98 Voyager Body

7/30/2019 98 Voyager Body

1/86

BODY

CONTENTS

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BODY COMPONENT SERVICE . . . . . . . . . . . . . . 21GENERAL SERVICE INFORMATION . . . . . . . . . . . 1PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . . 4

GENERAL SERVICE INFORMATION

INDEX

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GENERAL INFORMATIONSAFETY PRECAUTIONS AND WARNINGS . . . . . 1

GENERAL INFORMATION

SAFETY PRECAUTIONS AND WARNINGS

WARNING: EYE PROTECTION SHOULD BE USED

WHEN SERVICING GLASS COMPONENTS. PER-SONAL INJURY CAN RESULT.

USE A OSHA APPROVED BREATHING FILTERWHEN SPRAYING PAINT OR SOLVENTS IN A CON-FINED AREA. PERSONAL INJURY CAN RESULT.

AVOID PROLONGED SKIN CONTACT WITHPETROLEUM OR ALCOHOL BASED CLEANINGSOLVENTS. PERSONAL INJURY CAN RESULT.

DO NOT STAND UNDER A HOISTED VEHICLE

THAT IS NOT PROPERLY SUPPORTED ON SAFETYSTANDS. PERSONAL INJURY CAN RESULT.

CAUTION: When holes must be drilled or punchedin an inner body panel, verify depth of space to the

outer body panel, electrical wiring, or other compo-nents. Damage to vehicle can result.

Do not weld exterior panels unless combustiblematerial on the interior of vehicle is removed from

the repair area. Fire or hazardous conditions, canresult.

Always have a fire extinguisher ready for usewhen welding.

Disconnect the negative (-) cable clamp from thebattery when servicing electrical components thatare live when the ignition is OFF. Damage to electri-cal system can result.

Do not use abrasive chemicals or compounds on

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

vents on painted or upholstered surfaces. Damageto finish or color can result.

Do not hammer or pound on plastic trim panelwhen servicing interior trim. Plastic panels can

break.

Chrysler Corporation uses many different types of

push-in fasteners to secure the interior and exterior

t r im t o t h e b od y. M os t of t h es e f a st en er s ca n b e

r eu s ed t o a s s em b le t h e t r i m d u r in g v a r i ou s r ep a ir

p r oced u r es. At t im e s, a p u sh-in f a st e n er ca n n ot be

r e m o ve d w it h o u t d a m a g in g t h e f a st e n e r o r t h e co m -

ponent it is holding. If it is not possible to remove a

fastener without damaging a component or body, cut

or br ea k t h e f a s ten er a n d u se a n ew on e w h e n

in st a l l in g t h e com p on e n t . N e ver p r y o r p ou n d on a

p la st ic or p r essed -boa r d t r im com p on e n t . U sin g a

su it a ble f o r k-t y p e p r y in g d e vice , p r y t h e f a st e n erfrom the retaining hole behind the component being

removed. When installing, verify fastener alignment

w it h t h e r e t a in in g h o le by h a n d . Pu sh d ir e ct ly o n o r

over t he fa stener unt il it seats. Apply a low-force pull

t o t h e p a n e l t o ve r i f y t h a t i t is se cu r e .

When it is necessary to remove components to ser-

v ice a n o t he r, i t s h ou ld n ot b e n ece ss a r y t o a p pl y

e xce ssive f o r ce or ben d a com p on e n t t o r e m ove i t .

B e f or e d a m a g i n g a t r i m com p on en t , v er i fy h i dd en

fast eners or captured edges holding the component in

place.

NS/GS BODY 23 - 1


2/86

PAINT

INDEX

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GENERAL INFORMATION

AFTERMARKET PAINT REPAIR PRODUCTS . . . 3BASE COAT/CLEAR COAT FINISH . . . . . . . . . . . 2

PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PAINTED SURFACE TOUCHUP . . . . . . . . . . . . . 2WET SANDING, BUFFING, AND POLISHING . . . 2

GENERAL INFORMATION

PAINT CODEA pa in t cod e is p r ovid ed on t h e bod y cod e p la t e

l oca t e d i n t h e en g in e com pa r t m en t . R ef er t o t h e

I n t r o d uct ion se ct ion a t t h e f r o n t o f t h is m a n u a l f o r

body code plat e description. The pa int an d trim codes

are also included on the Vehicle Safety Label locatedon the drivers door end frame.

BASE COAT/CLEAR COAT FINISHOn most vehicles a tw o-part paint applicat ion (base

coat /clear coat ) is used. C olor paint tha t is a pplied to

primer is called ba se coat . The clear coat protects th e

ba se co a t f r o m u lt r a vio le t l ig h t a n d p r o vid e s a d u r a -

ble high-gloss finish.

WET SANDING, BUFFING, AND POLISHINGMin or a cid e t ch in g , o r a n g e p ee l, or sm u d g in g in

cle a r coa t or sin gle-st a g e f in ish es ca n be r e d uced

w it h l ig h t w e t sa n d in g , h a n d bu f f in g , a n d p o lish in g .If the finish has been wet sanded in the past, itcannot be repeated. Wet sanding operationshould be performed by a trained automotivepaint technician.

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

durability.

PAINTED SURFACE TOUCHUPW h e n a p a in t e d m e t a l su r f a ce h a s be e n scr a t ch e d

or chipped, it should be touched-up as soon as possi-

ble to a void corrosion. For best results, use Mopar

Scra tch Filler/P rimer, Touch-U p P a ints a nd Clea r Top

C oa t . Re fe r t o I n t r o d u ct ion g r ou p o f t h is m a n u a l f or

B o d y C od e P la t e in f or m a t ion .

TOUCHUP PROCEDURE

(1) S cr a p e loose p a in t a n d cor r osion f r om in sid e

scratch or chip.

(2) C le a n a f f e ct e d a r e a w it h Mo p a r Ta r/Roa d Oil

Remover, and allow to dry.

(3) Fill the inside of the scratch or chip with a coat

of filler/primer. Do not overla p prim er onto good sur-

f a ce f in is h . Th e a p pl ica t or b ru sh s h ou ld b e w e t

enough to puddle-fill the defect without running. Do

n ot st r ok e br u sh a p p lica t or on bod y su r f a ce . Allow

the filler/primer to dry ha rd.

(4) C over t h e f i ller /p r im e r w it h color t o u ch -u p

paint . Do not overlap touchup color onto the original

co lo r co a t a r o u n d t h e scr a t ch o r ch ip . B u t t t h e n e w

color to the original color, if possible. Do not stroke

a p pl ica t o r b r us h on b od y s u r fa c e. Al low t ou ch u p

p a i nt t o d r y h a r d .

(5) O n v eh i cl es w i t h ou t cl ea r coa t , t h e t ou ch u p

color ca n be l ig h t ly w e t sa n d e d (1500 g r i t ) a n d p ol-

ished with rubbing compound.

(6) On vehicles with clear coat , a pply clear top coat

t o t ou ch up pa in t w it h t he s a me t ech niq ue a s

described in Step 4. Allow clear top coat to dry hard.

If desired, Step 5 can be performed on clear top coat .

23 - 2 BODY NS/GS


3/86

AFTERMARKET PAINT REPAIR PRODUCTS

1997 EXTERIOR COLORS

EXTERIORCOLOR

CHRYCODE*

PPG BASF DUPONT

S-W

ACMEM-S

AKZO NOBELSIKKENS

Candy AppleRed Mt. TintClear Coat

RH2 4974 26098 B9616 51063 CHA95:RH2

5025 5106

Flame RedClear Coat

PR4 4679 23043 B9326 4691 CHA93:PR4

Dark RosewoodPearl Coat

REG 27558 25041 B9519 50266 CHA95:REG

Light Gold PearlCoat

SYL 83539 26097 B9618 51076 CHA95:SYL

Deep Hunter

Green Pearl

Coat

SG8 47439 26078 B9609 5106 CHA95:SG8

Light SilverfernPearl Coat

RJM 47383 25043 B9525 50269 CHA95:RJM

Island TealSatin Glow

SPJ 47425 26085 B9610 51065 CHA95:SPJ

Pale Iris Clear

Coat

SCP 18887 26093 B9625 51536 CHA96:SCP

Light Iris Pearl

Coat

PC5 4788 24078 B9455 48782 CHA94:PC5

Dark Iris Pearl

Coat

RCW 51844 26092 B9614 51061 CHA95:RCW

Medium BluePearl Coat

RBK 18757 25039 B9529 50264 CHA95:RBK

Bright WhiteClear Coat

GW7 4037 18238 B8833 37298 CHA88:GW

Golden WhitePearl Tri-Coat

SWP 83554 26095 B9623 51074 CHA96:SWP

83642 B9624 51075

Deep Amethyst

Pearl Coat

TCN 5246 27038 B9736 52566 CHA97:TCU

Taupe Frost

Pearl Coat

TTK 5244 27040 B9750 52567 CHA97:TTK

* H e r be r t s S t a n d o x a n d S p ie s H e ck e r u se t h e C h r y sle r p a in t co d e a s l ist e d o n t h e B o d y C o d e Pla t e .

1997 INTERIOR COLORS

INTERIORCOLOR

CHRYCODE

PPG BASF DUPONTS-W ACME

M-S

Mist Gray C3 35799/2-1576 25065 C9507 50508

Silver Fern JK 35798/2-1577 25066 C9509 50510

Camel K5 27731/2-1584 26120 C9603 51541

NS/GS BODY 23 - 3

GENERAL INFORMATION (Continued)


4/86

STATIONARY GLASS

INDEX

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DESCRIPTION AND OPERATION

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 4REMOVAL AND INSTALLATION

BODY SIDE/SLIDING DOOR STATIONARY

GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . 7WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DESCRIPTION AND OPERATION

SAFETY PRECAUTIONS

WARNING: DO NOT OPERATE THE VEHICLEWITHIN 24 HOURS OF WINDSHIELD INSTALLATION.

IT TAKES AT LEAST 24 HOURS FOR URETHANEADHESIVE TO CURE. IF IT IS NOT CURED, THEWINDSHIELD MAY NOT PERFORM PROPERLY INAN ACCIDENT.

URETHANE ADHESIVES ARE APPLIED AS A SYS-TEM. USE GLASS CLEANER, GLASS PREP SOL-VENT, GLASS PRIMER, PVC (VINYL) PRIMER ANDPINCHWELD (FENCE) PRIMER PROVIDED BY THE

ADHESIVE MANUFACTURER. IF NOT, STRUCTURALINTEGRITY COULD BE COMPROMISED.

BE SURE TO REFER TO THE URETHANE MANU-FACTURERS DIRECTIONS FOR CURING TIMESPECIFICATIONS, AND DO NOT USE ADHESIVE

AFTER ITS EXPIRATION DATE.VAPORS THAT ARE EMITTED FROM THE URE-THANE ADHESIVE OR PRIMER COULD CAUSEPERSONAL INJURY. USE THEM IN A WELL-VENTI-

LATED AREA.SKIN CONTACT WITH URETHANE ADHESIVE

SHOULD BE AVOIDED. PERSONAL INJURY MAYRESULT.

ALWAYS WEAR EYE AND HAND PROTECTIONWHEN WORKING WITH GLASS.

CAUTION: Protect all painted and trimmed surfaces

from coming in contact with urethane or primers.Be careful not to damage painted surfaces whenremoving moldings or cutting urethane aroundwindshield.

I t i s d i f fi cu lt t o s a l v a g e a w i n d sh i el d d u r i n g t h e

r em ov a l op er a t i on . Th e w i n d sh i el d i s p a r t of t h e

structura l support for the roof. The uretha ne bonding

used to secure the windshield to the fence is difficult

t o cu t o r cle a n f r o m a n y su r f a ce . I f t h e m o ld in g s a r e

se t in u r e t h a n e , i t w o u ld a lso be u n like ly t h e y cou ld

be sa lva g e d . B e f o r e r e m o vin g t h e w in d sh ie ld , ch e ck

t h e a va ila bil i t y o f t h e w in d sh ie ld a n d m o ld in g s f r o m

the parts supplier.

REMOVAL AND INSTALLATION

WINDSHIELD

Th e u r e t h a n e a d h e sive h old in g t h e w in d sh ield t ot h e op en in g p in ch w e ld (f en ce ) ca n be cu t u sin g a

s h a r p col d k n if e f r om t h e e xt e ri or of t h e v eh i cl e.

U sin g t h e co ld k n if e m e t h o d is e f f e ct ive i f t h e w in d -

s h iel d i s a l r ea d y b r ok en . I f t h e g l a s s m u s t b e s a l -

v a ged , cu tt in g t h e u ret h a ne a d hes iv e f rom t h e

interior of the vehicle using a reciprocating or oscil-

lat ing power knife is recommended.

RECOMMENDED TOOLS AND ADHESIVE

POWER KNIFE

Fein Power Cut-out Knife

Eq u a liz e r M a g nu m , I n t er ior Au t o G l a s s C u tO u t K n if e

ADHESIVE, PRIMER AND CLEANER

Mopar Win d sh ie ld G la ss P oly u r et h a n e p a cka g e ,

o r e q u iva le n t , m u st be u se d in o r d e r t o e n su r e t h a t

t h e v eh i cl e w i ll con f or m t o t h e F M VS S 212 w i n d -

sh ield r e t e n t ion st a n d a r d a n d t h e F MV S S 216 r oof

cr u sh st a n d a r d .

WINDSHIELD REMOVALEXTERIOR METHOD

(1) R emove inside rea r view mirror.

(2) Remove windshield wiper arms.

(3) Remove cowl cover.(4) Remove A-pillar trim panels.

(5) D i sen ga g e w i re con n ect or s t o w i nd sh iel d

defroster grid.

(6) Pla ce protective covers over instrument panel

and hood.

(7) Remove w indshield molding (Fig. 1). Using pli-

ers, pull outward on molding at the bottom of A-pil-

la r s.

(8) U s in g a s h a r p col d k n if e, cu t u r et h a n e a d h e -

s i ve h ol di n g t h e w i n d sh i el d t o t h e A-p il la r s , r oof

23 - 4 BODY NS/GS


5/86

header and cowl pinch weld fences (Fig. 2). A power

cutting device can be used if available.

(9) Separate windshield from vehicle.

WINDSHIELD REMOVALINTERIOR METHOD

(1) Remove inside rear view mirror.

(2) Rem ove in st r u m en t p a n e l t o p cover . Re fe r t o

G r o u p 8E, I n st r u m e n t Pa n e l .

(3) Remove A-pillar trim covers.

(4) D i sen ga g e w i re con n ect or s t o w i nd sh iel d

defroster grid.

(5) Pla ce protective covers over instrument panel

and hood.

(6) U s i n g a r eci pr oca t i n g or os ci ll a t i ng p ow e r

k n ife , cu t u r et h a n e a d h e sive h old in g t h e w in d sh ield

t o t h e A-p il la r s , r oof h ea d e r a n d cow l p in ch w e ldfences. Refer to instructions provided with the equip-

ment being used.

(7) Separate windshield from vehicle.

WINDSHIELD INSTALLATION

CAUTION: Open the left front door glass beforeinstalling windshield to avoid pressurizing the pas-senger compartment. If a door is slammed before

urethane bonding is cured, water leaks can result.

Allow the urethane at least 24 hours to cure

before returning the vehicle to use.To avoid stressing the replacement windshield,

the urethane bonding material on the windshieldfence should be smooth and consistent to the

shape of the replacement windshield. The support

spacers should be cleaned and properly installedon weld studs or repair screws at bottom of wind-shield opening.

(1) P la ce r e pla cem e n t w in d sh ield in t o w in d sh ield

opening and posit ion glass in the center of the open-

in g a g a in st t h e su p p o r t sp a ce r s.

(2) V e r if y t h e g la ss la y s e ve n ly a g a in st t h e p in ch

w el d fen ce a t t h e s id es , t op a n d b ot t om of t h e

replacement windshield. If not , the pinch weld fence

m u st be f o r m e d t o t h e sh a p e o f t h e n e w g la ss.

( 3 ) M a r k t h e g l a s s a t t h e s u p p o r t s p a c e r s w i t h a

g r e a se p e n cil o r p ie ce s o f m a sk in g t a p e a n d in k p e n

to use as a reference for installat ion (Fig. 3).(4) Re m ove r e pla cem e n t w in d sh ield f r om w in d -

shield opening.

(5) Posit ion the windshield inside up on a suitable

w o r k su r f a ce w it h t w o p a d d ed , w ood 10 cm by 10 cm

by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-

allel 75 cm (2.5 ft .) apart (Fig. 4).

WARNING: DO NOT USE SOLVENT BASED GLASS

CLEANER TO CLEAN WINDSHIELD BEFOREAPPLYING GLASS PREP AND PRIMER. POORADHESION CAN RESULT.

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

(7) Install molding to perimeter of windshield.

(8) Apply Glass Prep adhesion promoter 25 mm (1

in .) w id e a r o u n d p e r im e t er of w in d sh ield a n d w ip e

with clean/dry lint-free cloth until no str eaks ar e vis-

ible.

(9) Apply Glass Primer 25 mm (1 in.) wide around

perimeter of windshield. Allow at least three minutes

drying t ime.

(10) U sin g a r a z o r k n if e, r e m ove a s m u ch or ig in a l

u r e t h a n e a s p o ssible . D o n o t d a m a g e p a in t o n w in d -

shield fence.

(11) Apply pinch weld primer 15 mm (.75 in.) widea r ou n d t h e w i n d sh i el d f en ce. Al low a t l ea s t t h r ee

m in u t es d r y in g t im e .

(12) I f a low viscosit y u r et h a n e a d h e sive is u sed ,

in st a l l com p r ession sp a ce r s on t h e f en ce a r ou n d t h e

windshield opening (Fig. 5).

(13) Apply a 10 mm (0.4 in.) bead of uretha ne on

centerline of windshield fence.

(14) Wit h t h e a id of a h e lp er, p osit ion t h e w in d -

shield over the windshield opening. Align the refer-

en ce m a r k s a t t h e b ot t om of t h e w i n ds h ie ld t o t h e

support spacers.

Fig. 1 Windshield Molding

MOLDINGFENDERCOWL WINDSHIELDSUPPORTSPACER

Fig. 2 Cut Urethane Around Windshield

COLD KNIFEWINDSHIELD

NS/GS BODY 23 - 5

REMOVAL AND INSTALLATION (Continued)


6/86

(15) S lo w ly low e r w in d sh ield g la ss t o w in d sh ield

opening fence. Guide the molding into proper position

a s n e ce ssa r y . Pu sh w in d sh ie ld in w a r d u n t i l m o ld in g

is flush to roof line and A-pillars (Fig. 5).

(16) C l ea n a c ce ss u r et h a n e f r om e xt e ri or w i t h

Mopar Super Kleen or equivalent.

(17) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)m a sk in g t a p e sp a ce d 250 m m (10 in .) a p a r t t o h o ld

molding in place until urethane cures.

(18) E n ga g e w i re con nect or s t o w in ds hield

defroster grid.

(19) Install A-pillar tr im panels.

(20) Install cowl cover and wipers.

(21) Install inside rear view mirror.

(22) After urethane has cured, remove tape strips

a n d w a t e r t e st w in d sh ie ld t o ve r i f y r e p a ir .

BODY SIDE/SLIDING DOOR STATIONARY GLASST h e t e m p e r a t u r e o f t h e ve h icle sh o u ld be a t le a st

21 C (70 F) before removing the stat ionary quarter/

sliding door glass. Butyl sealer becomes more pliable

a t h ig h t e m p e r a t u r e s.

REMOVAL

(1) Rem ov e i nt er ior t r im a s n eces sa r y t o g a in

access at taching locations on back of glass.

(2) Remove nuts holding stat ionary glass to fence.

(3) U s in g r a z or k n if e, cu t b ut y l s ea l er h ol di n g

glass to fence from between the mounting studs (Fig.

6).

(4) Push glass from opening.

INSTALLATION

The stat ionary glass fence should be cleaned of all

old butyl sealer.

(1) Ap pl y a 6 m m (0. 25 i n .) b u t yl t a p e a r ou n d

p er im et e r of g la s s a s s em b ly en ca p s ul a t i on t r a c k.

E n s ur e t h a t t h e b u t yl t a p e i s w r a p ped a r ou n d t h e

mounting studs.

(2) P l a c e t h e g la s s i nt o t h e open in g a n d i ns er t

mounting studs through holes in fence.

Fig. 3 Center Windshield and Mark atSupportSpacers

A-PILLAR WINDSHIELDMARKS SUPPORTSPACERCOWL

Fig. 4 Work Surface Set up and Molding Installation

WINDSHIELD AND MOLD-INGSBLOCKS

Fig. 5 Lower Windshield Into Position

BREAK TAB OFFFLUSH AFTERINSTALLATION WINDSHIELD WITHMOLDING REFER-ENCEMARKSSEE VIEW AADHESIVESUPPORTSPACER* = COMPRESSI ONSPACERVIEW A

Fig. 6 Sliding Door StationaryGlass

NUMBERS INDICATE THETIGHTENING SEQUENCE6mm BEAD OF BUTYL TAPEBODY SIDE/SLIDING DOORGLASS

23 - 6 BODY NS/GS



7/86

(3) I n s t a l l n u t s t o h o ld s t a t i on a r y g la s s t o f en ce

(Fig. 6).

NOTE: Torque nuts to 3.4 Nm (30 in. lbs.) in thesequence indicated. Do not overtorque, or glassbreakage may result.

(4) Install interior tr im.

REAR WINDOWRe fe r t o t h e Win d sh ie ld p a r a g r a p h of t h is sect ion

for description of tools and adhesive systems that are

recommended for use in this procedure.

REAR WINDOW REMOVALEXTERIOR

METHOD

(1) Remove rear window wiper arm, if equipped.

(2) Re m ove scr e w s h old in g m o ld in g s t o l if t g a t e a t

the sides of the rear window (Fig. 7).

(3) U s i ng p li er s , p ul l ou t w a r d on m ol di n g a t t h e

t o p a n d bot t o m of l i ft g a t e .

(4) U s i ng a s h a r p col d k n if e, cu t u r et h a n e a d h e -

sive holding the rear window to the liftgate. A power

cutting device can be used if available.

(5) Separate rear window from vehicle.

REAR WINDOW REMOVALINTERIOR

METHOD

(1) Remove rear window wiper arm, if equipped.

(2) Re m ove scr e w s h old in g m o ld in g s t o l if t g a t e a t

the sides of the rear window (Fig. 7).

(3) Remove liftgate inside lamps and trim covers.

(4) Remove center high mounted stop lamp.

(5) U s i n g a r eci pr oca t i n g or os ci ll a t i ng p ow e r

knife, cut urethane adhesive holding the rear window

t o t h e l if t g a t e . Re fe r t o in st r u ct ion s p r ovid ed w it h

the equipment being used.

(6) Separate rear window from vehicle.

REAR WINDOW INSTALLATION

CAUTION: Open the left front door glass before

installing rear window to avoid pressurizing thepassenger compartment. If a door is slammedbefore urethane bonding is cured, water leaks canresult.

Allow the urethane at least 24 hours to cure

before returning the vehicle to use.To avoid stressing the replacement rear window,

the urethane bonding material on the rear windowfence should be smooth and consistent to the

shape of the replacement glass.

(1) Place replacement glass into rear window open-

ing.

(2) V e r if y t h e g la ss la y s e ve n ly a g a in st t h e p in ch

w el d fen ce a t t h e s id es , t op a n d b ot t om of t h e

r e pla cem e n t r e a r w in d ow . I f n ot , t h e f e n ce m u st be

f o r m e d t o t h e sh a p e o f t h e n e w g la ss.(3) U sin g a g r e a se p e n cil , m a r k t h e g la ss a n d l i f t -

g a t e in se ve r a l lo ca t io n s t o a id in st a l la t io n .

(4) Remove replacement gla ss from liftga te open-

ing.

(5) P osit ion t h e r e a r w in d ow in sid e u p o n a su it -

a b l e w o r k s u r fa c e w i t h t w o p a d d ed , w o od 10 c m b y

10 cm b y 50 c m (4 i n . b y 4 i n . b y 20 i n . ) b lock s,

placed parallel 75 cm (2.5 ft .) apart .

WARNING: DO NOT USE SOLVENT BASED GLASS

CLEANER TO CLEAN REAR WINDOW BEFOREAPPLYING GLASS PREP AND PRIMER. POOR

ADHESION CAN RESULT.

(6) C lea n i ns id e of r ea r w i nd ow w i t h a m m on ia

based glass cleaner and lint-free cloth.

(7) Ap p ly m o ld in g t o t o p a n d bo t t o m o f r e a r w in -

dow.

(8) Apply Glass Prep adhesion promoter 25 mm (1

in .) w id e a r o u n d p e r im e t e r o f r e a r w in d o w a n d w ip e

with clean/dry lint-free cloth until no str eaks ar e vis-

ible.

(9) Apply Glass Primer 25 mm (1 in.) wide around

p er im et e r of r e a r w in d ow . Allow a t lea st t h r e e m in -

u t e s d r y in g t im e .

(10) Apply P inchweld P rimer 15 mm (.75 in.) widea r o u n d t h e r e a r w in d ow f en ce. Allow a t lea st t h r e e

m in u t es d r y in g t im e .

(11) I f a low viscosit y u r e t h a n e a d h e sive is u sed ,

in st a l l com p r ession sp a ce r s on t h e f en ce a r ou n d t h e

rear window opening (Fig. 8).

(12) Ap pl y a 10 m m (0. 4 i n .) b ea d of u r et h a n e

along centerline of rear window fence.

(13) Wi t h t h e a i d of a h el pe r, p os it i on t h e r ea r

w in d o w o ve r t h e r e a r w in d o w o p e n in g a n d a l ig n t h e

reference ma rks.Fig. 7 Rear Window Side Moldings

MOLDINGLIFTGATE

NS/GS BODY 23 - 7



8/86

(14) Slowly lower the glass to rear window opening

fence. Guide the molding into proper posit ion as nec-

e s s a r y . P u s h g l a s s i n w a r d u n t i l m o l d i n g i s f l u s h t o

liftgate surface (Fig. 8).

(15) C l ea n e xce ss u r et h a n e f r om e xt e ri or w i t h

Mopar Super Kleen, or equivalent.

(16) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)m a sk in g t a p e sp a ce d 250 m m (10 in .) a p a r t t o h o ld

molding in place until urethane cures.

(17) I n st a l l r e a r w in d o w sid e m o ld in g s a n d w ip e r

arm (Fig. 7).

(18) Install interior tr im.

(19) After urethane has cured, remove tape strips

a n d w a t e r t e st r e a r w in d o w t o ve r i f y r e p a ir .

Fig. 8 Lower Rear Window Into Position

23 - 8 BODY NS/GS



9/86

SEATS

INDEX

page page


ARM REST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9BENCH SEAT BACK COVER . . . . . . . . . . . . . . . 17BENCH SEAT BACK HINGE COVERS . . . . . . . . 17BENCH SEAT BACK HINGE . . . . . . . . . . . . . . . 18

BENCH SEAT RISER1st REAR . . . . . . . . . . . 17BENCH SEAT RISER2nd REAR . . . . . . . . . . . 16BENCH SEAT TRACK2nd REAR . . . . . . . . . . 16BUCKET SEAT BACK ASSIST STRAP . . . . . . . . 10BUCKET SEAT BACK . . . . . . . . . . . . . . . . . . . . 13

BUCKET SEAT CUSHION PAN . . . . . . . . . . . . . 13BUCKET SEAT CUSHION SIDE COVER . . . . . . 11BUCKET SEAT RECLINERMANUAL . . . . . . . . 14BUCKET SEAT RECLINERPOWER . . . . . . . . 15

BUCKET SEAT RISERMANUAL TRACK . . . . . 14

BUCKET SEAT TRACK FRONT

COVERPOWER . . . . . . . . . . . . . . . . . . . . . 12BUCKET SEAT TRACK REAR

COVERPOWER . . . . . . . . . . . . . . . . . . . . . 12BUCKET SEAT TRACKMANUAL . . . . . . . . . . 15

CHILD RESTRAINT SEAT MODULE . . . . . . . . . 19HEAD RESTRAINT SLEEVE . . . . . . . . . . . . . . . 10HEAD RESTRAINTBENCH SEAT . . . . . . . . . . 10HEAD RESTRAINTBUCKET SEAT . . . . . . . . . . 9POWER SEAT SWITCH . . . . . . . . . . . . . . . . . . . 11

RECLINER HANDLEMANUAL . . . . . . . . . . . . . 11SEAT TRACKPOWER . . . . . . . . . . . . . . . . . . 16UNDER SEAT STORAGE BIN GUIDE . . . . . . . . 14UNDER SEAT STORAGE BIN LOCK/LATCH . . . 14

UNDER SEAT STORAGE BIN . . . . . . . . . . . . . . 13


ARM REST

REMOVAL

(1) Using a screw driver, pry cap from side of arm

rest (Fig. 1).

(2) Remove bolt holding arm rest to seat back.

(3) S e p a r a t e a r m r e st f r o m se a t .

INSTALLATION

(1) Pla ce a r m r e st in p o sit io n o n se a t .

(2) I n st a l l bo lt t o h o ld a r m r e st t o se a t ba ck .

(3) Insert cap into side of arm rest (Fig. 1).

HEAD RESTRAINT BUCKET SEAT

REMOVAL

(1) L if t h e a d r e st r a in t t o t o p o f t r a ve l .

(2) Depress lock button on side of sleeve at top of

seat back (Fig. 2).

(3) Pu ll h e a d r e st r a in t f r o m t o p o f se a t ba ck .

INSTALLATION

Reverse the preceding operation.

Fig. 1 Arm Rest

SEAT BACK ARM RESTSHOULDERBOLT CAPWASHERSTOP SCREW

Fig. 2 Head RestraintBucket Seat

HEADRESTRAINT SLEEVESLOCK BUTTON

NS/GS BODY 23 - 9


10/86

HEAD RESTRAINT BENCH SEAT

REMOVAL

(1) L if t h e a d r e st r a in t t o t o p o f t r a ve l .

(2) Remove escutcheon from head restraint sleeve.

(3) U sin g a sm a ll scr e w d r ive r, d e pr e ss r e t a in er

in w a r d t o r e lea se h e a d r e st r a in t (F ig . 3).(4) Pu ll h e a d r e st r a in t f r o m t o p o f se a t ba ck (F ig .

4).

INSTALLATION

(1) I n ser t r et a i n er a n d es cu t ch eon i nt o h ea d

restra int sleeve (Fig. 5).

(2) Insert head restraint into sleeve.

BUCKET SEAT BACK ASSIST STRAP

REMOVAL

(1) U s i n g a s m a l l s cr ew d r iv er, p ry s cr ew p lu g s

from ends of assist strap (Fig. 6).

(2) R em ov e s cr ew s h ol d in g a s s i st s t r a p t o s ea t

back.

(3) S e pa r a t e a ssist s t r a p f r om veh icle.

INSTALLATION(1) Place assist strap in posit ion on vehicle.

(2) I n st a l l scr ew s t o h old a ssist s t r a p t o se a t ba ck.

(3) I n ser t s cr ew p lu g s i n t o e n ds of a s s i st s t r a p

(Fig. 6).

HEAD RESTRAINT SLEEVE

REMOVAL

(1) Remove head restraint .

(2) Disengage closure holding bottom of tr im cover

together.

(3) R ea c h u n d er t r i m cov er t h r ou g h op en i ng a t

bottom of seat back.(4) Pin ch r e t a in e r ba r bs o n e n d o f h e a d r e st r a in t

sleeve together (Fig. 7).

(5) Pu ll h e a d r e st r a in t s le e ve u p w a r d a n d o u t t h e

t o p of t h e se a t ba ck f r a m e g u id e t u be (F ig . 8).

INSTALLATION

(1) I n se r t h e a d r e st r a in t s le e ve in t o g u id e t u be a t

t o p o f se a t ba ck .

(2) P u s h h ea d r es t ra i n t s leev e d ow n w a r d u n ti l

retainer clicks into lock posit ion.

Fig. 3 Head Restraint Sleeve Escutcheon

REAR SEATBACK HEADRESTRAINTESCUTCHEONSLEEVE

Fig. 4 Release Retainer

HEAD RESTRAINTSCREW DRIVERSLEEVE

Fig. 5 Install Retainerand Escutcheon

RETAINERESCUTCHEONHEAD RESTRAINT SLEEVE

Fig. 6 Bucket Seat Back Assist Strap

ASSIST STRAP SCREW PLUGSEAT BACK

23 - 10 BODY NS/GS



11/86

(3) En g a g e closu r e t o h old bot t o m of t r im cove r

together.

(4) I n st a l l h e a d r e st r a in t .

RECLINER HANDLE MANUAL

REMOVAL

(1) R em ov e s cr ew h ol di ng r ecl in er h a n d le t o

recliner spline sha ft (Fig. 9).

(2) Separate recliner handle from spline shaft .

INSTALLATION

(1) P l a c e r ecl in er h a n d l e i n p os it i on on s pl in e

sh a f t .

(2) Install screw to hold recliner handle to recliner

spline shaft (Fig. 9).

BUCKET SEAT CUSHION SIDE COVER

REMOVAL

(1) Remove screws holding seat cushion side cover

to bucket seat (Fig. 10).

(2) S l id e se a t cu sh io n r e a r l ist in g t o w a r d t h e ce n -

t e r o f t h e se a t t o g a in a cce ss t o r e a r scr e w .

(3) Remove screw h olding r ear of side cover to seat

cushion frame.

(4) Separate side cover from seat cushion.

(5) I f e q u ip pe d , d isen g a g e w ir e con n e ct o r f r om

power seat switch (Fig. 11).

INSTALLATION

(1) Place side cover in posit ion on seat cushion.

(2) I f e q u ip pe d , in ser t w ir e con n e ct o r in t o p ow e r

se a t sw it ch .

(3) I n st a l l scr e w t o h o ld r e a r of s id e cover t o se a t

cushion frame.

(4) Insta ll screws to hold seat cushion side cover to

bucket seat (Fig. 10).

POWER SEAT SWITCHD i a g n os t i c i n f or m a t i on f or p ow e r s ea t s w i t ch i s

lo ca t e d in G r o u p 8R, Po w e r S e a t s .

Fig. 7 Head Restraint Sleeve Retainer

GUIDE TUBE PINCH RETAINER TORELEASESEAT BACK FRAME

Fig. 8 Head Restraint Sleeve

S EAT BAC K F RAM E H EA D R ES TR AI NT SL EEV E R ETAI NE RGUIDETUBE

Fig. 9 Recliner HandleManual

CUSHION SIDECOVER RECLINER SPINE SCREWRECLINER HANDLE

Fig. 10 Bucket Seat Cushion Side Cover

SIDE COVERSEATCUSHIONTRACK COVER

NS/GS BODY 23 - 11



12/86

REMOVAL

(1) Remove seat cushion side cover.

(2) D i s en g a g e w i r e con n ect or f r om p ow e r s ea t

switch.

(3) Pry power seat switch knobs straight off switch

(Fig. 12).

(4) Re m ove scr e w s h old in g p ow e r se a t sw it ch t o

side cover (Fig. 13).

(5) Separate power seat switch from side cover.

INSTALLATION

(1) P l a c e p ow e r s ea t s w i t ch i n p os i t ion on s id e

cover.

(2) Install screws to hold power seat switch to side

cover (Fig. 13).

(3) P u s h pow e r s ea t s w it ch k nob s s t ra i gh t on

switch (Fig. 12).

(4) Engage wire connector into power seat switch.

(5) Install seat cushion side cover.

BUCKET SEAT TRACK FRONT COVER POWER

REMOVAL

(1) Re mov e s cr ew s h ol di n g f r on t cov er t o s ea t

track (Fig. 14).

(2) Separate front cover from vehicle.

INSTALLATION

(1) Place front cover in posit ion on seat .

(2) I n st a l l scr e w s t o h o ld f r o n t co ve r t o se a t t r a ck

(Fig. 14).

BUCKET SEAT TRACK REAR COVER POWER

REMOVAL

(1) D isen g a g e a r r o w h e a d r e t a in er f r om loop st r ip

holding rear cover to power seat track crossbar (Fig.

15).

(2) Disengage fasteners holding rear cover to slots

o n p o w e r se a t t r a ck .

(3) Separate rear cover from seat .

Fig. 11 Power Seat Switch Wire Connector

SEAT CUSHION SIDECOVERPOWER SEAT SWITCHWIRE CONNECTOR

Fig. 12 Power Seat Switch Knobs

POWER SEAT 6-WAYSWITCH POWER RECLINER SWITCHKNOBS

Fig. 13 Power Seat Switch

POWER SEATSWITCHSEAT CUSHION SIDECOVER

Fig. 14 Bucket Seat Track Front CoverPower

SEAT CUSHIONPOWER SEAT TRACKFRONT COVER

23 - 12 BODY NS/GS



13/86

INSTALLATION

(1) Place rear cover in posit ion on seat .

(2) Engage fasteners to hold rear cover to slots on

p o w e r se a t t r a ck .

(3) E n g a g e a r r ow h e a d r et a i n er i n t o l oop s t r ip t o

hold rear cover to power seat track crossbar (Fig. 15).

BUCKET SEAT CUSHION PAN

REMOVAL

(1) Remove bucket seat from vehicle.

(2) Remove seat cushion side covers.

(3) If equipped, remove power seat track front andrear cover.

(4) If equipped, remove stowage bin.

(5) Remove bolts holding seat cushion pan to seat

t r a ck .

(6) S e p a r a t e se a t cu sh io n p a n f r o m se a t .

(7) D isengage J -strip retainers holding seat cover

to cushion pan.

(8) S e pa r a t e se a t cu sh ion p a n f r om cover a n d p a d .

INSTALLATION

(1) Place seat cushion pan in posit ion in seat cover

a n d p a d .

(2) En g a g e J -st r ip r e t a in er s t o h old se a t cover t ocushion pan.

(3) Place seat cushion pan in posit ion on seat .

(4) I n s t a l l b ol t s t o h o ld s ea t cu s hi on p a n t o s e a t

t r a ck .

(5) If equipped, install stowage bin.

(6) I f e q u ip p e d , in st a l l p o w e r se a t t r a ck f r o n t a n d

rear cover.

(7) Install seat cushion side covers.

(8) Install bucket seat in vehicle.

BUCKET SEAT BACK

REMOVAL

(1) Remove seat cushion pan.

(2) Remove nut holding recliner to seat back fra me

(Fig. 16).

(3) Remove pivot bolts holding seat back frame tose a t t r a ck .

(4) Separate seat back from recliner.

INSTALLATION

(1) Place seat back mounting stud into recliner.

(2) I n s t a l l p iv ot b ol t s t o h ol d s ea t b a ck f r a m e t o

se a t t r a ck .

(3) I n st a l l n u t t o h o ld r e clin e r t o se a t ba ck f r a m e

(Fig. 16).

(4) I n st a l l se a t cush ion p a n .

UNDER SEAT STORAGE BIN

REMOVAL

(1) Re le a se u n d e r se a t s t o r a g e bin la t ch a n d o p e n

bin.

(2) D e pr e ss lock t a bs a t t h e r e a r /t o p e d g e o f t h e

storage bin (Fig. 17).

(3) Pull storage bin from bucket seat r iser.

Fig. 15 Bucket Seat Track Rear CoverPower

Fig. 16 Bucket Seat Back

NS/GS BODY 23 - 13



14/86

INSTALLATION

(1) En g a g e st o r a g e bin t r a ck s in t o g u id e s o n e a ch

side of seat r iser.

( 2 ) P u s h s t o r a g e b i n i n w a r d u n t i l l o c k t a b s s n a p

p a st r e t a in in g r id g e o n t r a ck s

(3) Verify storage bin latch operation.

UNDER SEAT STORAGE BIN GUIDE

REMOVAL

(1) Remove under seat storage bin.

(2) Remove screws holding storage bin track guide

to seat r iser (Fig. 18).

(3) Separate track guide from vehicle.

INSTALLATION(1) Place track guide in posit ion on seat r iser.

(2) Install screws to hold storage bin track guide to

seat riser (Fig. 18).

(3) I n st a l l u n d e r se a t s t o r a g e bin .

UNDER SEAT STORAGE BIN LOCK/LATCH

REMOVAL

(1) Open under seat storage bin.

(2) Remove screws holding under seat storage bin

lock/lat ch to stora ge bin (Fig. 19).

(3) S epara te lock/lat ch from bin.

INSTALLATION

(1) P lace lock/la tch in position on s tora ge bin.

(2) In sta ll screws to h old lock/latch to st orage bin

(Fig. 19).

(3) Verify under seat storage bin latch operation.

BUCKET SEAT RISER MANUAL TRACK

REMOVAL

(1) Remove seat from vehicle.

(2) If equipped, remove storage bin from riser.

(3) Rem ov e n u t s h ol di ng r is er t o m a n u a l s ea t

track (Fig. 20).

(4) S e pa r a t e r ise r f r o m se a t .

INSTALLATION

(1) Place riser in posit ion on seat .

(2) I n s t a l l n u t s t o h ol d r i s er t o m a n u a l s ea t t r a c k

(Fig. 20).

(3) If equipped, install storage bin into riser.

(4) Install seat into vehicle.

BUCKET SEAT RECLINER MANUAL

REMOVAL

(1) Remove bucket seat cushion pan.

(2) Remove E-clip holding pin in seat track.

(3) R e m ov e p in h ol di n g m a n u a l r ecl in er t o s ea t

track (Fig. 21).

(4) R em ov e n ut h ol di ng r ecl in er t o s ea t b a ck

f r a m e .

(5) Separate recliner from seat .

Fig. 17 Storage Bin

PASS. SI DEBUCKET SEATUNDER SEAT STORAGE BINRISER LOCK TAB

Fig. 18 Under Seat Storage Bin Guide

STORAGE BINTRACK GUIDERISER

Fig. 19 Under Seat Storage Bin Lock/Latch

UNDER SEAT STORAGE BIN LOCK/LATCH

23 - 14 BODY NS/GS



15/86

INSTALLATION

(1) Place recliner in posit ion on seat .

(2) I n ser t s tu d on s ea t b a ck t h rou gh h ole i n

recliner.

(3) I n st a l l n u t t o h o ld r e clin er t o se a t ba ck f r a m e .

(4) I n st a l l r o l l p in t o h o ld m a n u a l r e cl in e r t o se a t

track (Fig. 21).

(5) I n st a l l E-clip t o h old p in in se a t t r a ck .

(6) Install bucket seat cushion pan.

BUCKET SEAT RECLINER POWERREMOVAL


(2) R em ov e n ut h old in g s ea t ba ck fr a me t o

recliner.

(3) Using a suita ble punch, remove roll pin holding

recliner to seat track (Fig. 22).

(4) Separate recliner from seat track.

(5) Separate recliner from stud on seat back frame.

(6) Disengage wire connector from power recliner.

(7) Separate power recliner from seat .

INSTALLATION

(1) Place power recliner in posit ion on seat .

(2) Enga ge w ire connector into power recliner.

(3) I n ser t s t ud on s ea t b a ck t h rou gh h ole in

recliner.

(4) Place recliner in posit ion on seat track.

(5) I n s t a l l r ol l p in t o h ol d r ecl in er t o s ea t t r a c k(Fig. 22).

(6) I n st a l l n u t t o h o ld se a t ba ck f r a m e t o r e clin e r.


BUCKET SEAT TRACK MANUAL

REMOVAL


(2) Remove seat cushion pan.(3) Remove riser.

(4) On inboard track, remove nut holding recliner

t o se a t ba ck f r a m e .

(5) Re m ove bo lt h old in g sea t ba ck f r a m e t o se a t

track (Fig. 23).

(6) S e p a r a t e se a t t r a ck f r o m se a t a d ju st e r h a n d le

(Fig. 24).

(7) S e p a r a t e se a t t r a ck f r o m se a t .

INSTALLATION

(1) P la ce sea t t r a ck in p osit ion on se a t .

(2) P la ce a d ju st e r h a n d le in p osit ion on se a t t r a ck

(Fig. 24).(3) Insert stud on seat back frame into recliner.

(4) I n st a l l b ol t t o h ol d s ea t b a ck f ra m e t o s ea t

track (Fig. 23).

(5) On inboard track, install nut to hold recliner to

se a t ba ck f r a m e .

(6) Install r iser.


(8) Install seat in vehicle.

Fig. 20 Bucket Seat RiserManual Track

RISER SEAT TRACK

Fig. 21 Bucket Seat ReclinerManual

MANUAL RECLINERPINSEAT TRACKE-CLIPNUTSEAT BACK

Fig. 22 Bucket Seat Reclinerpower

POWER SEATTRACKROLL PINPOWER RECLINER

NS/GS BODY 23 - 15



16/86

SEAT TRACK POWERTh e p ow e r se a t t r a ck a n d m ot o r s a r e se r vice d a s

an assembly.

REMOVAL



(3) R em ov e n u t h ol di ng r ecl in er t o s ea t b a ck

frame.

(4) Re m ove bo lt s h old in g se a t ba ck f r a m e t o sea t

t r a ck .(5) Separate stud on seat back frame from recliner.

(6) Separate seat back from recliner.

INSTALLATION

I f pow e r s ea t t r a ck i s b ei ng r ep la ced , t r a n sf er

pow e r r ecl in er, w i re h a r n es s a n d t r im cov er s t o

replacement seat track.

(1) Insert stud on seat back frame into recliner.

(2) I n s t a l l b o lt s t o h o ld s ea t b a ck f r a m e t o s ea t

t r a ck .

(3) I n st a l l n u t t o h o ld r e clin er t o se a t ba ck f r a m e .


(5) Install seat in vehicle.

BENCH SEAT TRACK 2nd REAR

REMOVAL

(1) Re m ove 2n d r e a r se a t f r om ve h icle. Re fe r t o

Owners Manual for proper procedure.

(2) P la ce se a t on cle a n cove re d w o r k su r f a ce bo t -

tom side up.

(3) D ise n ga g e se a t t r a ck a d ju st er l in k w ir e f r om

track being removed.

(4) Re m ove n u t s h old in g t r a ck t o se a t r iser (F ig .

25).

(5) S e pa r a t e t r a ck f r om se a t r iser.

INSTALLATION

(1) Place track in posit ion on seat r iser.

(2) I n s t a l l n u t s t o h ol d t r a c k t o s ea t r i se r. (F i g.

25).(3) En g a g e se a t t r a ck a d ju st e r l in k w ir e on t o t r a ck

being installed.

(4) Install 2nd rear seat from vehicle.

BENCH SEAT RISER 2nd REAR

REMOVAL

(1) Remove seat track.

(2) R em ov e b ol t s h ol d in g r i se r t o s ea t cu s h ion

frame (Fig. 26).

(3) S e pa r a t e r ise r f r o m se a t .

INSTALLATION


Fig. 23 Bucket Seat TrackManual

SHOULDER BOLTRECLINERMANUAL SEAT TRACK

Fig. 24 Seat Track Adjuster Handle

RECLINERSEAT ADJUSTER HANDLEMANUAL SEAT TRACK

Fig. 25 Bench Seat Track2nd Rear

3-PASS 2ND REAR SEATRISER

TRACK

23 - 16 BODY NS/GS



17/86

(2) Install bolts to hold riser to seat cushion frame

(Fig. 26).

(3) I n st a l l se a t t r a ck .

BENCH SEAT RISER 1st REAR

REMOVAL

(1) R e m ov e 1s t r ea r s ea t f r om v eh i cl e. R ef er t o

Owners Manual for proper procedures.

(2) Pla ce se a t bot t o m sid e u p o n a cle a n cover e dwork surface.

(3) Remove bolts holding seat r iser to seat cushion

frame (Fig. 27).

(4) S e p a r a t e r ise r f r o m se a t .

INSTALLATION


(2) I n st a l l bo lt s t o h o ld se a t r ise r t o se a t cu sh io n

frame (Fig. 27).

(3) I n st a l l 1st r e a r se a t in t o ve h icle.

BENCH SEAT BACK COVER

REMOVAL

(1) U sin g a f or k t y p e p r y in g t o ol (C 4829), d isen -

g a g e p u sh -in f a st e n er s h old in g bot t o m of se a t ba ck

cover to seat back frame (Fig. 28).

(2) Disengage hooks holding top of seat back cover

t o se a t ba ck f r a m e .

(3) S e pa r a t e se a t ba ck cover f r om se a t .

INSTALLATION

(1) Place seat back cover in posit ion on seat .

(2) Engage hooks to hold top of seat back cover to

se a t ba ck f r a m e .

(3) Enga ge push-in fa steners to hold bottom of seat

back cover to seat back frame (Fig. 28).

BENCH SEAT BACK HINGE COVERS

REMOVAL

(1) If necessary, remove seat from vehicle. Refer to

Owners Manual for proper procedures.

(2) R em ov e s cr ew s h ol d in g l ow e r cov er t o s ea t

back hinge (Fig. 29).

(3) Separate lower cover from hinge.

(4) Re m ove scr e w s h old in g u p pe r h in g e cover t o

se a t ba ck h in g e .

(5) Separate upper cover from seat back hinge.

Fig. 26 Bench Seat Riser2nd Rear

RISER3PASS 2ND REAR SEAT

Fig. 27 Bench Seat Riser1st Rear

2-PASS 1ST REAR SEATRISER

Fig. 28 Bench Seat Back Cover

SEAT BACK REAR COVER1ST REAR CHILDRESTRAINT SEAT

NS/GS BODY 23 - 17



18/86

INSTALLATION

(1) P l a ce u pp er cov er i n p os i t ion on s ea t b a ck

hinge.

(2) Install screws to hold upper hinge cover to seat

back hinge.

(3) Place lower cover in posit ion on hinge.

(4) I n st a l l scr e w s t o h o ld lo w er cover t o se a t ba ckhinge (Fig. 29).

(5) If necessary, install seat in vehicle.

BENCH SEAT BACK HINGEB e n ch s ea t s e q ui pp ed w i t h ch i ld r es t r a i n t s ea t s

h a ve a n in t e r lo ck f e a t u r e t h a t w il l n o t a l lo w t h e se a t

ba ck t o f o ld f o r w a r d w it h t h e ch ild se a t o p e n .

REMOVAL(1) Remove bench seat back hinge covers.

(2) Remove shoulder bolts holding seat back hinge

to seat back frame (Fig. 30).

(3) Re m ove bo lt s h old in g se a t ba ck h in g e t o se a t

cushion frame.

(4) S e p a r a t e se a t ba ck h in g e f r o m se a t .

(5) D ise n ga g e sy n ch r on iz in g ca ble h ou sin g f r om

se a t ba ck h in g e.

(6) Disengage synchronizing cable end from (clip

on lef t s id e) h in g e la t ch r e le a se a r m .

(7) S e p a r a t e h in g e f r o m se a t .

INSTALLATION(1) Place hinge in posit ion on seat .

(2) En g a g e sy n ch r on iz in g ca ble e n d in t o (cl ip on

lef t s id e) h in g e la t ch r e le a se a r m .

(3) En g a g e sy n ch r on iz in g ca ble h ou sin g in t o se a t

back hinge.

(4) Pla ce se a t ba ck h in g e in p o sit io n o n se a t .

(5) I n s t a l l b ol t s t o h ol d s ea t b a ck h i ng e t o s ea t

cushion frame.

(6) Install shoulder bolts to hold seat back hinge to

seat back frame (Fig. 30).

(7) Install bench seat back hinge covers.

(8) Verify seat back hinge operation.

SYNCHRONIZING CABLE ADJUSTMENT

I f t h e s e a t b a ck h i n g es d o n ot r el ea s e a t t h e s a m e

t im e t h e sy n ch r on iz in g ca ble m u st be a d ju st e d .

(1) Re m ove se a t f r om veh icle. Re fe r t o O w n e r s

Manual for proper procedures (Fig. 31).

(2) U sin g a a w l , p r y sy n ch r on iz in g ca ble e n d f r om

clip on left seat back hinge.

(3) P u ll ca ble ou t of h ou sin g u n t i l ca ble is t ig h t .(4) Pu sh r e t a in in g cl ip o n h in g e la t ch r e le a se a r m

r e a r w a r d t o t a k e u p p la y in h in g e m e ch a n ism .

(5) Engage cable end into retaining clip on hinge.

Fig. 29 Bench Seat Back Hinge Covers

SEAT BACKHINGE HINGE COVERSREAR SEAT

Fig. 30 Bench Seat Back Hinge

SHOULDER BOLTREAR SEATHINGE

Fig. 31 SYNCHRONIZING CABLE ADJUSTMENT

REAR SEATCUSHIONAWLHINGE COVERCABLE ENDCLIP

23 - 18 BODY NS/GS



19/86

CHILD RESTRAINT SEAT MODULE

REMOVAL

(1) Close child restraint seat .

(2) Remove seat back cover.

(3) R em ov e s cr ew s h ol di n g ch i ld r es t r a i n t s ea t

module hinges t o seat back fra me lower ra il (Fig. 32).

(4) Return seat back to upright posit ion.

(5) Disengage push-in fast eners holding upper bol-

ster to child restraint seat module (Fig. 33).

(6) Re m ove scr e w s h old in g t o p o f m od u le t o se a t

back frame upper rail (Fig. 34).

(7) S e pa r a t e ch ild r e st r a in t sea t m od u le f r om sea t

back (Fig. 35).

INSTALLATION

(1) Place child restraint seat module in posit ion on

seat back (Fig. 35).

Fig. 32 Child Restraint Seat Lower Hinge

CHILD RESTRAINT SEATMODULE LOWER HINGE

Fig. 33 Child Restraint Seat Upper Bolster

UPPER BOLSTERCHILDRESTRAINTSEAT MODULEPUSH-IN FAS-TENER

Fig. 34 Child Restraint Seat Upper Screws

U PPE R BO L-STERCHILD RESTRAINT SEATMODULE

Fig. 35 Child Restraint Seat Module

1ST REAR SEAT BACKCHILD RESTRAINTSEAT MODULESEAT BACK HINGEINTERLOCK LEVER

NS/GS BODY 23 - 19



20/86

(2) Po sit ion sea t ba ck h in g e in t e rlock leve r over

t h e t op of t h e ou t b oa r d ch i ld r es t r a i n t s ea t h i ng e

(Fig. 36).

(3) I n st a l l scr e w s t o h o ld ch ild r e st r a in t se a t m od -

ule hinges to seat back frame lower rail (Fig. 32).

(4) I n s t a l l s cr ew s t o h ol d t op of m od u le t o s ea t

back frame upper rail (Fig. 34).(5) Engage push-in fasteners to hold upper bolster

to child restraint seat module (Fig. 33).

(6) Return seat back to folded posit ion.

(7) Install seat back cover.

(8) Verify child restraint seat operation.

Fig. 36 Interlock Lever

CHILD RESTRAINT SEATHINGE SEAT BACK HINGEINTERLOCK LEVER1 ST R EA R S EATBACKSEAT BACK FRAME RAIL

23 - 20 BODY NS/GS



21/86

BODY COMPONENT SERVICE

INDEX

page page

DIAGNOSIS AND TESTINGWATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . 22

WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . 23REMOVAL AND INSTALLATION

A-PILLAR LOWER EXTENSION TRIM . . . . . . . . 54A-PILLAR TRIM PANEL . . . . . . . . . . . . . . . . . . . 54

COWL COVER . . . . . . . . . . . . . . . . . . . . . . . . . 27COWL TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . 54FLOOR CARPET . . . . . . . . . . . . . . . . . . . . . . . . 69FRONT DOOR APPLIQUE . . . . . . . . . . . . . . . . . 37FRONT DOOR CHECK STRAP . . . . . . . . . . . . . 31

FRONT DOOR FRAME CLOSEOUTMOLDINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 36

FRONT DOOR GLASS RUN WEATHERSTRIP . . 37FRONT DOOR GLASS . . . . . . . . . . . . . . . . . . . 35

FRONT DOOR HINGE . . . . . . . . . . . . . . . . . . . . 31FRONT DOOR INNER BELT MOLDING . . . . . . . 34FRONT DOOR LATCH STRIKER . . . . . . . . . . . . 34FRONT DOOR LATCH . . . . . . . . . . . . . . . . . . . . 33

FRONT DOOR LOCK CYLINDER . . . . . . . . . . . 32FRONT DOOR OUTER BELT MOLDING . . . . . . 34FRONT DOOR OUTSIDE HANDLE . . . . . . . . . . 31FRONT DOOR REFLECTOR . . . . . . . . . . . . . . . 30

FRONT DOOR SILL PLATE . . . . . . . . . . . . . . . . 54FRONT DOOR TRIM PANEL . . . . . . . . . . . . . . . 28

FRONT DOOR WEATHERSTRIP . . . . . . . . . . . . 38FRONT DOOR WINDOW CRANK . . . . . . . . . . . 28

FRONT DOOR WINDOW REGULATOR . . . . . . . 36FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 30FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . 69FRONT WHEELHOUSE SPLASH SHIELD . . . . . 27FUEL FILL DOOR BLOCKER LATCH STRIKER . 50

FUEL FILL DOOR BLOCKER LATCH . . . . . . . . . 49FUEL FILL DOOR BLOCKER LOCKOUT LINK . . 49FUEL FILLER HOUSINGWITH BLOCKER

LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23HEADLINING . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . 25HOOD LATCH STRIKER . . . . . . . . . . . . . . . . . . 25

HOOD LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . 25HOOD RELEASE CABLE . . . . . . . . . . . . . . . . . 26HOOD RELEASE HANDLE . . . . . . . . . . . . . . . . 26HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

JACK STORAGE COVER . . . . . . . . . . . . . . . . . 57LEFT D-PILLAR TRIM PANEL . . . . . . . . . . . . . . 58LEFT QUARTER TRIM PANEL . . . . . . . . . . . . . . 61LIFTGATE CHMSL ACCESS PANEL . . . . . . . . . 75LIFTGATE HINGE . . . . . . . . . . . . . . . . . . . . . . . 73

LIFTGATE LATCH STRIKER . . . . . . . . . . . . . . . 76

LIFTGATE LATCH . . . . . . . . . . . . . . . . . . . . . . . 75LIFTGATE LOCK CYLINDER . . . . . . . . . . . . . . . 76

LIFTGATE OUTSIDE HANDLE . . . . . . . . . . . . . . 75LIFTGATE PROP ASSEMBLY . . . . . . . . . . . . . . 73LIFTGATE SILL PLATE . . . . . . . . . . . . . . . . . . . 55LIFTGATE STABILIZER WEDGE STRIKER . . . . 77

LIFTGATE STABILIZER WEDGE . . . . . . . . . . . . 76LIFTGATE TRIM PANEL . . . . . . . . . . . . . . . . . . 74LIFTGATE UPPER FRAME MOLDING . . . . . . . . 74LIFTGATE UPPER FRAME SIDE MOLDINGS . . 74LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

LOWER B-PILLAR TRIM COVER . . . . . . . . . . . . 56LUGGAGE RACK CROSSBAR . . . . . . . . . . . . . 78LUGGAGE RACK RISER COVER . . . . . . . . . . . 78LUGGAGE RACK SIDE RAIL . . . . . . . . . . . . . . . 78

OVERHEAD GRAB-HANDLES . . . . . . . . . . . . . . 55QUARTER GLASS . . . . . . . . . . . . . . . . . . . . . . . 77QUARTER TRIM BOLSTER . . . . . . . . . . . . . . . . 56RADIATOR CLOSURE PANEL

CROSSMEMBER . . . . . . . . . . . . . . . . . . . . . . 23RAIL LAMP MODULE . . . . . . . . . . . . . . . . . . . . 70REAR HEADER TRIM . . . . . . . . . . . . . . . . . . . . 55REAR HEVAC LOUVER AND BEZEL . . . . . . . . . 71

RIGHT D-PILLAR TRIM PANEL . . . . . . . . . . . . . 59RIGHT QUARTER TRIM PANEL . . . . . . . . . . . . 60

ROOF APERTURE (RAP) MOLDING . . . . . . . . . 77SEAT BELT BUCKLE FIRST REAR QUAD

BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66SEAT BELT BUCKLE FIRST REAR2

PASSENGER BENCH . . . . . . . . . . . . . . . . . . . 66SEAT BELT BUCKLE SECOND REAR3

PASSENGER BENCH . . . . . . . . . . . . . . . . . . . 67

SEAT BELT BUCKLEFRONT INBOARD . . . . . 63SEAT BELT FIRST REAR ANCHOR BRACKET

LWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66SEAT BELT FIRST REAR OUTBOARD SWB4

DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64SEAT BELT FIRST REAR OUTBOARDLWB4

DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65SEAT BELT LEFT FIRST REAR OUTBOARD

SWB3 DOOR . . . . . . . . . . . . . . . . . . . . . . 65SEAT BELT LEFT FIRST REAR OUTBOARD

LWB3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . 66SEAT BELT SECOND REAR

OUTBOARDSWB . . . . . . . . . . . . . . . . . . . . 69SEAT BELTOUTBOARD FRONT . . . . . . . . . . . 63SECOND RIGHT REAR OUTBOARD SEAT

BELTLWB W/REAR HEVAC . . . . . . . . . . . . . 68SECOND RIGHT REAR OUTBOARD SEAT

BELTLWB . . . . . . . . . . . . . . . . . . . . . . . . . . 67

NS/GS BODY 23 - 21
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22/86

SHOULDER BELT HEIGHT ADJUSTER KNOB . . 64

SHOULDER BELT HEIGHT ADJUSTERB ORC-PILLAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . . . . . 28SLIDING DOOR CENTER HINGE . . . . . . . . . . . 42

SLIDING DOOR CENTER STABILIZER . . . . . . . 48SLIDING DOOR CENTER STOP TRIM COVER . 40

SLIDING DOOR HOLD OPEN LATCHTRIKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43SLIDING DOOR HOLD OPEN LATCH . . . . . . . . 43

SLIDING DOOR INSIDE LATCH HANDLEBELLCRANK . . . . . . . . . . . . . . . . . . . . . . . . . 42

SLIDING DOOR INSIDE LATCH HANDLE . . . . . 40SLIDING DOOR INSIDE LATCH RELEASE

MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . 41SLIDING DOOR LATCH / LOCK CONTROL . . . . 45SLIDING DOOR LATCH STRIKER . . . . . . . . . . . 47SLIDING DOOR LOWER ROLLER ARM

BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

SLIDING DOOR LOWER ROLLER ARM . . . . . . 44

SLIDING DOOR OUTSIDE LATCH RELEASEHANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

SLIDING DOOR REAR LATCH . . . . . . . . . . . . . 47SLIDING DOOR SILL PLATE . . . . . . . . . . . . . . . 55

SLIDING DOOR STABILIZER SOCKET . . . . . . . 48SLIDING DOOR STABILIZER . . . . . . . . . . . . . . . 48

SLIDING DOOR STOP BUMPER . . . . . . . . . . . . 44SLIDING DOOR TRIM PANEL . . . . . . . . . . . . . . 40SLIDING DOOR UPPER ROLLER . . . . . . . . . . . 42

SLIDING DOOR WEATHERSTRIP . . . . . . . . . . . 49SLIDING DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 38STICK-ON BODY SIDE MOLDING . . . . . . . . . . . 50SUN VISOR SUPPORT . . . . . . . . . . . . . . . . . . . 71

SUN VISOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 71UPPER B-PILLAR TRIM COVER . . . . . . . . . . . . 55UPPER C-PILLAR TRIM . . . . . . . . . . . . . . . . . . 57

ADJUSTMENTS

SLIDING DOOR ADJUSTMENTS . . . . . . . . . . . . 79

DIAGNOSIS AND TESTING

WATER LEAKSWa t er l ea k s ca n b e ca u sed b y poor s ea l in g,

i m pr op er b od y com p on en t a l i gn m en t , b od y s ea m

porosity, missing plugs, or blocked drain holes. Cen-

t r i fu g a l a n d g r a v it a t i on a l f or ce ca n ca u s e w a t e r t o

d r ip f r om a loca t ion a w a y f r o m t h e a ct u a l lea k p oin t ,

m a k i ng l ea k d et e ct i on d if fi cu lt . Al l b od y s ea l i ng

p oin t s sh ou ld be w a t e r t ig h t in n o r m a l w e t -d r ivin g

conditions. Wat er flowing downwa rd from the front of

the vehicle should not enter t he passenger or luggage

com pa r t m en t . M ov in g s ea l in g s ur fa c es w i ll n ot

a l w a y s s ea l w a t e r t i gh t u n der a l l con d it ion s . At

t i m es , s i d e g l a s s o r d oor s ea l s w i l l a l l ow w a t e r t o

e n t er t h e p a ssen g e r com p a r t m e n t d u r in g h ig h p r es-

s u r e w a s h i n g or h a r d d r iv in g r a i n (s ev er e) con d i-

t ion s. Over com pen sa t in g on door or gla ss

a d ju s t m en t s t o s t o p a w a t e r l ea k t h a t occu r s u n d e r

severe conditions can cause premature seal wear and

excessive closing or lat ching effort . After completing

a repair , water-test vehicle to verify leak has stopped

before returning vehicle to use.

VISUAL INSPECTION BEFORE WATER LEAK

TESTS

Verify that f loor and body plugs are in place, body

d r a in s a r e cle a r, a n d bod y com p on e n t s a r e p r op er ly

a l ig n ed a n d sea le d . I f com p on e n t a l ig n m en t or se a l-

in g is n e ce ssa r y , r e f er t o t h e a p p r op r ia t e sect ion of

this group for proper procedures.

WATER LEAK TESTS

WARNING: DO NOT USE ELECTRIC SHOP LIGHTS

OR TOOLS IN WATER TEST AREA. PERSONALINJURY CAN RESULT.

Wh en t h e con d it i on s ca u s i ng a w a t er l ea k h a v ebeen determined, simulate the conditions a s closely

as possible.

I f a l ea k occu r s w i t h t h e v e hi cl e p a r ked i n a

s t ea d y l ig h t r a i n , f l ood t h e l e a k a r ea w i t h a n op en -

ended garden hose.

I f a lea k occur s w h ile d r ivin g a t h ig h w a y sp ee d s

in a st e a d y r a in , t e st t h e le a k a r e a w it h a r e a so n a ble

v el oci t y s t rea m or f a n s pr a y of w a t e r. D i rect t h e

spray in a direction comparable to actual conditions.

If a leak occurs when the vehicle is parked on an

in cline , h o ist t h e e n d o r sid e o f t h e ve hicle t o sim u -

la t e t h is con d it ion . Th is m e t h od ca n be u se d w h e n

the leak occurs when the vehicle a ccelera tes, st ops ort u r n s. I f t h e lea k occur s on a cce le r a t ion , h oist t h e

front of the vehicle. If the leak occurs when braking,

hoist the back of th e vehicle. If t he leak occurs on left

t u r n s, h oi st t h e l ef t s id e o f t h e v eh i cl e. I f t h e l ea k

occurs on right turns, hoist the right side of the vehi-

cle. For hoisting recommendations refer to Group 0,

L u br ica t ion a n d Ma in t e n a n ce, G e n e r a l I n f or m a t ion

section.

WATER LEAK DETECTION

To d e t ect a w a t e r lea k p oin t -of -e n t r y, d o a w a t e r

t e st a n d w a t ch f o r w a t e r t r a ck s o r d r o p le t s f o r m in g

on the inside of the vehicle. If necessary, remove inte-

rior tr im covers or panels to gain visual access to the

lea k a r e a . I f t h e h ose ca n n o t be p osit ion e d w it h ou t

bein g h e ld , h a ve so m eon e h e lp d o t h e w a t e r t e st .

Some water leaks must be tested for a considerable

l en g t h of t i m e t o b ecom e a p pa r e n t . Wh en a l ea k

a p p e a r s, f in d t h e h ig h e st p o in t o f t h e w a t e r t r a ck o r

drop. The highest point usually will show the point of

e nt r y. Af t er l ea k p oi n t h a s b ee n f ou n d , r ep a ir t h e

lea k a n d w a t er t es t t o ver ify t ha t t he lea k h a s

stopped.

23 - 22 BODY NS/GS


23/86

L oca t i n g t h e e n t r y p oi n t of w a t e r t h a t i s l e a k in g

i n t o a ca v i t y b et w e en p a n el s ca n b e d if fi cu lt . Th e

t r a pped w a t e r m a y s pl a sh or r u n f rom t h e ca v it y,

o f t e n a t a d ist a n ce f r o m t h e e n t r y p o in t . Mo st w a t e r

leaks of this type become apparent after accelerating,

stopping, turning, or when on an incline.

MIRROR INSPECTION METHOD

Wh e n a lea k p oin t a r e a is visu a lly o bst r u ct e d , u se

a su it a ble m ir r or t o g a in visu a l a cce ss. A m ir r or ca n

a lso be u sed t o d e flect l igh t t o a l im it e d-a cce ss a r e a

t o a ssist in lo ca t in g a le a k p o in t .

BRIGHT LIGHT LEAK TEST METHOD

S o m e w a t e r le a k s in t h e lu g g a g e co m p a r t m e n t ca n

be d e t ect ed w it h o u t w a t e r t e st in g. P osit ion t h e veh i-

cle in a br ig h t ly l i t a r e a . F r o m in sid e t h e d a r k e n ed

lu g ga g e com p a r t m e n t in spe ct a r o u n d se a ls a n d bod y

seams. If necessary, have a helper direct a drop light

ov er t h e s u sp ect e d l ea k a r e a s a r ou n d t h e l ug g a g ecom p a r t m e n t . I f l ig h t is visible t h r o u gh a n or m a lly

sealed location, water could enter through the open-

ing.

PRESSURIZED LEAK TEST M ETHOD

Wh en a w a t er l ea k i n t o t h e p a s se ng er com p a r t -

ment cannot be detected by water testing, pressurize

the passenger compartment and soap test exterior of

t h e veh icle. To p r essu r iz e t h e p a ssen g er com p a r t -

m e n t , clo se a l l d o o r s a n d w in d o w s, st a r t e n g in e , a n d

set heater control t o high blower in H EAT posit ion. I f

e n gin e ca n n o t be st a r t e d , con n e ct a ch a r g er t o t h e

b a t t e r y t o e ns u re a d e q ua t e v ol t a g e t o t h e b low e r.With interior pressurized, apply dish detergent solu-

t i on t o s u sp ect e d l ea k a r e a on t h e e xt e ri or of t h e

vehicle. Apply detergent solution with spray device or

s of t b r is t l e b r u sh . I f s oa p b u bb les occu r a t a b od y

seam, joint , seal or gasket, the leak entry point could

be a t t h a t lo ca t io n .

WIND NOISEWind noise is t he result of most a ir leaks. Air leaks

can be caused by poor sealing, improper body compo-

nent alignment, body seam porosity, or missing plugs

in th e engine compart ment or door hinge pillar a reas.

All bo d y se a l in g p o in t s sh o u ld be a ir t ig h t in n o r m a ldriving conditions. Moving sealing sur faces w ill not

a l w a y s s ea l a i r t i gh t u n d er a l l con d it i on s . A t t i m es ,

sid e g la ss or d oor sea ls w il l a l low w in d n oise t o be

n ot ice d in t h e p a ssen g er com p a r t m e n t d u r in g h ig h

cr os s w i nd s . O ve r com p en s a t i n g on d oor or g la s s

a d ju s t m en t s t o s t op w i n d n oi se t h a t occu r s u n d er

severe conditions can cause premature seal wear and

excessive closing or latching effort. After a repair pro-

ce du r e h a s b ee n p er f or m ed , t e st v eh i cl e t o v er i fy

noise has stopped before returning vehicle to use.

Wind noise can also be caused by improperly fit ted

ex t er i or m ol d in g s or b od y or n a m en t a t i on . L oos e

moldings can flutter, creating a buzzing or chattering

noise. An open cavity or protruding edge can creat e a

whistling or howling noise. In spect t he exterior of the

vehicle to verify that these conditions do not exist .

VISUAL INSPECTION BEFORE TESTS

V e r if y t h a t f lo o r a n d bo d y p lu g s a r e in p la ce a n d

bod y com p on e n t s a r e a l ig n ed a n d se a led . I f com p o-

n e n t a l ig n m en t or se a l in g is n e cessa r y, r e f er t o t h e

a p p r op r ia t e se ct ion of t h is g r ou p f or p r op er p r oce-

dures.

ROAD TESTING WIND NOISE

(1) Drive the vehicle to verify the general location

of t h e w in d n oise.

(2) Apply 50 mm (2 in.) masking tape in 150 mm

(6 i n .) l en g t h s a l on g w e a t h e rs t r ip s, w e ld s ea m s or

moldings. After ea ch length is a pplied, drive the vehi-cle. If noise goes aw ay aft er a piece of ta pe is applied,

remove tape, locate, and repair defect .

POSSIBLE CAUSE OF WIND NOISE

Mo ld in g s st a n d in g a w a y f r o m bo d y su r f a ce ca n

ca t ch w in d a n d w h ist le .

G a p s i n s ea l ed a r e a s b eh i nd ov er h a n g in g b od y

flanges can cause wind-rushing sounds.

Misaligned movable components.

Missing or improperly installed plugs in pillars.

Weld burn through holes.


GRILLE

REMOVAL

(1) Remove front fascia. Refer to Group 13, Frame

and Bumpers, for proper procedures.

(2) D ise n ga g e clips h old in g g r i lle t o f r on t f a scia

(Fig. 1).

(3) Remove plastic r ivets holding grille to fascia.

(4) Separate grille from fascia.

INSTALLATION

(1) Posit ion grille on fascia.

(2) I n st a l l p la st ic r ive t s t o h o ld g r i lle t o f a scia .

(3) I n st a l l c lips t o h o ld g r i l le t o f a scia a lon g bot -

tom of grille.

(4) I n st a l l f r o n t f a scia . Re f e r t o G r o u p 13, F r a m e

and Bumpers, for proper procedure.

RADIATOR CLOSURE PANEL CROSSMEMBER

REMOVAL

(1) Release hood latch and open hood.

NS/GS BODY 23 - 23

DIAGNOSIS AND TESTING (Continued)


24/86

(2) Mark outline of hood latch on crossmember to

a id in st a l la t io n .

(3) Remove bolts holding hood latch to crossmem-be r a n d p o sit io n la t ch o u t o f t h e w a y .

(4) Remove radiator sight shield.

(5) Remove engine air inlet resonator.

(6) R em ov e b ol t h ol di n g a i r cl ea n e r h ou s in g t o

crossmember.

(7) Remove screw holding coolan t recovery bott le

to crossmember.

(8) R em ov e b ol t s h ol di n g r a d i a t or i sol a t or s t o

crossmember.

(9) Remove bolts holding ends of crossmember t o

radiator closure panel (Fig. 2).

(10) L if t cr os sm em ber u pw a r d a n d a w a y f rom

radiator closure panel.

(11) Separate crossmember from vehicle.

INSTALLATION

(1) P la ce r a d ia t o r closu r e p a n e l cr ossm em ber in

position on vehicle.

(2) I n se r t e n d s of cr ossm em ber bet w e e n la y e r ed

m e t a l se ct io n s o f r a d ia t o r clo su r e p a n e l a t e a ch sid e

of radiator.

(3) I n s t a l l b ol t s t o h ol d e nd s of cr os s m em b er t o

radiator closure panel (Fig. 2).

(4) I n st a l l bolt s t o h o ld r a d ia t o r iso la t or s t o cr oss-

member.(5) Install screw to hold coolant recovery bott le to

crossmember.

(6) Insta ll bolt t o hold a ir clean er housing to cross-

member.

(7) Install engine air inlet resonator.

(8) I n st a l l r a d ia t o r sig h t sh ie ld .

(9) Align hood latch to marks on crossmember.

(10) I n st a l l bo lt s t o h o ld h o o d la t ch t o cr o ssm e m -

ber.

(11) Ve r if y h ood la t ch op er a t io n a n d h ood a l ig n -

ment.

HOOD

REMOVAL

(1) Raise hood to full up posit ion.

(2) Ma r k a l l bolt a n d h in g e a t t a ch m en t loca t ion s

w it h a g r ea se p en cil or ot h e r su it a ble d e vice t o p r o-

vide reference marks for installat ion.

(3) Remove the top bolts holding hood to hinge a nd

loosen the bottom bolts until they can be removed by

hand (Fig. 3).

(4) Wit h a ssist a n ce f r o m a h e lp er a t t h e op posit e

side of th e vehicle to support t he h ood, remove bot-

tom bolts holding hood to hinge.

(5) Separate the hood from the vehicle.

INSTALLATION

(1) P lace hood in posit ion on vehicle. With assis-

ta nce from a helper a t the opposite side of the vehicle

to support the hood, inst all bottom bolts to hold hood

t o h in g e f in g er t ig h t .

Fig. 1 Grille

GRILLE

FRONT BUMPER FASCIA

Fig. 2 Radiator Closure Panel Crossmember

RADIATOR CLOSURE PANELCROSSMEMBERFRONT FASCIA

Fig. 3 Hood

HOOD

HOOD LATCH STRIKERH OOD HA LF OF H OODHINGE

23 - 24 BODY NS/GS



25/86

(2) I n st a l l t o p bolt s t o h old h ood t o h in g e f in g er

t ig h t .

(3) Po sit io n bo lt s a t m a r k s a n d t ig h t e n bo lt s . T h e

hood sh ould be a ligned t o 4 mm (0.160 in.) gap t o the

f r on t f en d e rs a n d f lush a cr oss t h e t op su r f a ces a lo n g

fenders.

(4) Verify hood operation and alignment.

HOOD HINGE

REMOVAL

(1) Remove hood.

(2) Remove wiper unit . Refer to Group 8K, Wind-

shield Wipers a nd Wa shers, for procedure.

(3) Ma r k a l l bolt a n d h in g e a t t a ch m e n t lo ca t ion s

w it h a g r ea se p en cil o r ot h e r su it a ble d e vice t o p r o-

vide reference marks for installat ion.

(4) Remove bolts holding body ha lf of hood hinge

t o f r o n t f e n d e r f la n g e a n d se p a r a t e h in g e f r o m ve h i-

cle (Fig. 4).

INSTALLATION

(1) I f n e ce ssa r y , p a in t n e w h in g e be for e in st a l la -

tion.

(2) Pla ce bod y h a lf of h ood h in g e in p osit ion on

vehicle.

(3) Install bolts to hold hood hinge to front fender

flange.

(4) I n st a l l w ip er u n it . Re fe r t o G r o u p 8K , Win d -shield Wipers a nd Wa shers, for procedure.

(5) Install hood.

(6) Al ig n a l l m a r k s a n d s ecu r e b ol t s. Th e h ood

should be a ligned to 4 mm (0.160 in.) gap t o the front

fenders and flush across the top surfaces along fend-

er s . S h im s ca n b e a d d ed or r em ov ed u n der h ood

hinge to achieve proper hood height.

HOOD LATCH STRIKER

REMOVAL


(2) Remove bolts holding striker to inside of hood

(Fig. 3).

(3) Separate hood latch striker from vehicle.

INSTALLATION

(1) Posit ion hood latch striker on vehicle.

(2) Install bolts to hold hood latch striker to hood.

(3) Alig n h ood la t ch st r ik er t o e n ga g e sm oot h ly

into hood latch.

(4) Verify hood opera tion a nd alignment. Adjust as

necessary.

(5) Torque bolts to 100 140 in. lbs.

HOOD LATCH

REMOVAL


(2) Mark perimeter outline of latch on crossmem-

be r t o a id in st a l la t io n .

(3) Remove bolts holding hood latch to radiator clo-

sure panel crossmember (Fig. 5).

(4) Separate hood latch from crossmember.

(5) D isconnect hood release cable from hood lat ch

(Fig. 7).

(6) Separate hood latch from vehicle.

INSTALLATION

(1) Position hood latch on vehicle.

(2) Connect hood release cable from hood latch.

(3) Position hood latch on crossmember.

(4) Alig n h ood la t ch t o ou t l in e o f la t ch on cr oss-

member.

(5) I n st a l l bolt s t o h o ld h o od la t ch t o r a d ia t o r clo-

sure panel crossmember.

(6) Verify hood opera tion a nd alignment. Adjust as

necessary.

(7) Torque bolts to 100 140 in. lbs.

Fig. 4 Hood Hinge

HOOD

Fig. 5 Hood Latch

HOOD RELEASE CABLE

NS/GS BODY 23 - 25



26/86

HOOD RELEASE CABLE

REMOVAL

(1) Remove hood latch.

(2) D isen g a g e ca ble e n d f r om h ood la t ch lock in g

mechanism.

(3) Slide cable case end sideways in keyhole slot ofhood latch while pinching barb on cable case closed.

(4) Separate cable from latch (Fig. 7).

(5) Re m ove h ood r e le a se h a n d le f r om in st r u m en t

panel.

(6) D i s en g a g e r u bb er g r om m et ca b l e i n su la t o r

f r o m h o le in d a sh p a n e l .

(7) At t a ch a su it a ble len g t h of m e ch a n ics w ir e t o

la t ch e n d of ca ble t o a ssist ca ble in st a l la t io n .

(8) R ou t e ca b l e b a ck f r om l a t ch t h r ou g h e ng in e

com pa r t m e n t t ow a r d d a s h p a n el n ea r p ow e r b r a k e

booster (Fig. 6).

(9) Remove attaching clips from cable case.

(10) F rom inside vehicle, pull cable t hrough da shpanel until mechanics wire is exposed.

(11) Disconnect cable from mechanics wire.

(12) Separate hood release cable from vehicle.

INSTALLATION

(1) P l a ce h ood r el ea s e ca b l e i n p os it i on u n d er

instrument panel.

(2) At t a ch l a t ch en d of h ood r el ea s e ca b le t o

mechanics wire protruding through dash panel.

(3) Ro u t e ca ble f or w a r d t h r o ug h e n gin e com p a r t -

m e nt t ow a r d l a t ch b y p ul li n g on m ech a n i cs w i r e(Fig. 6).

(4) Disconnect mecha nics wire from cable.

(5) E n g a g e r u bb er g r om m et ca b l e i n su la t o r i n t o

h o le in d a sh p a n e l .

(6) Install hood release handle into instrument panel.

(7) Place cable in posit ion on latch.

(8) Slide cable case end sideways into keyhole slot

of hood latch.

(9) Enga ge cable end int o hood la tch locking mech-

a n ism .

(10) Install hood latch.

(11) Install at taching clips to cable case and install

clips into original holes in strut tower, fender, head-la m p a r e a , a n d r a d ia t o r closu r e p a n e l crossm em ber .

HOOD RELEASE HANDLE

REMOVAL

(1) Remove lower steering column cover and knee

blocker reinforcement.

(2) Remove h ood la tch cable.

(3) Remove screws holding hood latch release han-

dle to instrument panel brace (Fig. 8).

(4) S e p a r a t e h o o d la t ch r e le a se h a n d le f r o m ve h i-

cle.

INSTALLATION

(1) Posit ion hood latch release handle on vehicle.

(2) Install screws to hold hood latch release handle

t o in st r u m e n t p a n e l br a ce.

(3) Install hood latch cable.

(4) I n st a l l low e r st e er in g colu m n cover a n d k n ee

blocker reinforcement.

Fig. 6 Hood Release Cable Routing

GROMMETHOOD RELEASE CABLERADIATOR CLOSURE PANELCROSSMEMBER

Fig. 7 Hood Release Cable End Attachment

RELEASE CABLE CASEHOOD LATCHRELEASE CABLE END

Fig. 8 Hood Release Handle

INSTRUMENT PANEL BRACEHOOD RELEASE HANDLE

23 - 26 BODY NS/GS



27/86

COWL COVER

REMOVAL

(1) Remove wiper arms. Refer to Group 8K, Wind-

shield Wipers a nd Wa shers.

(2) Remove screws holding lower area of cowl cover

to wiper module (Fig. 9).(3) Disengage quarter turn fasteners holding outer

ends of cowl cover to wiper module.


(5) Remove w ing n uts holding front of cowl cover

to wiper module.

(6) C l os e h ood . D o n ot l a t ch . R em ov e ou t b oa r d

screws. (Fig. 10).

(7) Lift cowl cover upwa rd enough to ga in a ccess to

r ig h t w a sh e r h o se .

(8) D ise n g a g e w a sh e r h o se f r o m r ig h t w a sh e r n o z -

zle.

(9) Close hood. Do not latch.

(10) Separate cowl cover from vehicle.

INSTALLATION

Reverse the preceding operation.

FRONT WHEELHOUSE SPLASH SHIELD

REMOVAL

(1) Hoist and support vehicle on safety stands.

(2) Remove front wheel. Refer to Group 22, Wheelsand Tires, for proper procedures.

(3) Remove push-in fasteners holding splash shield

t o f r a m e r a i l f o rw a r d of su spe n sion .

(4) Remove push-in fasteners holding splash shield

t o f r a m e r a i l r e a r w a r d o f su sp e n sio n .

(5) R em ov e s cr ew s h ol d in g w h e el h ou s e s pl a s h

shield to front fender.

(6) Separate splash shield from vehicle (Fig. 11).

INSTALLATION

(1) Place splash shield in posit ion on vehicle (Fig.11).

(2) Install screws to hold wheelhouse splash shield

to front fender.

(3) I n st a l l p u sh - in f a st e n e r s t o h o ld sp la sh sh ie ld

t o f r a m e r a i l r e a r w a r d o f su sp e n sio n .

(4) I n st a l l p u sh - in f a st e n e r s t o h o ld sp la sh sh ie ld

t o f r a m e r a i l f or w a r d of su spe n sion .

(5) Install front wheel. Refer to Group 22, Wheels

and Tires, for proper procedures.

(6) Lower vehicle.

Fig. 9 Cowl Cover

Fig. 10 Cowl Cover Retainers

SCREW

Fig. 11 Front Wheelhouse Splash Shield

BUMPER FAS-CIA FRONT WHEELHOUSESPLASH SHIELDFRONTFENDER

NS/GS BODY 23 - 27



28/86

SIDE VIEW MI RROR

REMOVAL

(1) Release front door latch and open door.

(2) Remove screw holding molding t o base of side

view mirror (Fig. 12).

(3) Separate molding from mirror.(4) Remove bolts holding bottom of side view mir-

ror to A-pillar.

(5) Remove bolt holding top of side view mirror to

A-pillar (Fig. 12).

(6) If equipped, disengage power side view mirror

wire connector from instrument panel harness.

(7) Separate side view mirror from vehicle.

INSTALLATION(1) E ngage power side view m irror wire connector

into instrument panel harness, if equipped.

(2) Pla ce sid e vie w m ir r or in p osit ion on ve hicle

(Fig. 12).

(3) I n st a l l bolt t o h o ld t o p o f s id e vie w m ir r or t o

A-pillar.

(4) Install bolts to hold bottom of side view mirror

to A-pilla r.

(5) Place molding in posit ion on mirror.

(6) I n s t a l l s cr ew t o h ol d m ol d in g t o b a s e of s i de

view mirror.

FRONT DOOR WINDOW CRANK

REMOVAL

(1) U sin g a su it a ble t ool , d isen g a g e cl ip h o ldin g

window crank to regulator shaft (Fig. 13).

(2) Pu ll w in d o w cr a n k f r o m r e g u la t o r sh a f t .

INSTALLATION

(1) P osit ion w in d ow cr a n k t o r e g u la t o r sh a f t .

(2) P u sh w i n dow cr a n k on t o r eg ul a t or s h a ft t o

engage retaining clip.

FRONT DOOR TRIM PANEL

REMOVAL(1) Using a tr im stick (C-4755), pry courtesy lamp

from door tr im.

(2) Disengage wire connector from courtesy lamp.

(3) If equipped, remove screws holding door assist

handle to inner door panel.

(4) I f e q u ip pe d , r e m ove scr e w h old in g d oor p u ll

cup to inner door panel.

(5) If equipped, remove screws holding tr im panel

to door from below map pocket.

(6) If equipped, remove window crank.

(7) U sin g a t r im st ick , r e m ove scr ew cover f r om

switch panel.

(8) Re m ove scr e w s h old in g sw it ch p a n e l t o d oor

t r im .

(9) S ep a r a t e p ow e r a c ce ss a r y s w i t ch f r om d oor

trim (Fig. 14).

(10) Disengage power switch from wire connector.

(11) I f e q ui pp ed , u s in g a s m a l l, f la t b la d e d p ry

tool, remove memory sea t/mirror sw itch a nd disen-

gage wire connector (Fig. 15).

(12) I f equipped, remove screw holding door tr im

t o d o o r p a n e l f r o m be h in d in sid e la t ch r e le a se h a n -

dle.

(13) D i se ng a g e cl ip s h ol d in g d oor t r i m t o d oor

frame around perimeter of panel (Fig. 16).(14) L i ft t r i m p a n el u pw a r d t o d is en g a g e f la n g e

from inner belt molding at top of door.

(15) Tilt top of tr im panel a wa y from door t o gain

access to latch linkage.

(16) D ise n ga g e clip h old in g l in k a g e r od t o in sid e

latch release handle (Fig. 17).

(17) S e pa r a t e l in ka g e r od f r om la t ch h a n d le .

(18) Separate front door tr im panel from vehicle.

Fig. 12 Side View Mirror

SIDE VIEW MIRROR

MOLDING

Fig. 13 Window Crank

DOOR HANDLEREMOVAL TOOL WINDOWCRANK

23 - 28 BODY NS/GS



29/86

INSTALLATION

(1) H o ld t o p o f t r im p a n e l a w a y f r o m d o o r t o g a in

access to latch linkage.

(2) Place linkage rod in posit ion on latch handle.

(3) En g a g e cl ip t o h o ld l in k a g e r o d t

Documents

98 Voyager Body