STATIONARY GLASS
INDEX
page page
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS................... 4
REMOVAL AND INSTALLATION
BODY SIDE/SLIDING DOOR STATIONARY
GLASS............................... 6REAR WINDOW.......................... 7
WINDSHIELD............................ 4
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCHWELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
CHRYSLER DOES NOT RECOMMEND GLASS
ADHESIVE BY BRAND. TECHNICIANS SHOULD
REVIEW PRODUCT LABELS AND TECHNICAL DATA
SHEETS, AND USE ONLY ADHESIVES THAT THEIR
MANUFACTURES WARRANT WILL RESTORE A
VEHICLE TO THE REQUIREMENTS OF FMVSS 212.
TECHNICIANS SHOULD ALSO INSURE THAT PRIM-
ERS AND CLEANERS ARE COMPATIBLE WITH THE
PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
structural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficult
to cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.
REMOVAL AND INSTALLATION
WINDSHIELD
The urethane adhesive holding the windshield to
the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
WINDSHIELD REMOVAL ± EXTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Remove windshield wiper arms.
(3) Remove cowl cover.
(4) Remove A-pillar trim panels.
(5) Disconnect wire connectors to windshield
defroster grid.
(6) Place protective covers over instrument panel
and hood.
(7) Remove windshield molding (Fig. 1). Using pli-
ers, pull outward on molding at the bottom of A-pil-
lars.
(8) Using a sharp cold knife, cut urethane adhe-
sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 2). A power
cutting device can be used if available.
(9) Remove windshield from vehicle.
23 - 4 BODYNS
WINDSHIELD REMOVAL ± INTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Remove instrument panel top cover. Refer to
Group 8E, Instrument Panel and Systems.
(3) Remove A-pillar trim covers.
(4) Disconnect wire connectors to windshield
defroster grid.
(5) Place protective covers over instrument panel
and hood.
(6) Using a reciprocating or oscillating power
knife, cut urethane adhesive holding the windshield
to the A-pillars, roof header and cowl pinch weld
fences. Refer to instructions provided with the equip-
ment being used.
(7) Remove windshield from vehicle.
WINDSHIELD INSTALLATION
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment. If a door is slammed before
urethane bonding is cured, water leaks can result.
Allow the urethane at least 24 hours to cure
before returning the vehicle to use.
To avoid stressing the replacement windshield,
the urethane bonding material on the windshield
fence should be smooth and consistent to theshape of the replacement windshield. The support
spacers should be cleaned and properly installed
on weld studs or repair screws at bottom of wind-
shield opening.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the support spacers.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement windshield. If not, the pinch weld fence
must be formed to the shape of the new glass.
(3) Mark the glass at the support spacers with a
grease pencil or pieces of masking tape and ink pen
to use as a reference for installation (Fig. 3).
(4) Remove replacement windshield from wind-
shield opening.
(5) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 4).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(6) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.
(7) Install molding to perimeter of windshield.
(8) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of windshield and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.
(9) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying time.
(10) Using a razor knife, remove as much original
urethane as possible. Do not damage paint on wind-
shield fence.
(11) Apply pinch weld primer 15 mm (.75 in.) wide
around the windshield fence. Allow at least three
minutes drying time.
(12) If a low viscosity urethane adhesive is used,
install compression spacers on the fence around the
windshield opening (Fig. 5).
(13) Apply a 10 mm (0.4 in.) bead of urethane on
center line of windshield fence.
(14) With the aid of a helper, position the wind-
shield over the windshield opening. Align the refer-
ence marks at the bottom of the windshield to the
support spacers.
(15) Slowly lower windshield glass to windshield
opening fence. Guide the molding into proper position
as necessary. Push windshield inward until molding
is flush to roof line and A-pillars (Fig. 5).
Fig. 1 Windshield Molding
Fig. 2 Cut Urethane Around Windshield
NSBODY 23 - 5
REMOVAL AND INSTALLATION (Continued)
BODY COMPONENT SERVICE
INDEX
page page
DIAGNOSIS AND TESTING
WATER LEAKS.......................... 23
WIND NOISE........................... 24
SERVICE PROCEDURES
HEAT STAKING......................... 24
REMOVAL AND INSTALLATION
A-PILLAR LOWER EXTENSION TRIM........ 25
A-PILLAR TRIM PANEL................... 25
COWL COVER.......................... 25
COWL TRIM............................ 25
FLOOR CARPET........................ 26
FRONT DOOR APPLIQUE................. 28
FRONT DOOR CHECK STRAP.............. 28
FRONT DOOR FRAME CLOSEOUT MOLDINGS . 29
FRONT DOOR GLASS RUN WEATHER-STRIP . . 30
FRONT DOOR GLASS.................... 29
FRONT DOOR HINGE.................... 30
FRONT DOOR INNER BELT MOLDING....... 31
FRONT DOOR LATCH STRIKER............ 32
FRONT DOOR LATCH.................... 31
FRONT DOOR LOCK CYLINDER............ 32
FRONT DOOR OUTER BELT MOLDING....... 33
FRONT DOOR OUTSIDE HANDLE........... 33
FRONT DOOR REFLECTOR............... 34
FRONT DOOR SILL PLATE................ 34
FRONT DOOR TRIM PANEL................ 34
FRONT DOOR WEATHER-STRIP............ 36
FRONT DOOR WINDOW CRANK............ 36
FRONT DOOR WINDOW REGULATOR....... 36
FRONT DOOR.......................... 27
FRONT SEAT........................... 37
FRONT WHEELHOUSE SPLASH SHIELD..... 37
FUEL FILL DOOR BLOCKER LATCH STRIKER . . 38
FUEL FILL DOOR BLOCKER LATCH......... 38
FUEL FILL DOOR BLOCKER LOCKOUT LINK . . 38
FUEL FILLER HOUSING ± WITH BLOCKER
LATCH .............................. 39
GRILLE............................... 39
HEADLINING........................... 39
HOOD HINGE.......................... 41
HOOD LATCH STRIKER................... 42
HOOD LATCH.......................... 41
HOOD RELEASE CABLE.................. 42
HOOD RELEASE HANDLE................. 42
HOOD................................ 40
JACK STORAGE COVER.................. 43
LEFT D-PILLAR TRIM PANEL............... 43
LEFT QUARTER TRIM PANEL.............. 44
LIFTGATE CHMSL ACCESS PANEL.......... 47
LIFTGATE HINGE........................ 47LIFTGATE LATCH STRIKER................ 47
LIFTGATE LATCH........................ 47
LIFTGATE LOCK CYLINDER............... 48
LIFTGATE OUTSIDE HANDLE.............. 48
LIFTGATE PROP ASSEMBLY............... 49
LIFTGATE SILL PLATE.................... 49
LIFTGATE STABILIZER WEDGE STRIKER..... 49
LIFTGATE STABILIZER WEDGE............. 49
LIFTGATE TRIM PANEL................... 50
LIFTGATE UPPER FRAME MOLDING........ 50
LIFTGATE UPPER FRAME SIDE MOLDINGS . . . 51
LIFTGATE............................. 46
LOWER B-PILLAR TRIM COVER............ 51
LUGGAGE RACK CROSSBAR.............. 51
LUGGAGE RACK RISER COVER............ 52
LUGGAGE RACK SIDE RAIL............... 52
OVERHEAD GRAB-HANDLES.............. 52
QUARTER GLASS....................... 52
QUARTER TRIM BOLSTER................ 53
RADIATOR CLOSURE PANEL CROSSMEMBER . 53
RAIL LAMP MODULE..................... 54
REAR HEADER TRIM..................... 55
REAR HVAC LOUVER AND BEZEL.......... 55
RIGHT D-PILLAR TRIM PANEL.............. 55
RIGHT QUARTER TRIM PANEL............. 56
ROOF APERTURE (RAP) MOLDING.......... 57
SEAT BELT BUCKLE FIRST REAR QUAD
BUCKET............................. 58
SEAT BELT BUCKLE FIRST REAR ± TWO
PASSENGER BENCH................... 58
SEAT BELT BUCKLE SECOND REAR ± THREE
PASSENGER BENCH................... 59
SEAT BELT BUCKLE ± FRONT INBOARD..... 57
SEAT BELT FIRST REAR ANCHOR BRACKET ±
LWB ................................ 59
SEAT BELT FIRST REAR OUTBOARD ± LWB
FOUR DOOR.......................... 60
SEAT BELT FIRST REAR OUTBOARD ± SWB
FOUR DOOR.......................... 60
SEAT BELT LEFT FIRST REAR OUTBOARD ±
LWB THREE DOOR..................... 61
SEAT BELT LEFT FIRST REAR OUTBOARD ±
SWB THREE DOOR.................... 61
SEAT BELT SECOND REAR OUTBOARD ±
SWB ................................ 61
SEAT BELT SECOND RIGHT REAR OUTBOARD
±LWB ............................... 62
SEAT BELT ± OUTBOARD FRONT........... 59
SECOND RIGHT REAR OUTBOARD SEAT BELT
± LWB W/REAR HVAC................... 62
23 - 22 BODYNS
INSTALLATION
(1) Insert link into clip on fuel fill door.
(2) Engage clip to hold link to fuel fill door.
(3) Insert lockout link through grommet in panel
between inner and outer quarter panel.
(4) Close fuel fill door.
(5) Install fuel filler housing to outer quarter
panel.
(6) Verify that all clips on fuel filler housing are
fully engaged to outer quarter panel.
(7) Engage fuel filler lockout link into clip on fuel
fill blocker latch arm.
(8) Install water shield patch covering access hole
in C-pillar.
(9) Install left quarter trim panel.
FUEL FILLER HOUSING ± WITH BLOCKER LATCH
REMOVAL
(1) Remove left quarter trim panel.
(2) Remove water shield patch covering access hole
in C-pillar.
(3) Disengage latch release link from clip on fuel
fill blocker latch arm (Fig. 38).
(4) Open fuel fill door.
(5) Remove screws holding fuel fill neck to fuel
filler housing.
(6) Position fuel fill neck out of the way.
(7) Reaching inside fuel filler housing, release clips
holding housing to quarter panel (Fig. 40).
(8) Remove fuel fill door from vehicle.
(9) Disengage clip holding link to fuel fill door
(Fig. 39).
(10) Remove link from fuel fill door.
INSTALLATION
(1) Install spring to housing and door
(2) Snap door into housing.
(3) Insert lockout link into clip on fuel fill door.
(4) Engage clip to hold link to fuel fill door.(5) Insert lockout link through grommet in panel
between inner and outer quarter panel.
(6) Close fuel fill door.
(7) Install fuel filler housing to outer quarter
panel.
(8) Verify that all clips on fuel filler housing are
fully engaged to outer quarter panel.
(9) Place fuel fill neck in position.
(10) Install screws to hold fuel fill neck to fuel
filler housing.
(11) Engage latch release link into clip on fuel fill
blocker latch arm.
(12) Verify fuel fill blocker latch operation.
(13) Install water shield patch to cover access hole
in C-pillar.
(14) Install left quarter trim panel.
GRILLE
REMOVAL
(1) Remove front fascia. Refer to Group 13, Frame
and Bumpers, for proper procedures.
(2) Disengage clips holding grille to front fascia
(Fig. 41).
(3) Remove plastic rivets holding grille to fascia.
(4) Remove grille from fascia.
INSTALLATION
(1) Position grille on fascia.
(2) Install plastic rivets to hold grille to fascia.
(3) Install clips to hold grille to fascia along bot-
tom of grille.
(4) Install front fascia. Refer to Group 13, Frame
and Bumpers, for proper procedure.
HEADLINING
REMOVAL
(1) Remove sun visors and vanity mirrors.
(2) Remove sun visor center supports.
(3) If equipped, remove coat hooks.
(4) If equipped, remove roof rail modules.
Fig. 39 Fuel Filler Lockout LinkFig. 40 Fuel Filler Housing and Door
NSBODY 23 - 39
REMOVAL AND INSTALLATION (Continued)
(5) Remove A-pillar trim covers.
(6) Remove B-pillar upper trim covers.
(7) Remove C-pillar upper trim covers.
(8) Remove D-pillar upper trim covers.
(9) Remove rear door opening header trim.
(10) If equipped, remove overhead console.
(11) If equipped, remove reading lamp.
(12) Remove dome lamp.
(13) Remove push-in locking fasteners holding
headlining to rear roof header (Fig. 42) or (Fig. 43).
(14) Remove headlining from roof.
(15) Extract headlining through rear door opening.
INSTALLATION
(1) Insert headlining through rear door opening.
(2) Place headlining in position on roof.
(3) Install left sun visor support.(4) Install push-in locking fasteners to hold head-
lining to rear roof header (Fig. 42) or (Fig. 43).
(5) Install right sun visor support.
(6) Install sun visors and vanity mirrors.
(7) If equipped, install roof rail modules.
(8) If equipped, install coat hooks.
(9) Install dome lamp.
(10) If equipped, install reading lamp.
(11) If equipped, install overhead console.
(12) Install rear door opening header trim.
(13) Install D-pillar upper trim covers.
(14) Install C-pillar upper trim covers.
(15) Install B-pillar upper trim covers.
(16) Install A-pillar trim covers.
HOOD
REMOVAL
(1) Raise hood to full up position.
(2) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation.
(3) Remove the top bolts holding hood to hinge and
loosen the bottom bolts until they can be removed by
hand (Fig. 44).
(4) With assistance from a helper at the opposite
side of the vehicle to support the hood, remove bot-
tom bolts holding hood to hinge.
(5) Remove the hood from the vehicle.
INSTALLATION
(1) Place hood in position on vehicle. With assis-
tance from a helper at the opposite side of the vehicle
Fig. 41 Grille
Fig. 42 Headlining ± SWB
Fig. 43 Headlining ± LWB
23 - 40 BODYNS
REMOVAL AND INSTALLATION (Continued)
LIFTGATE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Remove screws holding liftgate wire connector
to rear header.
(3) Disconnect liftgate wire harness from body
wire harness.
(4) Remove liftgate upper frame molding.
(5) Disconnect rear window washer hose from
spray nozzle.
(6) Support liftgate on a suitable lifting device.
(7) Remove screws holding support cylinders to
liftgate.
(8) Remove bolts holding liftgate hinge to roof
header (Fig. 55).
(9) With assistance, remove liftgate from vehicle.
INSTALLATION
(1) With assistance, place liftgate in position on
vehicle.
(2) Install bolts to hold liftgate hinge to roof
header.
(3) Install screws to hold support cylinders to lift-
gate.
(4) Remove lifting device from under liftgate.(5) Connect liftgate wire harness into body wire
harness.
(6) Install screws to holding wire connector to rear
header.
(7) Connect rear window washer hose onto spray
nozzle.
(8) Install liftgate upper frame molding.
Fig. 54 Left Quarter and D-Pillar Trim Panels ± SWB
Fig. 55 Liftgate
23 - 46 BODYNS
REMOVAL AND INSTALLATION (Continued)
(9) Verify liftgate alignment. The liftgate should
have a gap to adjacent panels and fit flush across the
gaps. The gap is;
²7 mm (0.280 in.) to the fascia,
²6 mm (0.240 in.) to the roof,
²4 mm (0.160 in.) to the aperture.
LIFTGATE CHMSL ACCESS PANEL
REMOVAL
(1) Using a trim stick (C-4755), disengage clips
holding CHMSL access panel to liftgate trim panel.
(2) Remove access panel from vehicle.
INSTALLATION
(1) Place access panel in position on vehicle.
(2) Engage clips to hold CHMSL access panel to
liftgate trim panel.
LIFTGATE HINGE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device.
(3) Apply several layers of duct tape on the outside
of to roof across the gap to the lift gate to hold the
liftgate in position.
(4) Remove bolts holding liftgate hinge to roof
header.
(5) Remove bolts holding hinge to liftgate (Fig. 56).
(6) Remove hinge from vehicle.
INSTALLATION
(1) If necessary, paint replacement hinge before
installation.
(2) Place hinge in position on vehicle.
(3) Align hinge to marks on liftgate.
(4) Install bolts to hold hinge to liftgate (Fig. 56).
(5) Align hinge to marks on roof header.(6) Install bolts to hold liftgate hinge to roof
header.
(7) Remove duct tape from roof and liftgate.
(8) Support liftgate on a suitable lifting device.
(9) Verify liftgate alignment. Refer to Liftgate
Remove and Installation for proper gap measure-
ments.
LIFTGATE LATCH
REMOVAL
(1) Remove liftgate trim panel.
(2) Disengage outside handle link from clip on
latch.
(3) Disconnect wire connector from liftgate ajar
switch (Fig. 57).
(4) Remove screws holding latch to liftgate.
(5) Remove latch from vehicle.
INSTALLATION
(1) Place latch in position on vehicle.
(2) Install screws to hold latch to liftgate.
(3) Pull downward on outside handle link and
engage link to clip on latch.
(4) Connect wire connector to liftgate ajar switch.
(5) Verify liftgate fit and operation. Adjust as nec-
essary.
(6) Install liftgate trim panel.
LIFTGATE LATCH STRIKER
REMOVAL
(1) Open liftgate.
(2) Mark outline of striker on sill to aid installa-
tion.
(3) Remove screws attaching striker to sill (Fig.
58).
(4) Remove striker from vehicle.
Fig. 56 Liftgate Hinge
Fig. 57 Liftgate Latch
NSBODY 23 - 47
REMOVAL AND INSTALLATION (Continued)
(2) Engage hidden clips to hold molding to liftgate
upper frame (Fig. 66).
LIFTGATE UPPER FRAME SIDE MOLDINGS
REMOVAL
(1) Remove liftgate upper frame molding.
(2) Disengage hidden clips holding side moldings
to liftgate upper frame (Fig. 66).
(3) Remove liftgate upper frame side molding from
vehicle.
INSTALLATION
(1) Place liftgate upper frame side moldings in
position on vehicle.
(2) Engage hidden clips to hold side moldings to
liftgate upper frame (Fig. 66).
(3) Install liftgate upper frame molding.
LOWER B-PILLAR TRIM COVER
REMOVAL
(1) Slide lower seat belt cover rearward to expose
anchor bolt.
(2) Remove bolt holding lower seat belt anchor to
floor.
(3) Remove upper B-pillar trim cover.
(4) Remove access panel from B-pillar trim (Fig.
67).
(5) Remove screw holding lower trim cover to
B-pillar from below seat belt retractor.
(6) Disengage hidden clips holding lower trim
cover to B-pillar.
(7) Remove lower B-pillar trim cover from vehicle.
INSTALLATION
(1) Place lower B-pillar trim cover in position on
vehicle.
(2) Insert seat belt through hole in lower B-pillar
trim.
(3) Engage hidden clips to hold lower trim cover to
B-pillar.
(4) Install screw to hold lower trim cover to B-pil-
lar below seat belt retractor.
(5) Install access cover.
(6) Install upper B-pillar trim cover.
(7) Place seat belt anchor in position on floor so
webbing is pointed rearward and slightly outboard.
(8) Install bolt to hold lower seat belt anchor to
floor. Tighten all seat belt bolts to 39 N´m (29 in.
lbs.) torque.
(9) Verify that seat belt anchor does not interfere
with seat track travel.
LUGGAGE RACK CROSSBAR
REMOVAL
(1) Remove luggage rack front riser covers.
(2) Disengage lock and slide crossbar forward into
notch in front riser (Fig. 68).
(3) Remove crossbar from roof.
Fig. 67 Lower B-pillar Trim Cover
Fig. 68 Luggage Rack Crossbar
NSBODY 23 - 51
REMOVAL AND INSTALLATION (Continued)