOOR SEDAN LINING RETAINER SHELF PANEL LINING WHEELHOUSE INNER UPPER QUARTER PANEL SHELF PANEL SHELF PANEL WHEELHOUSE INNER PANEL 2 DOOR SPECIAL LOWER QUARTER PANEL LINING WHEELHOUSE INNER VIEW IN D...

Page 82: ...N DIRECTION VIEW IN CIRCLE J OF ARROW N SAME AT HEADER REAR LINING á í S WRAP MATERIAL AROUND FLANGE FINISH OFF WITH WELD 1 00 INCH COVER QUARTER CENTER PILLAR SECTION A A PANEL 4 DOOR SEDAN WHEELHOUSE INNER PANEL VIEW IN CIRCLE K LINING 4_DOOR SEDAN QUARTER PANEL VIEW IN DIRECTION OF ARROW R 2 DOOR SPECIAL AND 4 DOOR HARDTOP REAR UPPER QUARTER PANEL SILENCER SHELF PANEL TRIM PANEL LINING SCREW 4 ...

Page 83: ...ARD LINING Retainer Moulding Replacement The individual hard board headlining sections are held in position with semi flexible type plastic mould ings Fig 12 forced over the retainer sections of the roof bows Starting at either outer end remove end cap and pry the moulding off retainer When install ing moulding make certain it is fully seated and evenly spaced from side to side Install end caps in...

Page 84: ... Y INSTALLATION OUTER SILL LAP BELT BUCKLE END BUCKET SEAT VIEW IN DIRECTION OF ARROW R OUTER SILL BELT RETRACTOR SIDE VIEW IN DIRECTION OF ARROW Z INSTALLATION Fig 13 Front Seat Lap Belt D 2 Push section up at center to seat it in side on roof bows retainers 4 install mouldings on bow retainers and caps 3 Align edges of section with moulding retainer over ends LOOP BELT RETAINER LOOP SUPPORT FRON...

Page 85: ...ECTION OF ARROW Z PF297 Fig 17 Front Seat Lap Belt L Bucket 4 Raise trim panel at front and remove retainers from shelf panel 5 Slide trim panel forward and up to remove 6 Raise front edge of silencer pad and using a putty knife separate the silencer from cement Re move silencer 7 Remove all cement from shelf panel Installation 1 Apply cement to same areas of shelf panel from which old cement was ...

Page 86: ... 4 Apply cement to shelf panel end extensions 3 Slide trim panel into position and press re and press into position tainers into shelf panel holes 5 Install defogger outlet and window side gar FRONT SEAT SHOULDER BELT STOWAGE COVER INING ROOF RAIL FRONT SEAT SHOULDER BELT SHOULDER BOLT COVER VIEW IN DIRECTION OF ARROW Z FRONT SEAT LAP BELT FRONT SEAT SHOUDER BELT CLIP PLATE TO ROOF FRONT SHOULDER ...

Page 87: ...en the adjuster base andfloorpan To move seat fore or aft reposition the adjuster mounting bolts in the adjuster base RECLINING SEAT MECHANISM For ease of assembling the following procedures should be performed in sequence as listed BUCKET TYPE Fig 30 Back Latch Manual Release Bucket Recliner 1 Insert latch release assembly into recliner seat back from the rear passing between seat back right hand...

Page 88: ...t back and secure with screws one into hole in latch release and driving the left one into the seat back 4 Allow cable and latch assembly to pass on rear side of springs and feed latch on end of cable through rectangular hole in right side member panel of seat back 5 Place spring on latch pivot pin in right hand hinge arm of base Engage latch on cable and latch FLOOR PAN THIRD SEAT LAP AND REAR SE...

Page 89: ...bstructions 12 Damaged parts such as bent cable mounting brackets kinked cable housing bent actuator surface on bellcrank in latch release should be replaced 13 Install release button bezel to recliner back 14 Insert release button into bezel from back side 15 Take release button and bezel and place push button rod on release button through rectangular hole in latch release 16 Insert plastic guide...

Page 90: ...LT RETRACTOR INSTALLATION KNOB J NUT SCREW VIEW IN DIRECTION OF ARROW Y INNER TRACK ATTACHMENT SHOULDER BOLT SCREW ADJUSTER SPACER OUTER ADJUSTERS ONLY FRONT FLOOR PAN REAR TRACK ADJUSTER REINFORCEMENT SCREW HAND TIGHTEN FLOOR PAN N U T VIEW IN DIRECTION OF ARROW Z FWD 3RD SEAT ONLY SAFETY BELT INSTALLATION ADJUSTER PUSH NUT ADJUSTER SEAT FRAME REINFORCEMENT HAND TIGHTEN SCREW FRONT SEAT SHOULDER ...

Page 91: ...ition holes of clevis in adjuster with hole in bracket on seat back spring and cover and push clevis pin through bracket and both sides of clevis on spring Then install spring clip through hole in clevis pin 5 Position pivot brackets on recliner back spring and cover assembly within stanchions on base 6 Align holes and drive spring pin through holes in stanchion and pivot bracket on each side of r...

Page 92: ... REAR SIDE RAIL FLOOR PAN SEAT BACK SPRING SCREW CENTER FLOOR PAN PF75 Fig 29 Front Seat Adjusters L RELEASE HANDLE SCREW CLIP CLEVIS PIN ADJUSTER CABLE TRIM SHIELD SET SCREW RELEASE HANDLE RETAINING SPRING R I N G WASHER CUSHION Fig 30 Rec in ng Seat Bucket Type SHOULDER BOLT PF79 MyMopar com ...

Page 93: ... fasten with cotter pin 10 Force release handle down firmly against front seat cushion and pull cable housing of adjuster and cable away from handle to take up all slack 11 Fasten cable to side of front seat cushion with screws and tighten securely 12 Secure spring return to coil support wire on front spring and cover assembly 13 Insert wire adjuster lever return between off set in upper end of ca...

Page 94: ...ck spring 10 Install bumper and spacer washer to back by inserting bumper through hole in washer threading it into T nut in lower crossmember of back spring 11 Check operation of seat back latch by folding seat back rearward to engage lock latch on seat back latch with rod on striker 12 Press button on seat this should release the latch and allow the seat back to be folded forward 13 If latch does...

Page 95: ... 1 Position panel in rear compartment 2 Line up holes in hinge to floor and secure 3 Check alignment after securing INSTALLED POSITION LATCH SEAT CUSHION PF344 Fig 34 Front Seat Back Latch D Latch Striker Alignment Fig 38 1 Position security panel latch striker to shelf panel right and left side 2 Install bumpers to shelf panel latch 3 From luggage compartment rotate security panel to the closed p...

Page 96: ...MBLY SCREW CENTER FLOOR PAN COVER PANEL SHELF PANEL AREA SHELF PANEL BUMPER LATCH STRIKER MOUNTING SCREW S H E L F p A N E L SECURITY PANEL LATCH ASSEMBLY BUMPER LATCH ASSEMBLY PF322 Fig 38 Latch Striker Alignment inserting the rear edge of the cushion under the seat back The front lower frame of the seat incorporates retainers which fit into slotted brackets welded to the floor pan Rear Seat Back...

Page 97: ... E L H O U S E T T 7 T INNER PANEL 2ND SEAT BACK VIEW IN DIRECTION OF ARROW T VIEW IN DIRECTION OF ARROW V 2ND SEAT BACK COVER 2ND SEAT BACK COVER INNER 2ND SEAT BACK LOCK VIEW IN DIRECTION OF ARROW U 2ND SEAT BACK COVER OUTER HINGE CENTER FLOOR PAN VINOLEUM INSERT FLOOR PAN COVER HINGE COVER SUPPORT MOUNTING VIEW IN DIRECTION OF ARROW Y pF32O Fig 40 Back Latch Second Seat W Installation 1 Positio...

Page 98: ...of floor at rear of seat cushion and install screws attaching cushion mount ing straps to floor pan DJUSTER SEAT FRAME CUSHION ASSEMBLY SEATBACK SHELF PANEL I HANGERS SEATBACK STRAPS 5CRtW NN183 Fig 45 Rear Seat Cushion and Back THIRD SEAT BACK STATION WAGON Removal 1 With third seat back in the UP position Fig 48 remove the seat hinge links screws 2 Remove seat back and support panel assem bly 3 ...

Page 99: ...W SILENCER BRACKET PY97 Fig 47 Second Seat Cushion Station Wagon BACK CUSHION SEAT CUSHION r NK853 Fig 48 Third Seat Back and Cushion VIEW A USED WITH COLUMN SHIFT MOULDING CARPET SECTION CC SECTION EE NN4O8A Fig 49 Conso o Attachment W MyMopar com ...

Page 100: ... O N S O L E VIEW IN SECTION A A VIEVVMN SECTION B B LOCK CYLINDER FINISH PLATE SCREW CONSOLE BASE FINISH PLATE FINISH PLATE SCREW CARPET ASSEMBLY SECTION A A CONSOLE LID CONSOLE TUNNEL NUT FRONT FINISH PLATE MOUNTING BRACKETS CONSOLE ASSEMBLY PY286 Fig 50 Conso o Attachment J MyMopar com ...

Page 101: ...red on the spring and are firmly attached Make certain all buttons and medallions where used are pulled down securely and locked in posi tion As an aid in attaching the cover correctly mark the areas on the spring where the original cover was OUTSIDE QUARTER PANEL WINDOW LOUVER FRAME BRACKET ROOF DRAIN TROUGH WINDOW LOUVER BRACKET QUARTER WINDOW LOUVER pF83 Fig 51 Lowered Window Trim Charger SE at...

Page 102: ...only the number two 2 bulbs operate Page Headlights 1 Rear End Lighting 9 Single Headlight System The single beam system consists of two sealed beam bulbs The bulbs are the two filament type for low and high beam and are marked by a numeral 2 molded in the lens The low beam is intended for use in congested areas and on highways when meeting other vehicles within a distance of 500 feet The high bea...

Page 103: ...on 11 Remove each headlight trim panel Do not remove sealed beam retainer rims 12 Thoroughly clean headlight lenses COMPENSATING THE AIMERS 1 Place trar sit on floor in line with vertical cen terline of right front wheel Fig 1 Place split image target in like position at right rear wheel 2 Adjust range screw on transit until target split image coincides or merges into one unbroken line Make sure t...

Page 104: ...the spirit level is centered If DOWN or UP portion of the scale exceeds the following values the lights should be aimed Up Down No 1 Unit 4 4 No 2 Unit 4 4 KU428 Fig 3 Checking Aimer Calibration Horizontal Adjustment 1 With pointer of RIGHT LEFT scale still set at 0 sight through aimer viewing port Make sure that line of sight is perpendicular from eye to viewing port of aimer and that target imag...

Page 105: ...our lines are required on screen or wall Fig 6 a A horizontal line at the level of centers of headlights number 2 b A center vertical line which must be lined up with center of hood number 4 c A vertical line on left of screen or wall in line with center line of left headlight number 3 d A vertical line on right of screen or wall in line Fig 6 low Beam Adjustment Pattern with center line of right ...

Page 106: ...N SIGNAL INDICATOR LAMP PANEL FENDER SOCKET AND CABLE ASSEMBLY PF128 FRONT PARK AND TURN SIGNAL LAMPS Carline L Fig 2 Removal 1 To replace lens remove two 2 lens attaching screws and lift off lens 2 To replace bulb untwist socket from rear of grille and remove bulb Installation 1 Position socket assembly to back of grille and twist into locking position 2 Position lens assembly to front of grille ...

Page 107: ...ns and lift off lens Installation 1 Position lamp assembly to back of stone shield and install three 3 mounting screws 2 Connect lamp lead to harness FRONT PARK AND TURN SIGNAL LAMPS Carline D Polara Fig 6 Removal 1 Remove two 2 screws attaching assembly to panel and lift out lamp assembly 2 Disconnect lamp lead from harness To replace bulbs remove four 4 lens attaching screws from face of lens an...

Page 108: ...ER LAMPS Carline L J W Fig 8 Note Color of lens is the only difference between front and rear side markers Removal 1 Disconnect lamp lead from harness and re move two 2 capnuts attaching lamp assembly to fender 2 Lift lamp assembly away from outside of fend er To replace bulb untwist socket from back of hous ing Installation 1 Position lamp assembly in fender opening and install two 2 capnuts 2 Pu...

Page 109: ... two 2 screws PANEL FENDER SIDE SIDE MARKER LAMP BEZEL PF225 SCREW Fig 9 Front Fender Side Marker Lamps Carline D BULB CORNERING GASKET LENS FENDER PANEL J 4K SOCKET A N D CABLE HOUSING BULB SIDE MARKER NUT A N D WASHER STUD LOWER 2 CORNERING A N D SIDE MARKER LAMP PD533 Fig 10 Front Side Marker Lamps Carline D CORNERING AND SIDE MARKER LAMPS Carline D Fig 10 Removal 1 Working under fender remove ...

Page 110: ...ARKER LAMP LENS PF212 lamp assembly to lower deck 2 Lift out lamp assembly To replace lens after steps 1 and 2 above unsnap lens from housing Installation 1 Position lamp assembly to lower deck and in stall eight 8 nuts 2 Push bulb sockets into proper openings TAIL STOP TURN SIGNAL AND BACK UP LAMPS Carline L Two Door Hardtop and Four Door Sedan Fig 4 Removal 1 Remove two 2 screws attaching lamp a...

Page 111: ...n Signal and B up Lamps Carline L 2 Door Hardtop and 4 Door Sedan STUD HOUSING GASKETS BACK UP LENS SEAL TUDS TAIL STOP TURN SIGNAL LENS PD534 Fig 5 Tail Stop Turn Signal and B up Lamps Carline J 3 Remove three 3 screws attaching housing to bumper and lift off housing assembly To replace lens or bulbs remove lens attaching screws from face of lens and lift out lens Installation 1 Position housing ...

Page 112: ...ss and side mark er lamps 3 Install rear bumper TAIL STOP TURN SIGNAL AND BACK UP LAMPS Carline D Monaco Fig 9 Removal 1 Disconnect lamp leads from harness and side marker lamp 2 Remove rear bumper 3 Remove three 3 clips attaching lamp assem bly to bumper To replace bulbs or lens remove eight 8 screws from lens face and lift out lens Installation 1 Position lamp assembly and install three 3 clips ...

Page 113: ...ND SIGNAL LAMP BULB GASKET PF217 Fig 8 Tail Stop Turn Signal and B up Lamps Carline D Polara SCREW TO LICENSE LAMP TAIL STOP TURN SIGNAL AND BACK UP LAMP REAR BUMPER HOUSING SOCKET AND CABLE ASSEMBLY TAIL BUL SCREW U NUT BEZEL TAIL STOP AND TURN SIGNAL BULB Fig 9 Tail Stop Turn Signal and B up Lamps Carline D Monaco PF218 MyMopar com ...

Page 114: ... and W Station Wagons Fig 12 Removal 1 Remove license plate 2 Twist socket and pull to release from lamp housing 3 Pull wedge base bulb from socket 4 Remove two 2 screws securing lamp assem bly to bumper The mounting screws are a special tapping type to be used with the acrylic plastic lamp 5 Remove lamp housing from bumper Installation 1 Position lamp housing to bumper 2 Attach two 2 screws secur...

Page 115: ...on 2 Snap socket out of bumper and disconnect lamp lead from harness to replace complete assem bly Installation 1 Mount complete lamp assembly into bumper 2 Snap lens into socket and connect lamp power lead to harness REAR BUMPER LICENSE LAMP Carline D Except Station Wagon Fig 16 Removal 1 Hold license plate assembly open 2 Twist socket and pull to release from lamp housing 3 Release license plate...

Page 116: ...D CABLE ASSEMBLY REAR BUMPER BACK UP LAMP VIEW IN DIRECTION OF ARROW A PF226 Fig 17 RR Bumper Back up Lamps Carline W Wagon CONCEALED HEADLAMPS GENERAL INFORMATION The headlamp doors are electrically operated A single electric motor mounted behind the center of the grille is a series wound type with two field wind ings The motor has a worm gear drive and internal limit switches A relay and circuit...

Page 117: ...amp doors disconnected as operating the motor without load will damage motor If the system is still inoperative perform step 2 2 CAUTION This test bypasses the limit switches so power should be applied only momentari ly to avoid system damage Using jumper wires test motor operation by using the car battery as a direct source of power Apply power to the motor terminals after limit switch and check ...

Page 118: ...MP DOOR BUSHING ORSION SPRING CRANK RIVET ASSEMBLY UPPER GRILLE PANEL VIEW IN DIRECTION OF ARROW O MOTOR MOUNTING BRACKET m m o o FRONT BUMPER o PLASTIC MOULDING Fig I Headlamp Door Adaption Carline D PD494A T MyMopar com ...

Page 119: ...ove the gear and examine for stripped or worn teeth If no damage is observed perform step 2 Limit switch evaluation If gear damage is ob served replace the gear assembly with parts from the service kit as detailed below a Position a new cam of the same color as the original cam in the locator slot of the new gear b Install the O rings from the original gear at each end of the shaft of the new gear...

Page 120: ...ice Procedures 5 Test system operation CAUTION Do not operate the motor with headlamp doors disconnected as operating the motor without load will damage the motor HEADLAMP DOORS Removal 1 Disconnect motor leads at harness connector Fig 1 2 Rotate motor hand wheel clockwise if doors are closed or counter clockwise if doors are open PB2 8 Fig 6 Testing Switch Operation INDICATOR LUG ON GEAR SHAFT LI...

Page 121: ...ttery ground strap 8 Connect motor leads at harness connector Fig 1 SECURITY ALARM SYSTEM Introduction The security alarm system as available on P D C and Y carlines factory equipped with power door locks courtesy lamp switches at all doors and a pow er tailgate lock when applicable provides an alarm signal that consists of the headlamp tail lamp and side marker lamp flashing plus the horn soundin...

Page 122: ...ch the alarm shall stop if the key operated door switch is turned to the disarm position See Figure 2 for location of alarm control unit Checkout Procedure NOTE If the hood cannot be opened due to a run down battery causing the hood latch to block in the locked condition proceed as follows 1 Attach the negative jumper cable to ground courtesy light door switch 2 Place the key in the door lock turn...

Page 123: ...TE For Suburban vehicles proceed to Step 19 17 Open trunk and the alarm should remain OFF 18 Manually close trunk latch and the alarm should go ON Unlock the latch close the trunk the alarm should remain ON Proceed to Step 22 for other than Suburban vehicles 19 Tailgate should be locked Unlock tailgate by lifting door lock button Alarm should go ON Open the tailgate and push door lock button down ...

Page 124: ...ontrol unit decides when the alarm should be ON or OFF a Defective bulb or door switch a Turn ignition switch to OFF then us ing the key unlock the driver s door alarm should turn OFF b Remove connector to switch then key unlock the driver s door if alarm turns OFF replace the switch c Unplug all 3 harness connectors at the control unit alarm should turn OFF Attach a new alarm control unit to the ...

Page 125: ... lock on the driver door or unlock on the passengers door 3 between the white and black wire the circuit should be OPEN except when the key is turned in the di rection of unlock on the driver door or lock on the passengers door If the switch does not function as ex plained above replace the switch d Unplug all 3 connectors at the alarm control unit and attach a substitute alarm unit Lock the open ...

Page 126: ...e alarm control unit a Check basic car wiring 12 RIGHT SIDE DOORS NOT LOCKED 12A ALARM REMAINS ON WHEN PASSENGER DOOR IS KEY UNLOCKED 13A ALARM REMAINS OFF WHEN HOOD IS OPENED 13B HEADLAMPS NOT FLASHING AND HORN NOT PULSING DURING ALARM a Headlamp Time Delay By Pass Relay headlamps ON all during alarm b Alarm Control Unit headlamps and horn ON or OFF all during alarm 14 DOME LAMP DOES NOT OPERATE ...

Page 127: ...d replace switch a Disconnect the harness at the switch and ground harness lead If the alarm goes ON the switch is either not properly grounded or defective b Use Step 17 Latch Switch c Unlock the trunk to open the latch unplug all three 3 connectors at the alarm control unit and attach a new unit Lock the driver s door using the key then close the latch again If alarm goes ON replace alarm contro...

Page 128: ...ISTANT PF4O5 CONTROL SWITCH Fig ì Basic System V and L carline Page Repairing Grid Lines 28 Timer Relay Testing 28 Control Switch 27 through the grid system for a specified time and then shuts off The timer system permits current flow for a period of 3 to 7 minutes Control Switch The heater rear window control switch is a three position switch which is spring loaded to return from ON or OFF to its...

Page 129: ...od A reading of 0 volts indicates a break in the line between the Mid Point C and the Driver side of the line A reading of 12 13 volts indicates a break PF4O7 Fig 3 Time Delay Relay between the Mid Point C and ground Point B Timer Relay Testing 1 Ground the relay case and connect a jumper wire between terminals X and Y Fig 3 Connect a 12 volt test light between L and ground 2 Apply a 12 volt power...

Page 130: ... feed in wiring is good 3 Remove test lamp and connect feed to circuit breaker 4 Disconnect wiring from other side of circuit breaker Connect the 12 volt test lamp in series be tween circuit breaker and good ground if test lamp lights circuit breaker is good 5 Remove test lamp and connect wiring harness NU523 Fig I Switch Control Assembly 6 Disconnect wiring harness at connector under seat Connect...

Page 131: ...ack on clean surface 2 Position adjuster to seat assembly and install attaching bolts 3 Install seat assembly following procedure out lined under Seat Assembly and Adjuster MOTOR Removal CAUTION Anytime the motor cable and housing assemblies or vertical and horizontal transmission as semblies require maintenance the assemblies must be synchronized to insure easy and proper operation 1 Remove seat ...

Page 132: ... front 5 16 inch clevis pin UPPER CHANNEL ASSEMBLY VERTICAL SPRINGi VERTICAL TRANSMISSION HORIZONTAL TRANSMISSION TORSION BAR CABLE AND HOUSING IÜASSEMBLY NU527 Fig 5 Cab e and Housing Application 4 After clevis pin is removed slowly release the tension on the vertical spring 5 Remove cotter key and rear 3 8 inch clevis pin and upper channel assembly 6 Remove horizontal spring 7 Remove the through...

Page 133: ...tboard seating positions except those in the third seats of station wagons This type of retractor provides for convenient storage of lap belts and also makes it easy for occupants to adjust belts snugly for maximum protection Lap belts at center seating positions are equipped with adjustable buckles as are belts in the third seats of station wagons Easy Belt Stowage Belts can be stowed in various ...

Page 134: ...ine of panel Replaces headlamp wash er relay C Carlines On instrument panel lower rein forcement left of steering column Replaces head lamp washer relay Y Carlines Same as C carl ne Light Indicator Located in clus ter below fuel gauge Replaces old belt doors fuel indicators under brow in map lamp assembly Located in bezel to right of instru ments and fac ing left door Located in speedometer back d...

Page 135: ...g Section of this unit for further circuit information Procedure The Trouble Shooting Procedure Step numbers described below correspond directly with the Checking Procedure Step numbers as listed previ ously in the Checkout Procedure Correction Stepi Warning light and buzzer turn ON when they should remain OFF l a Auto Transmission Neutral Safety a If car starts in neutral safety switch Switch Swi...

Page 136: ... test light between the blue wire with white tracer terminal at buzzer connector and a known ground If test light does not go on check the wire for continuity between the fuse clip and the buzzer connector If open circuit is found repair or replace harness Check connector at lamp If connector is alright replace bulb If new bulb does not light check the following a Assure that lamp is at 12 volts b...

Page 137: ...rness Step 3 Light and buzzer do not go OFF when the driver s lap belt is extended 9 5 inches or more Step 4 Light and buzzer do not come ON as they should when test buttocks is placed on passenger s seat 1 Driver s Seat Belt Retractor Switch Retractor switch contacts should open when belt is extended 9 5 or more 2 Seat Switch Front Passenger Seat The seat switch contacts should be open if properl...

Page 138: ...ors and switch assembly Passenger s Seat Belt Retractor Switch Assure that belt is fully retracted Using Switch contacts should be open a continuity light check at switch ter when belt is retracted minals to assure contacts are closed If open replace retractor and switch as sembly Seat Switch Seat switch contacts Disconnect seat switch connector Check shorted to switch beam under seat if switch te...

Page 139: ...replace switch body Each switch is tested in the same manner The motor should run if not test continuity be tween the switch and the motor Should continuity be established and motor still does not run proceed to the window lift motor test WINDOW LIFT MOTOR TEST NOTE All window lift motors are of the permanent magnet field configuration Connect the positive lead from a test battery to one of the tw...

Page 140: ...IP SEAL NU583A WORM GEAR GEAR AND PINION Fig 3 Motor Lubrication GEAR AND PINION REPLACEMENT AND LUBRICATION Door and quarter window repair kits consisting of the gear and pinion assembly and seal are available as part number 2808914 or equivalent for the rubber coupling and part number 2932973 or equivalent for the spring or roller coupling Part number 3744280 or equivalent is the kit for tailgat...

Page 141: ...tained connect the voltmeter to the battery side of the cir cuit breaker If a reading of 12 1 2 volts is obtained the circuit breaker is probably defective and should be replaced If a reading of 12 1 2 volts is not ob UNLOCK RELAY BUSS BAR ELECTRIC DOOR LOCK RELAYS BODY FRONT PILLAR LOWER RIGHT LOCK RELAY SCREW PF585 tained inspect for a broken feed wire or loose con nection To determine which sol...

Page 142: ...te should unlock and remain unlocked until the ignition is turned on again 8 If the solenoid does not operate see the elec trical test procedure NOTE If the system does not operate properly during this test repeat the adjustment and the checkout pro cedures ELECTRICAL TEST PROCEDURE TAILGATE CARLINE P D and C NOTE The battery must be in normal condition be fore testing Make certain the solenoid is...

Page 143: ...ush the unlock switch located on the in strument panel and the tailgate should unlock d Release the unlock switch and the tailgate should lock e With the ignition in the ON or ACCESSORY position attempt to pull the tailgate locking button up and at the same time try to open the tailgate as a door The push button should travel a short distance before a vibration is felt or heard The door should not...

Page 144: ...nstrument panel on Carline R and W and located in glove box on Carline P D C and Y and the deck lid should unlock 3 In the event the deck lid fails to unlock check for the following a Solenoid lead wire connected and 10 volts or more available at the solenoid b Proper ground established through latch mounting screws c With latch removed plunger spring is un damaged and properly attached d Solenoid...

Page 145: ...Y SIX 6 Rear Defogger Air Conditioning Clutch Temperature Gauge Fuel Gauge Voltage Lim ter Oil Gauge Rallye Cluster CAVITY SEVEN 7 Heater Blower Motor Air Conditioning Blower Motor CAVITY EIGHT 8 Radio Back Up Lamps Reverse Gear Indicator Lamp Tachometer Feed Rallye Only Turn Signal Includes Stop Lamp Front Turn Signal Turn Signal Indicators 5 20 20 20 Amps Amps Amps Amps CAVITY ONE 1 Brake Warnin...

Page 146: ...unning Lamps Electric Brakes Amps Amps 30 Circuit Breakers Power Tailgate Window and or Power Windows 30 Tailgate Lock Solenoid 15 CARLINES P D CAVITY ONE 1 Air Conditioning Relay Window Lift Safety Relay Dual Brake Lamp Oil Pressure Lamp Seat Belt Lamp Seat Belt Relay Seat Belt Buzzer CAVITY TWO 2 Horn Dual Horn Relay Key In Buzzer CAVITY THREE 3 Hazard Flasher Includes Stop Lamps Front Turn Sign...

Page 147: ... 1004 211 1 or 551 or 1004 Door Ajar Indicator 1892 1892 Fender Mounted Turn Signal Indicator 161 2 161 2 161 2 Front Park and Turn Signal H57NA 2 1157 1157NA Gear Selector Indicator Column I6I I6I I6I Gear Selector With Console 57 57 Glove Compartment 1891 1891 1891 Headlamp Switch Rheostat Valve 28 OHMS 15 5 OHMS 15 5 OHMS High Beam Indicator 158 57 1895 Instrument Cluster and Speedometer I58 3 ...

Page 148: ...Radio AM FM Stereo I8I6 Reverse 4 Speed Transmission Indicator 53 Sealed Beam Hi Beam No 1 4001 Sealed Beam Hi Lo Beam No 2 4000 Seat Belts Indicator 1892 Side Marker 168 4 Station Wag Front 168 2 Rear 1893 W Rallye 1892 I6I 1156 2 57 1891 1004 161 2 1157 or 1157NA I6I 57 1891 15 OHMS 57 57 7 1445 67 562 I8I6 I8I6 53 4001 4000 1892 168 4 Stereo Indicator Switch Lighting Tail Stop and Turn Signal T...

Page 149: ...ypes 41 45 and 46 51 Legend and Color Code 48 Power Window and Door Lock Carlines D P and C 60 Radio Rear Speaker 61 Rear Defogger Heater and Air Conditioning Carl nes D P C and Y 61 Seat Belt Warning System Carl nes J B R W D P C and Y 59 Security Alarm System Carlines D P C and Y 63 The vehicle identification number on the instru ment panel starts with a capital letter which indicates the carlin...

Page 150: ...TRACER CARLINE B AND J BULKHEAD DISCONNECT PF134 Fig 2 Bulkhead Disconnect Carline B and J CAVITY COLOR DESCRIPTION ENGINE COMPARTMENT SIDE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 BR R BP Y DGN DBL DGN BK BK Y BK Y BK T WINDSHIELD WIPER BR ON INSTRUMENT PANEL SIDE WINDSHIELD WIPER SEAT BELT AIR CONDITIONER MOTOR WINDSHIELD WIPER WINDSHIELD WIPER BACK UP LAMP W ON INSTRUMENT ...

Page 151: ...K R DBD Y BK R Y BK TRACER INSTRUMENT PANEL SIDE CARLINE Y ENGINE TEMPERATURE INDICATOR LAMP COLD SENTRY SIGNAL LAMP CARLINE Y IGNITION STARTER IGNITION RUN AMMETER FUSIBLE LINK R ON INSTRUMENT PANEL SIDE CARLINE Y TEMPERATURE OIL PRESSURE BAH FEED AMMETER CARLINE Y RIGHT CORNERING LAMP RIGHT TURN SIGNAL TAN INSTRUMENT PANEL SIDE HI BEAM CARLINE Y HORN LEFT CORNERING LAMP LEFT TURN SIGNAL LGN ON I...

Page 152: ...AMP L4A 16V L9C 16BK L9D 16BK H2A 16DGN R RIGHT DUAL HEADLAMP L3C 16R L3B 16R L9D 16BK L9E 18BK H2 16DGN R L9C 16BK L9 16BK HEADLAMP GROUND L3B 16R L3A 16R L9 16BK H2 i6DGN R LEFT DUAL HEADLAMPS L4A 16V L4 16V D6 16BK LGN L9A 16BK L9B 18BK L6A 18BK Y L9B 18BK LEFT MARKER LAMP D6 16BK LGN LEFT PARK AND TURN SIGNAL BULKHEAD CONNECTOR D6A 18BK LGN Fig 5 Front End Wiring Carline J and W Body Types 41 ...

Page 153: ...DGN R f V1 S m D5A I8BK T J 18BK T L3A l6R n L9C 16BK L9A 18BK LEFT DUAL HEADLAMPS L3A 16R J L3 16R L4 16V 1 L9 16BK L9C 16BK i L6C i8BK Y L9B 18BK D6A 18BK LGN L6 18BK Y L6A 18BK Y D28 18LGN L9B 18BK a n u D6A 18BK LGN L3B 16R L3 16R L4A 16V L 4 1 6 V 28 27 32 31 2630 1 2529 D5 L 18BK BK T D29 18 T P5 2OBK CO L6 18BK Y D28 18LGN D6 18BK LGN D6 18BK LGN L6A 18BK Y V10 18BR P5 2OBK í BRAKE WARNING ...

Page 154: ...L WIRING LEFT SIDE COWL TO LAMP WIRING RIGHT BACK UP B2B 18V I ced ï i 3 iftv GROUND LICENSE LAMP L7B 18BK L7A 18BK D8 18DGN LEFT BACK UP TO LEFT TAIL LAMP WIRING MAIN BODY HARNESS l8BR RIGHT SIDE I8DGN LEFT SIDE l8BK TAIL STOP BODY A T U R N L A M P WIRING SIDE MARKER LAMP L18BK rnh TAIL LAMP îHí WIRING DIAGRAM CAR LINE W BODY TYPES 45 AND 46 l8BR RIGHT SIDE l8DGN LEFT SIDE 18 PGNr TW B K p 1 TAI...

Page 155: ...8 G Y TO MAIN HARNESS REAR LAMPS CARLINE W BODY 21 23 29 16GY GROUND RIGHT SIDE MARKER LAMP X2B 18GY L7 18BK D7 18BR RIGHT TURN STOP 18BK TAIL LAMP X2A 18GY X2 18GY B2 18V 1 RIGHT BACK UP LAMP 1 D7 18BR L7 18BK L7B 18BK B2 18V L7C 18BK LICENSE LAMP B2A18VH ì i I P J i UV A 18BK D 8 18DGN _X2C 16GY 18GY LEFT BACK UP LAMP LEFT TAIL STOP TURN LAMP X2A 18GY Õ GROUND T O A I N R E A R S HARNESS CARLINE...

Page 156: ...l X2 l8GY DOOR JAMB SWITCH REAR DOOR SWITCH CABLE BODY TYPES 41 AND 43 G R U M11 18BK TRUNK LAMP AND SWITCH TO FUEL GAUGE SENDING UNIT SIDE MARKER LAMP TURN STOP TAIL BACK UP AND LICENSE LAMP WIRING SHOWN RIGHT SIDE LEFT SIDE SYSTEM OPPOSITE X2 l8GY TAIL STOP AND LAMP TURN SIGNAL BACK UP LAMP L7 18BK OPT W L7 18BK LICENSE LAMP TAIL STOP TURN BACK UP AND LICENSE WIRING SHOWN LEFT SIDE RIGHT SIDE SY...

Page 157: ...25A SB W I 5 H I SWITCH W25A 12Y TO LEFT DOOR JAMB SWITCH WITHOUT SECURITY ALARM W25 12Y W5 12R W15 12BR W15A 12BR W5 12V W5 12V NEUTRAL UP DOWN W15A 14BR W25A 14Y UP DOWN DO NOT USE ON DODGE CARLINE SWITCH NORMALLY OPEN CLOSES WHEN GATE IS CLOSED WITH SECURITY ALARM LOCK UNLOCK WITHOUT SECURITY ALARM M2 18BK M1 18BK 18BR 18DGN L7 18BK M1 18P M1 18P TAILGATE SOLENOID SWITCH SWITCH NORMALLY CLOSED ...

Page 158: ...RUMENT PANEL WIRING RIGHT SIDE COWL ISO i 18O RIGHT REAR CHANNEL A GEAR SHIFT SELECTOR LAMP CONSOLE GEAR SELECTOR LAMP WIRING DOME LAMP WIRING O PART OF MAIN BODY HARNESS TRUNK LAMP WITH INTEGRAL MERCURY SWITCH TRUNK LAMP WIRING 18BK 18BK HIGH LOW 18W IT LEFT SIDE COWL PART OF INSTRUMENT PANEL WIRING DEFOGGER MOTOR WIRING m m O O z c PD589 Fig 12 Accessories Carline J and B V1 en MyMopar com ...

Page 159: ...dy Types 45 and 46 TO LEFT FRONT DOOR MASTER SWITCH OF INSTRUMENT PANEL WIRING LEFT SIDE COWL PART OF INSTRUMENT PANEL WIRING LEFT SIDE COWL TRUNK AREA LEFT ELECTRIC ELECTRIC DECK LID D E LID RELEASE WIRING LEFT FRONT IDOOR WINDOW LIFT MOTOR LIFT W TCH R I G g o o R R O N T PART OF INSTRUMENT PANEL WIRING LEFT SIDE COWL DEFOGGER MOTOR WIRIN WIRE LOOP FOR WINDOW LIFT LOCK OUT SWITCH LEFT SIDE COWL ...

Page 160: ...ER SIDE LEFT RETRACTOR LEFT SEAT BELT _ J R G H T EAT BELT SWITCH RETAINER SWITCH RIGHT SEAT RETAINER SWITCH SWITCH RIGHT RETRACTOR SWITCH PF298 Fig Ì5 Seat Belt Warning System Carline J B R W D P C and Y DECK LID RELEASE SOLENOID X42 14BK MOLDED CONNECTOR RED X42 14BK TO SWITCH WIRING ON INSTRUMENT PANEL Fig 16 Electric Deck Lid Release Carline D P C and Y PF3ll MyMopar com ...

Page 161: ...14 14GY 1 W24 14DGN X34 14P X33 14O X2 2OBK X2 2OBK X62 2OV X63 2OW X33 14O L_ v NOTE SPLICE 8 USED FOR GROUNDING OF SECURITY ALARM ONLY X33 W4 W14 14O 14Y UGY X2 2OBK X62 2OV X63 2OW X33 14O 1 X35 18O W22 12V X32 18LGN X36 I8P Wi2 rW22 Ì2P I 12V FEEDG UNLOCK X34 14P o X33 14O J LOCK RIGHT FRONT I DOOR BUTTON LOCK AND UNLOCK SWITCH CJ1 s m m 3 O RIGHT FRONT DOOR WINDOW LIFT MOTOR RIGHT FRONT DOOR ...

Page 162: ...43 DCO 0 23 41 43 YO 0 00 REAR WINDOW DEFOGGER RESISTOR C13 16DGN Oj C14 16BK EL GROUND REAR WINDOW DEFOGGER MOTOR PF313 Fig 18 Rear Defogger Heater and Air Conditioning Carline D P C and Y TO STEREO COMPONENT WIRING ON INSTRUMENT PANEL TO FADER SWITCH WIRING ON INSTRUMENT PANEL TO STEREO COMPONENT WIRING ON INSTRUMENT PANEL TO FADER SWITCH WIRING ON INSTRUMENT PANEL X52 18DGN X54 18R X53 18DBL X5...

Page 163: ...CH BENCH SEAT OR LEFT BUCKET SEAT OR LEFT 50 50 SPLIT SEAT ADJUSTER SEAT MOVES UP IN REAR SEAT MOVES UP IN FRONT SEAT MOVES UP IN FRONT SEAT MOVES FORWARD HORIZONTAL f ì SEAT MOVES L y UP IN FRONT RIGHT SEAT ADJUSTER MOTOR LEFT SEAT ADJUSTER MOTOR LEGEND SPLICE ÏÏ MALE FEMALE INSULATORS VIEWED FROM TERMINAL SIDE COLOR CODE BK BR BL GN P R W Y BLACK BROWN BLUE GREEN PINK RED WHITE YELLOW WITH TRACE...

Page 164: ...H2A 16DGN R H2A 16DGN R HORN H2A 16DGN R STARTER RELAY op L9 2OBK H9 2OBK I IAI IOR X24 2OR J2 12DBL J2 2ODBL X22 2ODBL X35 180 X63 2OW X62 2OV X63 2OW X62 2OV ALARM CONTROL CENTER 2OGY H5 2OGY PF287 Fig 21 Security Alarm System Carline D P C and Y MyMopar com ...

Page 165: ...illustrations indicate the particular step number being read in the adjustment procedure Prior to adjusting glass all doors must be correctly Page Up Stops 13 Window Lift Switch 14 Quarter Panels 14 Belt Line Weatherstrip 14 Garnish Mouldings 14 Glass Adjustment 15 Handles 14 Trim Panels 14 Watershield 14 Quarter Window Hardtop 15 Adjustments 15 Down Stops 16 Front Track 16 Installation 16 Removal...

Page 166: ...assembly Front and Rear Track Parallelism 13 Run glass approximately 2 3 down 14 Tighten glass run rear channel and bracket assembly lower bracket nut GLASS SCREW FRONT STOP VIEW IN CIRCLEY FRONT TRACK GASKET SLIDE GLASS V 16 FASTENER UP STOP MOUNTING LOCATION FRONT TRACK TAB INDEX HOLE UP STOP BRACKET TAB UP STOP MOUNTING SCREW MOUNTING HOLE FRONT TRACK BUMPER UP STOP PF563 Fig 2 2 Door Up Stop H...

Page 167: ...acket 8 Secure front track upper and lower mounting brackets with screws 9 Align holes in lift bracket with fasteners in glass and secure with screws FRONT TRACK RETAINER Fig 4 Glass Replacement BUMPER NU301 POLARA MONACO SIDE GLASS 6 3 FASTENER SCREW MOUNTING SCREW UP STOP BRACKET TAB MOUNTING UP STOP BUMPER FRONT TRACK SIDE GLASS PF564 Fig 5 Glass Assembly GLASS REAR TRACK Removal 1 Remove the d...

Page 168: ...regulator with a spring nut MANUAL REGULATOR REGULATOR ARMS SHEET METAL DOOR ACCESS PANEL LIFT CHANNEL PF565 MOUNTING SCREW SHEET METAL DOOR ACCESS PANEL CONNECTOR ELECTRIC REGULATOR PF566 Fig 9 Regulator Electric 2 Door REGULATORS ELECTRIC The manual and electric operated regulators Fig 9 are attached through an access hole to the door inner panel with screws Refer to the Body Electrical Unit 5 i...

Page 169: ...vent wing leg un til shoulder bottoms out against door panel reinforce ment and a parallelism exists between glass edge and roof rail weatherstrip 11 Loosen nut assembly on vent wing leg adjust ing stud 12 Force vent wing leg outboard until secondary seal is accomplished between glass and roof rail weatherstrip 13 Snug nut assembly and loosen screws to per form adjustment 14 Loosen rear channel up...

Page 170: ...4 2 Position weatherstrip on glass front edge with notched end in up position 3 Raise edge of weatherstrip and insert slide at attachment in glass Secure by pressing together 4 With glass and vent wing in inverted position Fig 14 insert slides on glass assembly into vent wing division channel 5 Insert anti rattle into division channel adjust ing bracket loop opposite loop joint 6 Insert smooth end...

Page 171: ...rew loosely Fig 15 3 Insert channel lower stud into slot of support assembly and secure with nut 4 Tighten upper support screw 5 Install door glass 6 Install up stop at rear channel DOOR GLASS REGULATOR The manual and electric operated regulators Fig 16 are attached to the door inner panel with screws Refer to the Electrical Group for test procedures and wiring diagrams for electric operated regul...

Page 172: ...ck from switch body and remove switch from 4 Remove regulator through large access hole in panel door panel VENT WING REGULATOR Removal 1 Remove screws attaching regulator to door in ner panel belt reinforcement Fig 18 Installation 1 Through large access hole position and align sleeve on regulator coupling over vent wing pivot shaft 2 Position and align regulator body to attaching SCREW SCREW MOTO...

Page 173: ... snug tighten nut 5 Test operation and inspect alignment of glass Tighten callouts 6 and 7 securely GLASS REPLACEMENT Removal 1 Remove lift channel to door glass fastener screws _ 5 L NU377 Fig 19 Sedan Rear Door Glass Adjustments 2 Rotate front edge of glass rearward and up to disengage ends of glass from run channels 3 Lift glass assembly out of door 4 Remove lift fasteners from glass Fig 20 Ins...

Page 174: ...osition pivot chan nel over slide on regulator idler arm 3 Align pivot bracket mounting holes with holes in door inner panel and secure with screws 4 Install rear door glass GLASS LIFT BRACKET FIG 23 SLIDE Removal 1 Remove rear door glass to lift bracket screws 2 Move lift bracket forward on front slide disengage bracket from rear slide GLASS RUN to NU313 Fig 22 P vot Bracket 3 Move bracket rearwa...

Page 175: ...nel to reinforcement front screw 4 Set rear glass front frame parallel to rear frame of front door glass by lifting track panel bot tom edge 5 Snug tighten rear and center floating screws in cage nuts In Out and Secondary Seal 6 Force bottom of track panel in or out for sec ondary seal with roof weatherstrip 7 Snug tighten adjusting bracket to track panel screws 8 Snug tighten adjusting bracket to...

Page 176: ... NU337 Upper Attachment four inches and raise door glass to the full up posi tion 6 Raise track panel slowly until up stop on glass Fig 29 are cleared through door 7 Raise track panel completely and remove glass and panel assembly Fig 30 8 Place track panel and glass assembly on a pro tected surface with the glass facing downward 9 Remove track stabilizer guide screws Fig 31 and remove guides from...

Page 177: ...ficiently to allow installing the down stop to track panel screws 9 Install track panel to door panel screws screws at panel top edge 10 Align holes in glass lift bracket with fasten ers in glass and install screws 11 Install up stop brackets on door inner panel UP STOPS The rear up stop Fig 27 is attached to slotted areas in the door shut face between the inner and outer panels The front up stop ...

Page 178: ... Switch Slide a thin blade behind the switch housing front TRACK PANEL U NUT BRACKET Fig 32 1 rack Panel Assembly QUARTER PANELS GARNISH MOULDINGS The garnish mouldings should be aligned and held in position to assure satisfactory alignment Do not over tighten screws or moulding will become dam aged at screw hole area TRIM PANELS To remove quarter window trim panel it is first necessary to remove ...

Page 179: ...ve nut and move upper rear track attachment forward so weatherstrip and front of glass is against front door glass Snug secure nut 7 Loosen pivot bracket nuts adjust pivot brack et and snug secure nuts 8 Position front and rear up stops down against glass lower frame and snug secure screws 9 Lower glass until glass top edge is even with or slightly below belt line of outer panel 10 Snug secure low...

Page 180: ...move nut and washer from sleeve nut at upper end of track Fig 39 2 Remove track lower plate to support screw 3 Push track inward and move track and roller assemblies rearward to disengage rollers from glass lower frame 4 Remove track and rollers out of panel through large access hole 5 Remove roller assemblies from track Fig 40 NU329 Fig 37 Pivot Bracket Installation 1 Position roller and guide as...

Page 181: ... panel through large access opening 2 Position roller assembly into slot of glass low er frame 3 Insert track upper sleeve into hole of inner panel NU286 Fig 41 Rear Track 4 Align track lower plate on support and secure with screw 5 Place spring washer concave side facing out board on sleeve nut and install retaining nut GLASS LOWER FRAME Removal Fig 42 1 Remove quarter glass assembly 2 Remove rea...

Page 182: ...the mounting bracket around the lift pivot WINDOW LIFT SWITCH Slide a thin blade behind the switch housing front and back to depress retaining clips and pull switch out from panel Carefully separate multiple terminal block from switch body and remove switch from panel GLASS ADJUSTMENTS SEDAN MODELS 1 Raise glass to approximately 1 8 inch below window opening frame 2 Adjust regulator pivot bracket ...

Page 183: ...and rear edges in glass runs 4 Lower glass and align lift fasteners to holes in lift channel 5 Secure glass to lift channel with screws 6 Test operation of quarter window RETAINER WEATHERSTRIP SCREW LIFT BRACKET SCREW NU33l Fig 45 Quarter Window Replacement GLASS RUN AND WEATHERSTRIP RETAINERS Removal 1 Remove glass assembly 2 Remove run from front top and rear retainers Fig 46 3 Remove weatherstr...

Page 184: ...rip into retainer 7 Posit on glass front run to retainer loading bottom leg between panels at belt line 8 Index upper front corner making a water tight joint and to tab at bottom of retainer 9 Press into retainer full length to secure 10 Through large access hole position rear run to retainer indexing to lower end of roof rail weatherstrip to create a seal 11 Press securely into retainer for full ...

Page 185: ...re lower nuts on glass run of tailgate 5 Close tailgate test for ease of operation and inspect alignment GLASS REPLACEMENT Removal 1 Support glass at bottom and remove glass to frame channel screws Fig 49 2 Slide glass up and out of tailgate Installation 1 Apply lubricant to surfaces of glass regulator sliding blocks 2 To install glass it will be necessary to force slides outward TAIL GATE GLASS R...

Page 186: ... the glass adjustment procedures GLASS ADJUSTMENTS HARDTOP Adjustments Ventless Door Fig ì Fore and Aft 1 Raise glass completely 2 Move glass fore or aft to set glass to belt line weatherstrip 3 Tighten glass track upper bracket at belt line Parallelism of Glass to Primary Seal 4 Move pivot bracket up or down and set glass parallel to weatherstrip 5 Tighten pivot bracket 6 Adjust up stops Page Ins...

Page 187: ...ENER ROLLER STABILIZER CHANNEL FASTENER PB396 CORONET CHARGER SIDE GLASS 6 23 FRONT DOOR ATTACHING SCREW REGULATOR PB389 Fig 3 Front Door Regulator Assembly is imperative the linkage be securely clamped in a vise to lock it in place Failure to do this allows the assist spring to drive the mounting bracket around the lift pivot SEDAN AND STATION WAGON Adjustments Fig 4 1 Run glass all the way up 2 ...

Page 188: ...ust quarter window track at upper attachment until rear of glass lightly touches belt line weatherstrip 2 Raise window seating top of glass against roof rail weatherstrip and front of window level with top of front door window 3 Adjust upper track until front of window is aligned with rear of front door window 4 Adjust lower front until front of window is aligned rear of front door window at roof ...

Page 189: ...de along the entire length of the arc on the outboard side of sector and to front and rear arm roller studs TAILGATE GLASS Adjustments Fig lì Prior to adjusting glass the tailgate must be cor rectly fitted to its opening the inner belt weather strip installed and all glass and related hardware component attaching screws and nuts loosened 1 With tailgate opened in tail gate position push glass agai...

Page 190: ...ubricant to surfaces of glass regulator sliding blocks 2 To install glass it will be necessary to force slides outward 3 Push glass in runs so that centering pin hole is aligned with pin 4 Install gasket frame channel and glass at taching screws gaskets and T nut GLASS RUN CHANNELS Removal 1 Remove the tailgate glass assembly 2 Remove tailgate glass run channel screws Fig 13 3 Remove channel assem...

Page 191: ...ack 31 Quarter Window Glass Adjustment 30 Quarter Window Parallelism and Secondary Seal 30 Quarter Window Regulator 32 VENTLESS GLASS ADJUSTMENT Numbers shown on glass adjustment Reference Il lustration Fig 1 indicate particular step number in adjustment procedure ADJUSTMENTS FIG 1 Parallelism and Primary Seal 1 Raise window completely Page Rear Up Stop 30 Slide and Up Stop to Quarter Window 31 Gl...

Page 192: ...nder side of glass push weld stud and spacer thru lowest hole outside surface snug secure to glass 6 Assemble spacer and support assembly to glass 7 Place washer and support assembly to glass 8 Install screw and washer assembly and support to glass 9 Assemble fastener to lift channel front hole provided in glass and press to shoulder T FASTENER GUIDE AND SCREW LUBRICATION SCREW AND WASÍER WASHER N...

Page 193: ...r arm roller in pivot bracket position mounting plate or electric motor bracket to attaching DOOR ACCESS HOLE FRONT DOOR LUBRICATION CHANNEL SUPPORT AND RETAINER ASSEMBLY SCREW AND WASHER PY478 Fig 5 Lower Front Track Support holes in door inside panel 3 Secure with screw and washer to manual win dow regulator or electric window regulator FRONT DOOR GLASS INSTALLATION 1 Install glass rear stabiliz...

Page 194: ...nt track attachment so front of window is aligned with rear edge of front door glass by pushing track adjusting stud fore and aft in support slot To get secondary seal turn adjusting screw in and out as required Secure jam nut on adjusting screw Front Up Stop 6 Push front up stop bracket on front track down against slide on lower frame and secure at taching nut Rear Up Stop 7 Push rear up stop bra...

Page 195: ...e and Up Stops PY487 major access hole in quarter inside panel Position to front track slots in full down position 4 Secure with screw and washer SLIDE AND UP STOP TO QUARTER GLASS Fig 12 1 Position glass and frame assembly on bench 2 Apply lubricant to bolt and slide track 3 Assemble lubricated bolt to washer and slide 4 Position threaded end of bolt with slide and washer assembly to taped hole i...

Page 196: ...quarter inside panel insert idler arm roller slide in pivot bracket channel position mounting plate or motor bracket to at taching holes in quarter inside panel and secure with screw and washer DART INDEX Page Sedan Door Glass Adjustments 35 Door Glass Replacement 36 Glass Replacement Rear Doors 37 Rear Doors Adjustment 36 Rear Door Stationary Glass 37 Regulator Replacement 36 Regulator Replacemen...

Page 197: ... and rear track assembly to door 6 Assemble bellcrank rear slide and lift bracket to glass 7 Assemble glass and slide assemblies and install on lift channel and regulator arm slide to glass 8 Install up stops to track front and rear to door 9 Install inner panel belt reinforcement bracket to door panel 10 Install bumper down stop to lower center of door Window Regulator Fig 3 The regulator is moun...

Page 198: ...2 Assemble bracket for rear slide to track slide and glass assembly 3 Assemble gasket to rear track bracket 4 Assemble spacer and tee nut to rear track slide 5 Assemble washer and stud to front door glass hook front and rear 6 Install gasket to lift channel and spacer to channel 7 Install washer gasket and spacer to lift channel assembly 8 Assemble bellcrank and gasket to glass surface pushing stu...

Page 199: ...g vent wing up or down UP STOP SCREW AND WASHER VIEW IN CIRCLES A AND B ASSEMBLY TRACK STABILIZER U NUT DOOR PF583 Fig 10 Glass Stabilizer The assembly moves forward and downward to re lieve a binding condition of the door glass and rear ward and upward to remove looseness Loosen vent wing to door face screws and adjusting screws at lower end of division channel With glass raised move entire vent ...

Page 200: ...Loosen front run channel lower mounting screw Fig 12 2 Move run channel forward and slide glass out of channel 3 Remove regulator arm from lift bracket chan nel 4 Remove glass from door 5 Push plug out of lift bracket rivet 6 Pinch expandable ends of rivet together and push rivet out of glass Installation 1 Position lift bracket and gasket on glass and install rivet and plug Before installing glas...

Page 201: ...pper and lower ends Fig 15 and remove channel 2 Move the glass and weatherstrip assembly forward and out of window opening 3 Inspect the weatherstrip LIFT BRACKET Fig 14 Rear Door Glass Replacement Sedan LUBRICANT NP619 EALER UPPER RUN SECTION A A NP618 Fig 15 Rear Door Stationary Glass Sedan Installation 1 Position glass and weatherstrip assembly to window opening and move rearward into upper fra...

Page 202: ...o be reinstalled place on a protected surface 7 All old adhesive should be removed from glass and opening reveal using a putty knife or razor blade DO NOT use an oil base solvent to remove adhesive 8 Using steel wool remove loose flakes of adhe sive and old primer from reveal Use light air pres sure to clean reveal and surrounding areas Installation 1 Inspect moulding retaining clips Remove and st...

Page 203: ...vers WINDSHIELD Non Cemented Type Removal 1 Cover cowl hood and fender area with a pro tective covering 2 Remove windshield garnish mouldings 3 Remove windshield outer mouldings using Tool C 4009B 4 Unlock weatherstrip Fig 4 by prying lip of weatherstrip apart inserting a fibre wedge and with a slight twist to wedge unlock weatherstrip by mov ing tool around weatherstrip 5 Carefully loosen weather...

Page 204: ...s on outside from inside car push against glass at one of the upper corners and remove glass from weatherstrip 4 Place glass on a cloth covered bench 5 Remove weatherstrip from fence Fig 6 Installation 1 Inspect weatherstrip fence to be certain it is clean smooth and straight 2 Flow a continuous ribbon of sealer on each lip and around entire length of weatherstrip glass groove 3 Install weatherstr...

Page 205: ...pect relationship of glass to fence complete ly around opening The glass to body fence overlap QUARTER GLASS QUARTER WINDOW WEATHER STRIP PB212 Fig 9 lnstall ng Quarter Window Weatherstrip should be equal across the top and sides 5 Apply a piece of masking tape over each side of glass and roof extensions Slit tape vertically at edge of glass so when glass is installed tape on glass can be aligned ...

Page 206: ...ick 17 Clean interior surface of glass 18 Water test window Use a cold water spray do not run a heavy stream of water directly on fresh ly applied adhesive If leaks are evident work applied adhesive into leak point Additional material can be applied and worked into leak point 19 Install mouldings clean glass exterior surface and remove protective covers STATION WAGON GLASS REPLACEMENT NON CEMENTED...

Page 207: ...pull lip of weatherstrip over glass Fig 13 GLASS APPLICATION AT B B APPLICATION AT A A NU44l 6 Seat glass in weatherstrip using hand pres sure 7 Apply rubber lubricant to weatherstrip locking tab and insert locking tab into weatherstrip groove using a fiber stick 8 Apply and press secure sealer to joint of weatherstrip body lock upper pillar and roof side rail outer front area Fig 14 9 Apply and p...

Page 208: ... if ap plicable 2 Cut through adhesive using tempered wire 028 gauge maximum 3 Remove the glass from opening by applying even pressure on inside of glass FRAME Fig 18 Glass Installation Installation 1 Remove old adhesive and old primer from fence using steel wool Do na use on oil base solvent to remove adhesive 2 Wipe the bond surface of fence using lactol spirits or equivalent 3 Follow immediatel...

Page 209: ...face 10 Apply butyl tape to entire periphery of fence starting from the middle of the belt Fig 17 11 Check to see that tape is installed in trough 12 Cut excess tape away and butt the ends with sufficient pressure to form a tight contact 13 Do not compress tape below spacer lip on fence Fig 17 14 Install glass by hand using care not to con taminate primed surfaces 15 Index glass against the B pill...

Page 210: ...oof To close the roof panel the switch is moved to the CLOSED position The panel then moves for Page Operation 1 Roof Weatherstrip 14 Service Procedure 6 Sunroof Manual Sliding Top 13 ward in the guide rails and as it nears the end of forward travel the rear portion moves upward on two ramps Fig 2 then the lifter places the panel flush with the roof and seals it tightly in the opening The Sunroof ...

Page 211: ...o flexible gear cables that are attached to the roof panel and control its movement Fig 6 Four plastic drain tubes one on each side are in corporated in the windshield pillar area and in the rear quarter area to catch water seepage that may by pass the weatherstrip seal around the roof open ing The two forward tubes Fig 7 are routed from the roof panel trough down through the right and left windsh...

Page 212: ...ANUAL OPERATING HANDLE CRANK HANDLE Fig 4 Crank Handle Application MOTOR CONNECTION PIGTAIL MOTOR ELECTRIC MOTOR DRIVE CLUTCH SCREW MOTOR TO SWITCH PIGTAIL Fig 5 E ectric Motor DRIVE PINION SWITCH PD347 MyMopar com ...

Page 213: ... GUIDE UPPER DRIVE GEAR FLEXIBLE CABLES PD348 Fig 6 Drive Pinion Gear and Cables control switch on the roof panel Two wires one for from the switch to the motor A wire from the motor the open cycle and one for the close cycle are routed is grounded to the windshield header by a screw PD349 Fig 7 Drain Tubes MyMopar com ...

Page 214: ...ND INSERT IN WIRE E TERMINAL FEMALE TERMINAL 4 0 0 9 00 2096466 TERMINAL 2097173 INSULATOR A B C D E F K CIRCUIT BREAKER TO RELAY RELAY TO BATTERY TERMINAL PIGTAIL FROM BATTERY TERMINAL RELAY TO IGNITION HARNESS PIGTAIL TO IGNITION WIRE HEADER WIRE GROUND TO INSTRUMENT PANEL 35 00 5 00 2 00 9 00 4 00 78 00 14 00 RED RED RED BLUE WHITE BLUE WHITE RED BLACK MAIN INSTRUMENT PANEL WIRING HARNESS 24277...

Page 215: ...f required Panei Alignment Rear Left or Right 1 To obtain a flush fit with the roof loosen 3 8 locknut on lifter pin Fig 11 2 Using a screwdriver turn adjusting screw clockwise to lower roof panel and counterclockwise to raise panel Fig 11 3 After proper alignment is obtained tighten locknut 4 Adjust opposite rear lifter pin in same man ner if required Ramp Alignment 1 If roof panel does not rise ...

Page 216: ...anel Doesn t Run True c Cable Guide Alignment d Not Enough Clutches e Guide Shoe Jammed on Track f Lifter Pin Broke a Normal Wear a Bad Switch b Circuit Breaker c Wiring Harness Connectors d Motor Connector e Bad Motor a Repair Jammed Area b Align Panel c Adjust Cable d Add Clutch Washers e Adjust Guide Shoe f Replace Lifter Pin or Cable Assem blies a Replace Cable a Replace Switch b Check Breaker...

Page 217: ...TOR HOUSING CABLE GUIDE DRAIN TUBE FRONT DRAIN TUBE FRONT GUIDE RAIL LEFT CORNER CABLE GUIDES GUIDE SHOE ASSEMBLY GUIDE RAIL RIGHT VINYL COVER SLIDING PANEL DRAIN TUBE REAR HEADLINER PANEL FRAME Fig 13 Roof Panel Disassembled View PD355 MyMopar com ...

Page 218: ...rom headliner 2 Pull electrical connector through opening and disconnect wires Installation 1 Install connector wires on switch 2 Install switch through front of headliner by pressing switch in until retaining clip engages 3 Test switch for proper function SUNROOF PANEL REAR SLIDE AND CABLE Fig 13 Panel Removal 1 Open Sunroof approximately three inches 2 Remove two screws from front of headlining ...

Page 219: ... the right cable is routed in the straight center FRONT GUIDE ASSEMBLY ROTATED INBOARD GUIDE RAIL PD359 Fig 7 7 Removing Lifter Pin and Cable Assembly from Retainer track of the drive cable housing and into the lower track on left side 5 Lubricate cables at the areas of the elbow guides with Lubriplate or equivalent and install both front corner upper guide shoes 6 Recheck cable assembly for cente...

Page 220: ...n slide retainers on roof paüeî 6 Engage each rear lifter pin into retainer hole and install retainer spring plate on slide pin 7 Actuate switch check operation of roof panel and note fit of panel to roof If any adjustments are necessary refer to Adjustment and Repairs 8 Install headlining on roof panel DRAIN HOSE REPLACEMENT Front Drain Hose ï i v a11 g a r Ì S h m o u l d i n gs and carefully pu...

Page 221: ...8 12 SUNROOF ì 4 MyMopar com ...

Page 222: ...ly in the opening and weatherstrips For part name identification see Legend for Figure 22 in this unit For part identification see Figure 22 in this unit LEGEND FOR FIGURE 22 1 Housing 2 Bracket Track 3 Bracket Rear 4 Tube Housing Rear 5 Tube Housing Front 6 Track Housing Right Left 7 Retainer Track 8 Cover Cable Side 9 Coyer Cable Front 10 Guide Cable Front 11 Screw Oval Head Tapping 12 Guide Ass...

Page 223: ...e Installation 1 Apply a 75 diameter ball of sealer to joint of roof panel and reinforcement Fig 23 2 Press sealer into joint to effect proper seal 3 Apply seal assembly to roof and reinforcement starting at either rear edge of roof panel 4 Press firmly onto flange around perimeter of opening as shown in Fig 23 5 Install seal assembly to roof sliding panel using fasteners starting with hole in cen...

Page 224: ...ement becomes tacky position cover on roof aligning centerline marks 5 Apply cement to one half of roof panel and extension and to the cover half on same side Fig 2 6 When the cement becomes tacky position cov er on roof panel 7 Repeat steps 5 and 6 for the opposite side 8 Using a new paint roller pressurize cover to the roof working from center area toward drain troughs 9 Press cover into windshi...

Page 225: ... rear window mouldings 22 Remove masking material and inspect cover for air bubbles AIR BUBBLE REMOVAL 1 Place strips of masking tape over surface of bubble 2 Using a No 19 hypodermic needle and suitable syringe insert 3M Vinyl Trim Adhesive No 8064 or equivalent into bubble area Extreme care must be used to avoid depositing any adhesive on the top surface of the vinyl cover The perforation must b...

Page 226: ...leaner when necessary 3 Remove about two tablespoons of Chrysler Grain on material or equivalent from the container place it on a steel or glass surface then apply 10 to 12 drops of catalyst from the small bottle quickly mix it together thoroughly and spread it evenly over the paintable mold release area using the offset pallette knife working the Grain on or equivalent into the Fig 8 Mixing Grain...

Page 227: ...ween edges to be welded for expansion contraction and for a good bite by the welding compound 3 Heat vinyl around tear to reactivate glue and press vinyl into it If it will not stay down use Chrysler vinyl top to metal glue or equivalent keep ing at least one sixteenth inch away from all edges to be welded 4 Clean area to be refinished with Chrysler Parts Leather Cleaner or equivalent and allow to...

Page 228: ...he vinyl material around the hole To correct this remove the heat using the thumb of your free hand to press the edges of the vinyl material down into the welding compound the edges will now lie flat as you apply heat to cure the weld UNLESS THE WELDING COMPOUND IS PROPERLY CURED IT WILL FALL APART 14 At first the welding compound will appear milky but as the heat cures it it will turn translucent...

Page 229: ...g 18 First Layer Application VINYL TOPv INTERMEDIATE IBS R O O F LAYER S REPAIR AREA PB88 Fig 19 Secondary Layer Application Fig 21 Grain Pattern Die Application Fig 22 Vinyƒ Color Spray LEVEL SURFACE WITH TOOL EDGE Fig 20 Final Layer Application Fig 23 Finisfied Repair MyMopar com ...

Page 230: ...F FOREIGN SUBSTANCES BE REMOVED FROM THE SUR FACE AND GRAIN OF THE VINYL MATERIAL SPRAYING OF COLORS Chrysler Uticolor or its equivalent materials are not paints or dyes but liquid vinyl The vinyl surface must be properly cleaned The first coating should be a wet one not flooded allowing it to dry about fifteen minutes depending on the atmosphere The second a normal spray coating If blushing occur...

Page 231: ...y and remove backing paper in a smooth 180 degree motion Under hot humid conditions a slight jerking motion will aid in paper backing removal Thoroughly wet application surfaces of body and the adhesive surface of the overlay with the wetting solution and immediately apply overlay grained side out to the body Adjust overlay so 1 2 inch of mate rial shows beyond all edges and apply wetting solu tio...

Page 232: ...EFLECTOR ROOF AIR QUARTER PANEL MOULDING ƒ SECTION L L APPLY HEAT THEN CUT SLIT WITH PLASTIC TOOL AFTER APPLICATION OF OVERLAY AND PRESS TO METAL AS SHOWN MATCH COLORS ON GAS INDEX OVERLAY TO T A N K C O V E R T O COLORS ON PANEL SLOTS AS SHOWN DARí WOOD GRAIN VIEW IN CIRCLE Z AND Y TYPICAL FOR ALL OVERLAYS L I G H T WOOD GRAIN l OO FLAT TRIM TO EDGE OF METAL SECTION E E FUEL FILLER DOOR COVER LEF...

Page 233: ... CIRCLE Z TAILGATE OUTER PANEL SECTION J J FRONT FENDER PANEL BUMPER 38 MIN THIS AREA TO BE APPLIED WITH DOOR PARTIALLY OPEN 38 MIN SECTION E E LEFT SIDE ONLY REAR DOOR OUTER SECTION A A TAIL LAMP RIGHT SIDE 38 MIN PANEL QUARTER OUTER REAR PANEL TAILGATE OUTER 38 MIN TAIL LAMP FILLER TAIL LAMP OPENING TO TAILGATE SECTION H H Fig 2 Wood Grain Application Coronet SECTION B B F R O T D E R f FRONT DO...

Page 234: ...s prepared by adding two or three level teaspoons of a mild detergent per one gallon of clean warm 80 degrees to 95 degrees F water NEVER USE SOAP OR HARSH DETER GENTS 15 Immediately apply wetted decorative film to body Apply wetting solution to outer surface of film to provide for easy squeegeeing 16 Using a squeegee pressurize film to body with firm overlapping strokes to remove all air bubbles ...

Page 235: ...required bump out any dings in the sheet metal by approved procedures 3 Remove as much of the wood grain panel as possible by peeling it back starting at one corner A heat lamp steam jet or heat gun may be used to soften the film and adhesive and thereby facilitate removal 4 If all the wood grain film cannot be removed by hand the panel must be sanded down to the primer or bare metal using 50 to 8...

Page 236: ...ngs Repair of Ma or Damage to the Clear Top Coat 1 To repair extensive surface scratches and marks in the clear coating remove the mouldings surrounding the wood grain film 2 Lightly sand the entire panel removing all defects with 400 grit sandpaper 3 Wipe off the surface with a clean rag damp ened with a clean solvent such as VM P naphtha isopropyl alcohol or heptane 4 Tack off with tack rags to ...

Page 237: ...per ation If the base printed woodgra n film is damaged during sanding the entire applique must be replaced 2 Wipe off the surface with a clean rag damp ened with a clean solvent such as VM P naphtha isopropyl alcohol or heptane 3 Tack off with tack rags to remove all dirt and lint from the sanded surfaces 4 Using a touch up brush apply an Air Dry Re pair Clean Enamel Top Coat Minimum film thickne...

Page 238: ...MATION The procedures for weatherstrip sealing and re placement are incorporated with the procedures of the component unit The sealing illustrations used in this unit show the area sealed during manufacture of the vehicle These areas should be considered when testing for leaks For added information to sealing windnoise and HOLD GUN NOZZLE IN DIRECTION OF ARROW N D O NOT SPRAY OR FLOW V 3 SEALER IN...

Page 239: ... PILLAR FRONT FLOOR PAN DASH PANEL SEALER COWL SIDE SILL INNER VIEW IN DIRECTION OF ARROW Z PD43O SEALER NU364 Fig 5 Quarter Panel Inside D cate the area for sealing When testing with water use a spray simulating rain or a garden hose with out the nozzle and regulate the pressure to an ap proximate 3 inch stream All water tests must be made starting at the bottom of the door opening or weatherstri...

Page 240: ...SEALER BALL SEALER REAR FLOOR PANEL EXTENSION BALL SEALER VIEW IN CIRCLE X VINYL SEAL GLASS ASSEMBLY QUARTER WINDOW SEALER SIDE SILL OUTER 2 DOOR HARDTOP OR 2 DOOR SPECIAL QUARTER PANEL WHEEL HOUSE PANEL WHEEL HOUSE INNER PANEL VIEW IN DIRECTION VIEW IN DIRECTION OF ARROW U 3 8 DIA BEAD SEALER WHEELHOUSE ASSEMBLY RIGHT SIDE VIEW IN CIRCLE W OF ARROW Y VIEW IN DIRECTION OF ARROW Z PF25 Fig 7 Quarte...

Page 241: ... THROTTLE CABLE MUST BE DASH KEPT FREE OF SEALER PANEL SEALER COWL TOP PANEL BALL SEALER v 1 00 DASH PANEL VIEW IN DIRECTION OF ARROW W VIEW IN CIRCLE X Fig 9 Dash Panel and Cowl Top W COWL TOP PANEL DASH PANEL SEALER SEALING WASHER BALL PF2l SEALER DASH PANEL SEALER SEALER VIEW IN CIRCLE Z SEALER DASH PANEL VIEW IN CIRCLE Y THIS AREA TO BE KEPT FREE OF SEALER BRUSH SEALER OVER WELDS NOTE HOLE FOR...

Page 242: ... DIRECTION OF ARROW Z Fig 11 Dash Panel and Cowl Top L PF23 DASH PANEL LEFT SEALING WASHER STUD BALL SEALER DASH PANEL PANEL COWL TOP VIEW IN DIRECTION OF ARROW W SEALER DASH PANEL VIEW IN CIRCLE Y SEALER VIEW IN CIRCLE V TYPICAL EACH SIDE DASH LINER FASTENER FRONT FLOOR PAN SEALER VIEW IN CIRCLE Z COWL PLENUM SEALER VIEW IN DIRECTION OF ARROW X PANEL COWL PLENUM DASH PANEL BALL LEFT DASH PANEL SE...

Page 243: ...TRIP RETAINER VIEW IN DIRECTION OF ARROW S ROOF RETAINER WEATHERSTRIP ROOF SIDE DRAIN TROUGH ATTACH SLOT ROOF EXTENSION TROUGH ROOF SIDE DRAIN REAR OUTSIDE QUARTER PANEL BALL SEALER SEALER VIEW IN DIREaiON OF ARROW K 2 DOOR HARDTOP Fig Ì3 Roof Rail D TROUGH ROOF SIDE DRAIN FRONT ROOF RAIL SIDE OUTER ROOF RAIL INNER VIEW IN DIREaiON OF ARROW Z PF16 ROOF SIDE DRAIN ROOF PANEL 1 2 DIA BALL SEALER ROO...

Page 244: ...NER VIEW IN CIRCLE T ROOF RAIL SEALER ROOF PANEL QUARTER PANEL DRAIN TROUGH SEALER PILLAR SEALER VIEW IN DIRECTION OF ARROW Y Fig 7 5 Roof Rail J SEALER DRAIN TROUGH SEALER PILLAR OF ARROW Z SEALER AREA LOWER FRONT PILLAR PF17 VIEW IN DIRECTION OF ARROW X SEDAN SIDE DRAIN TROUGH SEALER FRONT UPPER BODY PILLAR SEALER WINDSHIELD FRAME ROOF SIDE RAIL OUTSIDE QUARTER PANEL VIEW IN DIRECTION OF ARROW W...

Page 245: ...OUTER BALL SEALER COWL TOP COWL SIDE PANEL SEALER DASH PANEL VIEW IN CIRCLE X FRAME WINDSHIELD y COWL TOP SIDE OUTER VIEW IN DIRECTION CAP BODY OF ARROW Y S I D E S I L L PANEL COWL SIDE SEALER SIDE SILL INNER OF ARROW W BALL SEALER WINDSHIELD FRAME JL jf L O W E R J PILLAR BALL SEALER SEALER PANEL COWL SIDE PANEL P I L L A R C O W L S I D E SEALER VIEW IN DIRECTION SEALER DASH PANEL REINFORCEMENT...

Page 246: ...ig 19 Front Pillar J SEALER COWL INNER SIDE BALL SEALER SEALER BALL SEALER BALL SEALER DASH PANEL SILL INNER FRONT COWL PLENUM COWL TOP VIEW IN DIRECTION OF ARROW A FOR MANUAL TRANSMISSION ONLY DASH PANEL SEALER FRONT FLOOR PAN COWL PLENUM DASH PANEL SEALER COWL INNER SIDE SEALER BALL SEALER VIEW IN DIRECTlOt LOF ARROW B FRONT FLOOR PAN NOTE REMOVE EXCESS SEALER AND MAINTAIN A SMOOTH SURFACE NOTE ...

Page 247: ... VIEW IN CIRCLE T QUARTER PANEL EXTENSION QUARTER PANEL BALL SEALER SEALER QUARTER PANEL BAU SEALER SEALER BALL SEALER QUARTER PANEL REINFORCEMENT BALL SEALER STRIKER UPPER DECK PANEL DRAIN TROUGH LOWER DECK PANEL SEALER DRAIN TROUGH SEALER OUTSIDE QUARTER PANEL VIEW IN DIRECTION OF ARROW S LOWER DECK PANEL REAR FLOOR PAN OF ARROW Z DRAIN TROUGH LOWER REINFORCEMENT BALL SEALER VIEW IN CIRCLE U SEA...

Page 248: ...ORNER VIEW IN DIRECTION OF TAILGATE PANEL P A N E L SEALER WHEELHOUSE AND QUARTER PANEL PANEL EXTENSION SUPPORT OUTSIDE QUARTER PANEL QUARTER PANEL INSIDE REAR LEFT r QUARTER OUTSIDE PANEL WHEEL HOUSE PANEL GUSSET RETAINER BALL SEALE SEALER QUARTER PANEL EXTENSION VIEW IN CIRCLE W VIEW IN DIRECTION QUARTER OF ARROW P P A N E L S BRACKET QUARTER PANEL GUSSET QUARTER OUTSIDE PANEL VIEW IN DIRECTION ...

Page 249: ... FLOOR PAN FRONT QUARTER PANEL TO REAR FLOOR PAN EXTENSI _ REAR FLOOR PAN y E W IN DIRECTION OF VIEW IN DIRECTION ARROW W OF ARROW V LEFT SIDE CENTER FLOOR PAN BALL SEALER CENTER ONT EXTENSION C E N J E R FLOOR PAN WHEEL HOUSE INNER REAR FLOOR PAN FRONT FLOOR PAN WHEEL HOUSE OUTER PANEL VIEW IN DIRECTION OF ARROW Z RIGHT SIDE TAIL PIPE PLATE SEALER VIEW IN DIRECTION OF ARROWJ 4 00 VIEW IN CIRCLE U...

Page 250: ...ION OF ARROW T 3 4 INCH SEALER BALLS VIEW IN DIRECTION OF ARROW V INCH SEALER BALLS VIEW IN DIRECTION OF ARROW Z VIEW OF s 3c VIEW X O F SEALER IN DIRECTION ARROW U IN DIRECTION ARROW R SEALER VIEW OF IN DIRECTION ARROW W VIEW OF IN DIRECTION ARROW S VIEW OF IN DIRECTION ARROW X SEALER VIEW IN DIRECTION OF ARROW Z NU365 Fig 25 Underbody D MyMopar com ...

Page 251: ...AR FLOOR PAN EXTENSION VIEW IN DIRECTION OF ARROW B 2 DOOR COUPEƒ HARDTOP AND SPECIAL m SEALER DECK RETAINER TROUGH QUARTER PANEL D R A I N TROUGH VIEW IN DIRECTION OF ARROW J QUARTER PANEL SEALER DECK EXTENSION LOWER VIEW IN DIRECTION DECK PANEL OF ARROW R SEALER REAR FLOOR PAN DRAIN TROUGH D R A N LOWER G H DECK PANEL SEALER QUARTER PANEL LOWER DECK RETAINER DECK EXTENSION SEALER STRIKER QUARTER...

Page 252: ...RROW N QUARTER PANEL QUARTER PANEL TAIL LAMP GUSSET TAIL LAMP OPE RIGHT SIDE 3 4 DIA BALL SEALER 1 8 DIA BEAD SEALER VIEW IN DIRECTION OF ARROW P CENTER PILLAR ROOF PANEL REAR ROOF ƒ f HEADER FRAME QUARTER PANEL OUTSIDE EXTENSION QUARTER PANEL ROOF PANEL 1 8 DIA BEAD SEALER TAILGATE PILLAR REAR FLOOR PAN TO TAIL 3 4 DIA BALL SEALER HEADER FRAME VIEW IN DIRECTION OF ARROW T REAR SUPPORT BUMPER IMPA...

Page 253: ...ALER REINFORCEMENT FLOORPAN F L O O R P A N FLOOR PAN CENTER VIEW IN CIRCLE U WHEELHOUSE INNER FRONT FLOOR PAN WHEELHOUSE OUTER FLOOR PAN COVER REAR FLOOR PAN VIEW IN DIRECTION OF ARROW W CONSOLE MODELS REAR FLOOR PAN EXTENSION WHEELHOUSE OUTER VIEW IN DIRECTION OF ARROW Y FLOOR PAN CENTER RIGHT QUARTER PANEL TO REAR FLOOR PAN FLOOR PAN CENTER LEFT VIEW IN DIRECTION OF ARROW X VIEW IN DIRECTION OF...

Page 254: ...or chrome finish and can SEALERS AND COMPOUNDS easily be removed with a cloth before it sets Super Rubber Cement May be used where a strong bonding of rubber parts to painted or unpainted steel surfaces is desired attachment of weatherstrip on door and luggage com partment lid or for attachment of felt pads Windshield Rubber Seais A heavy viscosity rubber expander Sealer can be used where rubber i...

Page 255: ...plied to a coat of a product when enough of the solvent has passed off for recoating Page Ref nish ng 2 Rust Protection 2 Spot Repairs 3 Paint Bake Oven Treatment Textured Grilles 3 Paint Charts 4 This is a coat of thinner to which may be added a small amount of retarder and applied as a final coat to increase flow and lustre of lacquer type finishes Priming The function of a primer is to form a b...

Page 256: ... or equivalent A chemically clean surface allows for effective sanding and assures adhesion of the undercoats and finish color 3 Sand old finish This operation removes sur face deterioration feathers out scratches nicks stone bruises or any other minor imperfections Water sand with MOPAR Multi Purpose 360 grit paper or its equivalent 4 Blow off entire car using high pressure air to eliminate dirt ...

Page 257: ... from heat before car enters paint bake ovens or be completely removed from cars FIBER GLASS FINISHES Fiber glass should be treated much the same as body steel however it is a non corrosive material and does not require chemical conditioners Replacement or new panels may contain silicone oils on the surface due to the manufacturing process used These oils must be removed from the surface Fiber Gla...

Page 258: ...Y7OFQ5 AY7OHT8 AY69EW1 AY69TX9 AY69FY1 AY69DY2 AY69JY3 AY7OJY6 AY7OJY9 or STRIPING COLORS CHRYSLER CODE 2513 2424 2423 2306 2508 2136 2515 2316 2514 2312 2427 2301 2425 2033 9300 2211 8I574 2517 2509 2510 equivalent D W L J D W L J D W L J D W L J D D W L J D W L J D W L J D W L J D D W L J D D D W L J D W L J W L J D D W L J D W L J D W L J DITZLER CODE 2033 9000 14016 23724 23740 44647 or equiva...

Page 259: ...chman I Wheelhouse tire cover moulding and grille assembly wheelhouse cover m Quarter window and upper tailgate moulding coachman n Roof rail mouldings o Rear deck and seat panel assembly floor COLOR NAME CHRYSLER CODE NO DITZLER CODE DIA REMARKS Black Dark Blue Poly Dark Parchment Light Parchment Light Gold Dark Gold Dark Green AB61DX9 AB61HB8 AB61HL5 AB61HL2 AB61JY5 AB61JY7 AB61HF6 9388 14486 23...

Page 260: ...ndow moulding o C pillar moulding and spare tire cover upper moulding p Headliner retainer roof rail and rear door q D pillar speaker grill r Floor pan assembly panels hinges fillers and mouldings s Tail gate upper garnish mouldings coachman t Quarter window belt moulding coachman COLOR NAME CHRYSLER CODE NO DITZLER CODE DIA REMARKS Black Dark Blue Poly Brite Blue Poly Dark Parchment Light Parchme...

Page 261: ...d e f g h h a b c d e f g a b c d e f g h a b c d e f g h a b c d e f g h INTERIOR LOW GLOSS FINISH COLORS CHALLENGER Used On a Instrument panel b Glove box door inner and outer check arm c Ash receiver face and handle d Stereo speaker grills e Steering column f Steering housing assembly g Steering column collapsible can h Housing steering column lock control with floor mounted transmission contro...

Page 262: ...rformed whenever the stub frame has been removed replaced or repaired As a guide in accomplishing body to frame align ment use original shims when replacing frame Align front suspension and aim headlights after body to frame alignment has been completed For SEDAN HARDTOP 1 IN EACH SIDE OF FRAMED 5 1 2 22 1 8 H6 33 H 4 1 16 body to frame alignment dimensions refer to Body Alignment Dimensions Follo...

Page 263: ...AME ALIGNMENT K MEMBER ATTACHING BOLT SIDE VIEW Fig 3 Body Alignment Dimensions Car line V and L PY9O9A FRONT SPRING POINT D OR E BODY O LINE SIDE VIEW Fig 4 Body Alignment Dimensions Carline B and J PY913A MyMopar com ...

Page 264: ...2 Fig 5 Body Alignment Dimensions Carl ne R and W 16 33 H T 21 35 16 33 53 33 52 41 STATION WAGON 44 50 44 52 STATION WAGON 57 98 60 90 STATION WAGON ü 7 32 A 4 72 5 22 STATION WAGON 1 20 1 02 STATION n WAGON NK1166C Fig 6 Body Alignment Dimensions Carline P and D MyMopar com ...

Page 265: ...52 44 52 STATION WAGON 52 41 STATION WAGON 60 90 STATION WAGON 472 5 22 STATION WAGON 1 36 1 02 STATION r WAGON Fig 7 Body Alignment Dimensions Carline C NK1168B 7 32 4 72 225 NP665 Fig 8 Body Alignment D mensions Carline Y MyMopar com ...

Page 266: ...ood on top of main support beam and to lower flat surface of the side sills Then lower rear axle to lowest position to assist in balancing body weight when frame assembly is removed 8 Position a hydraulic transmission jack under the frame rear crossmember It is recommended that the following service pro cedure be used when removing isolated stub frames after the above steps 1 through 8 have been p...

Page 267: ... and the bolts tight 2 Remove bumper to hood latch support bracket 3 Remove bumper rod assembly 4 Remove bumper rubber pad 5 The lower nut at the radiator yoke position should be removed on both sides 6 Do not loosen bolts at the dash foot position and at the frame rear position at this time 7 By supporting the body adequately on the sills but not on any portion at the front end sheet metal and lo...

Page 268: ...s and slide torsion bars toward the rear far enough to clear lower control arms Be careful not to damage balloon type seals See Front Suspension Group 2 in Chassis Service Manual 8 Remove ball joint studs from steering knuckles 9 Remove wheelhouse splash shields 10 Remove upper shock absorber attaching nuts then slide shock absorbers and dust shields out of well in frame 11 Remove upper control ar...

Page 269: ...al NOTE Removal and installation instructions listed below apply to both right and left side unless other wise indicated 1 Disconnect power steering return and pressure hose from left side only 2 Remove steering column to steering gear roll pin 3 Remove three 3 screws from floor plate 4 Remove two 2 screws from steering column to instrument panel bracket 5 Pull steering column away from steering g...

Page 270: ...EMBER ASSEMBLY FRONT LOWER ISOLATOR NOTE QUANTITY AS REQUIRED FOR PROPER HEIGHT DIMENSION CO O a BASE A N D SLEEVE REAR UPPER ISOLATOR O REAR LOWER ISOLATOR WASHER BOLT PF13 Fig I7 Rubber Isolated Crossmember And Stub Frame Carl ne R and W MyMopar com ...

Page 271: ...olts to 50 foot pounds Fig 13 5 Lower jack supporting engine enough to posi RUBBER ISOLATOR PF52 Fig 13 Matched Shims Position ng Carline R and W tion and align engine support bolts in slotted supports on crossmember 6 Position lower control arm with pivot shaft placed through isolated crossmember Pivot bracket against torsion bar adjusting bolt Install flatwasher and bolt and torque to 145 foot p...

Page 272: ... 19 Attach transmission torque shaft to transmis sion housing with one 1 screw and washer Attach one 1 clip securing front and rear rod to torque shaft Attach one 1 clip securing torque shaft to frame sidemember 20 Install torsion bar and install torsion bar re tainer 21 Lower car to ground allowing normal weight to be applied to lower control arm and tighten lower control arm shaft nut Torque nut...

Page 273: ...oor Pan 4 19 Shelf Trim Panel 4 9 Station Wagon 4 20 Second Seat Back 4 20 Second Seat Cushion 4 21 Third Seat Back 4 22 Page Third Seat Cushion 4 25 LUBRICATION Body Maintenance 2 1 Deck Lid Hinges 2 3 Deck Lid Latch 2 3 Door Hinges 2 1 Door Locks and Linkage 2 2 Door Lock Ratchet and Striker 2 2 Door Remote Links 2 2 Fuel Tank Access Door Hinge 2 5 Hood Hinges 2 1 Hood Lock and Safety Catch 2 1 ...

Page 274: ...ors 3 25 Fenders 3 22 Grille 3 25 Hood 3 20 Outside Air Vents 3 19 Radiator Yoke Support 3 22 Page Tailgate 3 31 Torsion Bar 3 32 Dart 3 47 Air Shield and Cross Bar 3 51 Bumpers 3 51 Deck Lid 3 56 Doors 3 52 Fenders 3 50 Grille 3 51 Hood 3 48 Outside Air Vents 3 48 Radiator Yoke Support 3 51 Polara Monaco 3 1 Bumpers 3 5 Cowl 3 1 Deck Lid 3 17 Doors 3 5 Fenders 3 4 Grille 3 5 Hood 3 3 Outside Air ...

Page 275: ... 6 4 Regulators 6 4 Regulator Arms Manual 6 4 Regulator Motor Replacement 6 4 Up Stops 6 4 Window Lift Switch 6 4 Glass Tailgate 6 21 Page Adjustments 6 21 Glass Replacement 6 21 Installation 6 21 Removal 6 21 Regulator Replacement 6 22 Installation 6 22 Removal 6 22 Hardtop Rear Door Glass 6 11 Adjustments 6 11 Glass Assembly 6 13 Glass Lift Brackets 6 13 Glass Replacement 6 11 Installation 6 12 ...

Page 276: ... 1 Roof Weatherstrip 8 14 Service Procedure 8 6 Sunroof Manual Sliding Top 8 13 Page VINYL ROOF Air Bubble Removal 9 2 Cover Replacement 9 1 Spraying of Colors 9 7 Vinyl Repair 9 4 Clean Surface 9 3 Making Graining Tool 9 3 WOOD GRAIN OVERLAY Application of Overlay 10 1 Inspection 10 4 Repairs Major Damage to Wood Grain Film 10 5 Major Damage to Clear Top Coat 10 4 Minor Damage to Clear Top Coat 1...