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2
INTRODUCTION AND GENERAL INFORMATION
MANUAL DESCRIPTION
INTRODUCTION
This publication contains the essential removal, installation, adjustment and maintenance proce- dures for servicing all Body Styles. This informa- tion is current as of time of publication.
INDEX
The preceding page contains a “Table of
Contents” which lists the unit number and subject title of each main body unit. The first page in each main body unit has an index to the subjects included in that unit. of the subject matter. This refers to the year and the session issue number 3.
1969
The Master Technician Service Conference is a training supplement available wherever Chrysler
Corporation automotive services are available.
It should be clearly understood that the Master
Technician’s Service Conference does not constitute legal authority for performing service operations.
It’s value lies in greater understanding of a specif- ic subject, which results in increased ability to ac- curately diagnose malfunctions.
PAGE NUMBERS
All page numbers consist of two sets of digits separated by a dash. The digits preceding the dash identify the main body. The digits following the dash represent the consecutive page number within the particular body unit. The page numbers can be found on the upper left or right of each page.
TEXT
Unless otherwise specified, each service procedure covers all body styles. Procedures covering specific styles are identified by the car line letter, body type or similar designation. A description of these designations is covered in this unit under
“VEHICLE AND ENGINE NUMBERS”.
VEHICLE AND ENGINE NUMBERS
VEHICLE NUMBER: The vehicle number (serial number) is located on a plate (Fig. 1) which is attached to the instrument panel between the left windshield wiper pivot and the left “A” post. It can easily be seen by looking through the windsh- ield from the outside.
I o
CHRYSLER
C O R P O R A T I O N O I
11
L
USTRA TIONS
Where possible, illustrations are placed in close proximity to the accompanying text and should be used as part of the text.
VEHICLE IDENTIFICATION NUMBER PLATE
INSTRUMENT PANEL LOCATED NR464
ALPHABETICAL INDEX
An alphabetical index is found at the rear of the
Service Manual to aid in locating specific subjects and components.
MASTER TECHNICIAN’S SERVIC€
CONFERENCE (M. TIS.C.)
Throughout the service manual, refernce to
M.T.S.C. material for the subject can be found at the beginning of the particular section. Example:
M.T.S.C. 69-3 may be called out in the beginning
Fig. 1 Vehicle Identification Number Plate
All vehicle numbers contain thirteen digits. The vehicle number is a code which tells the carline
(1st digit), price class (2nd digit), body type (3rd and 4th digit), engine displacement (5th digit), model year (6th digit), assembly plant (7th digit), and vehicle sequence number (last six digits).
This vehicle number is also stamped on the en- gine block. On six cylinder engines it is on a pad located below the number 6 spark plug at the cyl- inder head joint face. On eight cylinder engines it is on a pad located just to the rear of the right engine mount on the pan rail.
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INTRODUCTION AND GENERAL INFORMATION 3
1st Digit
Carline
2nd Digit
Price Class
3rd & 4th Digits
Body Type
5th Digit
Eng. Displace- 6th Digit merit CU. In,
7th Digit
Model Year Assembly Plant
V-Valiant E-Economy
B-Barracuda M-Medium
H-H igh
R-Satellite P-Premium
P-Fury
T-Tax i
S-Special
0-Su perstoc k
N-New York Taxi
21-1 Dr. Sedan Coupe
23-2 Dr. Hardtop
27-Convertible
2 9 2 Dr. Sport Hardtop
41-4 Dr. Sedan
4 3 4 Dr. Hardtop
45-2 Seat Station Wagon
46-3 Seat Station Wagon
C-C hry
sl
er
Y-Imperial
B-198
C-225
E-Spec. Ord. 6
G-3 18
H-340
K-360
L-383
N-383 H/Perf.
R-426 Hemi
T-440
U-440 H/Perf.
V-440 3/2 Bbl.
Z-Spec. Ord. 8
1-1971 A-Lynch Road
B-Hamtramck
C-J efferson
D-Belvidere
E-Los Angeles
F-Newark
G-St. Louis
H-New Stanton
P-Wyom ing
(Export)
R-Windsor
ENGINE NUMBERS: All engine serial numbers contain fourteen characters and digits. The first two designate power train, the next three are the cubic inch displacement, the next one designates low compression, the next four are based on a 10,
OOO day calendar and the last four designate en- gine built that day. All 198 and 225 cubic inch engines have the serial numbers stamped on the joint face at right corner, adjacent to number 1 cylinder bore. All 318, 340 and 360 cubic inch engines have the serial numbers stamped on the front of the block just below the left cylinder head. All 383, 426 and 440 cubic inch engines have the serial numbers stamped on the cylinder block pan rail at the left rear comer below the starter opening.
On all engines, information identifying undersized crankshaft, oversized tappets, low compression, oversized cylinder bores, engine built that day, the shift and 10,OOO day calendar is stamped on the cylinder block at various locations depending on engine. There can be as many as fifteen characters and digits in this location. 198 and 225 cubic inch engines are stamped on the joint face at right comer, adjacent to number 1 cylinder bore, after serial number. 318, 340 and 360 cubic inch en- gines are stamped on the front of the block just below the left cylinder head. 383 cubic inch en- gines are stamped on the right bank joint face just forward of the number 2 cylinder bore. 426 and 440 cubic inch engines are stamped on the left bank pad, adjacent to front tappet rail. For additonal information on engines, see Chassis
Service Manual.
BODY CODE PLATE: Includes schedule date, body type, engine code, transmission code, tire code, trim code and paint codes (Fig. 2).
0 . . 0 . . 0 . . 0 . . 0 . . 0 . .
0
0 . . 0 . . 0 . . 0 . . 0 . .
0
0 . . 0 . . 0 . . 0 . . 0 . . 0 . .
0 . . 0 . . 0 . . 0 . . 0 . . 0 . .
++ ++ +++
+-t
+++
++++-t+
VIN NUMBER
Fig. 2 Body Equipment Identification Plate
It is located on the left front fender side shield or wheel housing.
TIRE PRESSURE: A decal showing the recom- mended tire pressure is located on the body pillar at the rear of the left front door opening
(“B”
post). Tire Pressure data can be found in the
Chassis Service Manual.
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CAPACITY CONVERSION TABLE
0
10
20
30
40 us.
1 14
1 12
314
1
1 114
1112
1 314
2
2 114
2 112
2 314
3
3 114
3 112
3 314
4
4 114
4 112
4 314
5
5 114
5 112
5 314
6
6 114
6 112
6 314
Gallons
Imperial
318
518
U.S.
7
7 1/4
7 112
7 314
Imperial
5 314
6
6 114
6 112
U.S.
15
15 112
16
16 112
16 314 314
1
1 114
1 112
1 314
1 314
2
2 114 a 8
8 114
8 112
8 314
9
9 114
9 112
9 314
6 314
6 314
7
7 114
7 112
7 314
8
8
17
17 112
18
18 112
19
19 112
20
20 112
2 112
2 314
3
3
3 114
3 112
3 314
4
4 114
4 114
4 112
4 314
5
5 114
5 112
5 112
10
10 114
10 112
10 314
11
11 114
11 112
11 314
12
12 114
12 112
12 314
13
13 112
14
14 112
8 114
8 112
8 314
9
9 114
9 114
9 112
9 314
10
10 114
10 112
10 112
10 314
11 114
11 314
12
21
21 112
22
22 112
23
23 112
24
24 112
25
25 112
26
26 112
27
27 112
28
29
30
0
CAPACITY CONVERSION U.S. GALLONS TO LITERS
~~
1 2 3 4
Liters
00.0000
37.8533
75.7066
1 13.5600
1 51.41 33
Liters
3.7853
41.6387
79.4920
1 17.3453
155.1 986
Liters
7.5707
45.4240
83.2773
121.1306
158.9840
Liters
1 1.3560
49.2098
87.0626
1 24.9 160
162.7693
Liters
15.1413
52.9947
90.8480
128.7013
166.5546
I
mberial
12 112
13
13 114
13 314
14
14 114
14 112
15
15 112
15 314
16 114
16 314
17
17 112
18
18 114
18 314
19 114
19 112
20
20 112
20 314
21 114
21 314
22
22 112
23
23 114
24 114
25
5
Liters
18.9267
56.7800
94.6333
132.4866
170.3400
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6 INTRODUCTION AND GENERAL INFORMATION
BOLT TORQUE
TORQUE REFERENCES
HEAD MARKINGS-Head marking identification shall consist of radial lines extending to the across flats top circle. The identification shall be easily legible and distinct from manufacturer's trade mark, but need not be in any particular relation to the hexagon. The manufacturer's trade mark shall be legible, in the center of the bolt head, and not over 1/3 of the cross flats dimension.
I
GRADE GRADE 5 GRADE 8
SA€
CLASSIFICATION
0
I
1 80"
I
120"
I
60" PB283) fig. 3 Bolt Head ldentifkation
SIZE GRADE1 GRADE 5 GRADE 8
6-32
8-32
10-24
10-32
12-24
1/4-20
10
12
17
20
25
40
Above dotted line-In. Lbs.
Below dotted line-Ft. Lbs.
130 185
1/4-28 45 130 185
5/16-18
5/16-24
318- 1 6
- -
7/16:14
_ _ _ _
100 l l o
180
I
200 280 r 2 B - - - - - -
78-
-
Z L J
30
35
55
42
49
70
711 6-20
1/2-13
1/2-20
9/16-12
9/16-18
518-1 1
518- 1 8
314- 16
60
85
95
115
130
170
180
200
75
105
120
145
160
21 0
225
245
0
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MAINTENANCE AND CARE 1-1
MAINTENANCE AND CARE
INDEX
APPEARANCE
Page
...........................................................
1
ACRYLIC FI N ISH ES-PO LI SH
BRIGHT METALS-POLISHING
CONVERTIBLE
I N G
..................
.......................
4
4
Backlight
........................................................
1
................................................................
1
Boot
.........................................................................
1
Top
...........................................................................
1
Well
..........................................................................
1
GLASS
.......................................................................
4
INTERIOR TRIM
.....................................................
1
Cargo Area (Station Wagon)
Carpets and Rubber Mats
.........................
..............................
4
3
.........................
4 Color Restoration or Change
Door Panels
..........................................................
3
General Instructions
Glove Compartment
..........................................
..........................................
1
3
Headliners
..............................................................
Luggage Compartment
Package Shelfs
Side Cowl Trim Panels
Test for Material Type
POLISHING
.....................................
....................................................
Sealers-Leather and Vinyl
............................
Seats
Page
3
4
3
4
........................................................................
3
Bodycloth-Knit Type
Spots and Stains
.....................................
................................................
2
....................................
1
3
.....................................
1
Acrylic Finishes
Bright Metals
.......................................................
Scratches and Overspray
TIRES
VINYL
..............................................................
4
...................................................
................................
.........................................................................
ROOF COVERING
4
4
4
4
...................................
1
DRAINHOLES
...........................................................
4
LUBRICATION
...........................................................
4
GENERAL INFORMA TION
The procedures for maintaining “new car” ap- pearance of material covered in the APPEAR-
ANCE section are those most generally used. The final results may vary due to application of agents by persons inexperienced at this work and also from the type of foreign element on the material.
For satisfactory results, appearance maintenance should be performed by qualified experienced personnel using the recommended agents and established service procedures.
APPEARANCE
CON VERT161 E
Never lower a wet top. Dampness may cause formation of mildew, and damage to the fabric will result. Top- Frequent brushing and vacuum- ing will keep the top free of abrasive dust and dirt. When washing, the top material should be thoroughly wet.
For scrubbing, use only a soft, natural bristle hand scrub brush. Use warm water and naphtha bar type soap as the cleaning agent. Do not wash in direct sunlight. Scrub with soap suds, starting in the center and gradually working toward the edges. Rinse with clean water to remove all traces of soap. Allow to dry completely before lowering.
Backlight-The tempered glass. backlight (rear window) is a solid
Top Boot and Well-Remove all abrasive dust and dirt from boot and well by brushing or vacuuming. For scrubbing, use only a soft, natural bristle hand scrub brush. Use warm water and naphtha type bar soap. Rinse with clean water.
Use a soft absorbent cloth to dry.
VINYL ROOF
CO
VERING
In a well ventilated area, saturate a clean cloth with recommended Vinyl Roof Cleaner and
Conditioner. Wipe surface using a circular motion.
With another clean cloth, wipe excess material from top. Allow to dry for ten minutes.
INTERIOR TRIM
Most stains can be removed while they are fresh and have not hardened and set into the fabric. An exception is mud or clay, which should be al- lowed to dry so that most of it can be brushed off. It is helpful, to know the nature of the stain- ing matter so the correct cleaning agent may be used.
General Instructions: Use a very small piece of clean cotton cheesecloth approximately 3 in. x 3 in. Squeeze most of the liquid from the fabric and it is less likely to leave a ring. Wipe the soiled fabric very lightly with a lifting motion. Always work from the outside toward the center of the spot. Turn the cheesecloth over as soon as one side becomes stained to prevent working the stain matter back into the cleaned portion. Use clean cheesecloth as soon as both sides become stained.
Testing For Type of Material-Natural cloth will burn like string, slow and smoky. Synthetic mate- rial such as nylon, burns fast and “balls up” into a hard mass. Sample material for testing can be found under the seat cushion, sun visor and dome light brackets, or back of the trim panels. Another method of testing is to rub the back of a finger- nail over the surface of the material. Synthetic materials appear to “whistle” when this is done.
Body Cloth-Knit Type Insert-Spot Cleaning-
(Grease, oil, adhesive, crayon, lipstick, similar
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1-2
MAINTENANCE AND CARE
stains and any stains of undetermined origin).
Wipe off as much of the staining material as pos- sible with clean cheesecloth. Using K2R aerosol spotlifter, or equivalent, spray stained area from a distance of 8 to 10 inches. Allow to dry (a white powder will form). Brush or vacuum powder from surface. Repeat operation should any stain remain.
Entire Insert-Cleaning Only-(Waterspots, dirt, foodstains, coffee and other water borne stains).
Vacuum or brush off as much of the staining ma- terial as possible. Shield adjacent cushion or back
(not to be cleaned) to prevent wetting. Use a wip- ing motion outward from the contaminated area to the edges of the insert with clean lukewarm water and clean cheesecloth. Rub with water until entire insert is wet. Do not soak insert. If clear water did not remove soil, use cleaner equivalent, diluted one part cleaner to one part water and again clean entire insert.
Entire Insert or Pipe-Cleaning Only-(Grease, oil, adhesive, crayon, lipstick and similar stains).
Wipe off as much of staining material with clean cotton cheesecloth. Wet another piece of clean cheesecloth with the recommended spot remover and fabric cleaner, or equivalent and squeeze out excess cleaner until cheesecloth is drip free. Use a wiping motion outward from the stained area to the edges of the pipe or bisquit and clean com- plete area. Unfold cheesecloth to expose clean are- as frequently so staining material being removed is not re-deposited on fabric. Continue until foreign matter is no longer visible and entire fabric cover or individual pipe or bisquit is dampened. In cases of severe staining, a second cleaning may be required. Be sure to use the minimum amount of solvent required to clean affected area. Excessive solvent may damage the foam underpadding.
Oil and Water Repellent Application-The cleaned area must be completely dried before ap- plying repellent. Perform following operation only in a well ventilated area. Avoid prolonged breathing of vapors o r contact with eyes. Using
Scotchgard Fabric Protector, or equivalent, hold spray can 6 to 8 inches from fabric and with slow back and forth sweeping motions, spray fab- ric until evenly wet. Be sure to overlap spray patterns. Repeat spraying operation with a spray pattern perpendicular (at 90 degrees) to the first application. Allow to dry for a minimum of one hour before fabric is sat on.
Spots and Stains-When using water to remove a spot, be sure to wash entire section after spot has been removed to avoid water stains.
Before cleaning seats, door panels, headliner, etc., remove as many spots as possible.
Use a putty knife to break up and remove en- crusted foreign matter. Vacuum thoroughly.
Apply the recommended spot removing agent
0 with a clean cloth or sponge. Work in a wide cir- cle to prevent making a ring and work toward center.
Surface Spots-Brush out with a small hand brush, using care not to damage fabric when brushing.
Deep Penetrating Spots-Apply the spot removing agent by brushing. When spot is thoroughly worked and saturated, use high air pressure to blow dirt down through material. Occasionally the entire spot may not be removed and it will then be necessary to cover the area with a light appli- cation of dye.
Water Stains-Water stains in fabric materials can be removed with a cleaning solution made from one cup of ordinary table salt and one quart of water. Vigorously scrub solution into stain and rinse with clean water. Water stains in nylon and other synthetics should be removed with a com- mercial type spot remover compounded for the specific material being cleaned.
Mildew-Clean area around mildew with warm suds. Rinse with cold water, soak mildew area with solution of one part common table salt and two parts water, then wash with the recommended upholstery cleaner.
Rust Stains-Keep rust remover solution away from your skin. Wash hands immediately if exposed. Clean extra well under fingernails.
Read instructions on the bottle before using.
Wrap a small strip of cloth around each button to avoid leaving a ring on upholstery material.
Dampen the stained area with water. Apply a commercial rust remover solution. Sponge with clean water to clean rust from upholstery buttons.
Moisten buttons with a few drops of water ap- plied with a small piece of sponge or cloth. Apply one or more drops of rust remover. Fast dry clean areas with heat lamps.
Chewing Gum and Tar-Avoid using spotting or cleaning solution that will dissolve
or
soften gum or tar. Place a cube of ice on gum or tar to harden it. Remove as much as possible with a dull knife when it is in this hardened state. Mois- ten remainder with cleaning fluid and scrub clean.
In some cases soak with cleaning fluid and blow the stain through using high air pressure.
Ice Cream and Candy-Use a putty knife to re- move as much substance as possible. Use care not to damage fibers of upholstery. Most candy has a sugar base and can be removed by rubbing area with a cloth wrung out in warm water. An oily type of candy, after using warm water, should be cleaned with an upholstery type cleaner that will emulsify with the oil. Rinse with water and re- move remaining stains with cleaning fluid.
Bloodstains-Never use warm or hot water. Use a clean cloth wrung out in cold water and rub
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MAINTENANCE AND CARE 1-3
the stain. If stain is not completely removed, use spot remover or vinyl cleaner and apply with a brush.
Wine or Alcohol-Avoid use of soap. Scrub stain with a cloth moistened in luke warm water. Re- move remaining stains with a regular cleaning solution.
Shoe Polish-Scrub area with a cloth saturated with cold water. Remove wax base polishes by sponging with spot remover.
Grease, Oil, lipstick and Related Stains-Use spot remover to avoid leaving a ring. Cleaning from outside of spot and work toward center.
When spot has been removed, dry fabric with a clean cloth.
Urine-Use clean cloths for each operation. Satu- rate cloth with lukewarm soap suds (mild neutral soap) and sponge stain. Using cold water and a cloth, rinse area thoroughly. With a solution of one part household ammonia and five parts water, saturate a cloth and apply to stain for one minute. Rinse with a wet cloth.
Nausea-Use clean cloths for each operation.
Sponge area with a cloth dipped in cold water.
Wash lightly with lukewarm water and soap (mild neutral). Dip a cloth in cold water and rub affect- ed area. If any stain remains, clean with a cloth moistened with a volatile cleaner.
Headliners-Cloth Type-Mix a solution of water and a foaming type upholstery cleaner (as shown on the container) to produce thick suds. Use only foam when cleaning, as saturation with liquids may result in streaks, spots or shrinking.
On nap type, lay down nap, usually left to right. Do not stop, when washing a headliner.
Complete the entire operation a t one time using the same cleaning solution.
Starting in a rear corner, clean only one or two sections at a time. Thoroughly work suds into cloth with a nautral sponge. Use circular or short back and forth strokes to remove all dirt. When the sponge glides easily, leaving an even distrib- ution of foam and headliner appears clean, finish cleaning with sweeping motions in one direction.
Hard Board Type-Apply a solution of upholstery cleaner and water with a sponge. Use circular or short back and forth stroke and wipe with a dry clean cloth. If headliner is extremely dirty, wash with vinyl cleaner using the same procedure.
Vinyl Type-Apply vinyl cleaner with a sponge
(or if extremely dirty scrub with a brush) wipe clean with a dry clean cloth.
Seats and Door Panels-Mix one pint upholstery cleaner to one gallon of water. If extremely dirty, add more cleaner to solution.
Do not soak around buttons. Scrub thoroughly with a brush or sponge. Avoid over soaking the material, do one section at a time only. Frequent- ly stains will be evident when material is damp but will disappear when dry. Use care not to damage fabric by attempting to brush out
“stubborn” spots. Spots should be removed before washing. After part has been scrubbed, remove loosened dirt by rubbing area briskly with a clean cotton towel or soft rag. Make final strokes on one direction.
Nylon or Synthetic Fabrics-For average condi- tions use methods and materials used in washing cloth upholstery. When material is extremely dirty, use multi-purpose cleaner full strength and a stiff scrub brush. Scrub thoroughly in all directions.
Wipe off dirt and excess cleaner with a clean cot- ton towel or soft rags. leather, leatherette or Vinyl Fabric-Use multi- purpose cleaner full strength and a stiff scrub brush. Apply to surface and let set for two minutes then scrub thoroughly. Clean between all seams and in all cracks and underneath beading.
Wipe off dirt and excess material with a clean cotton towel or soft rag.
Package Shelf-Hard Board Type-Clean using a solution of upholstery cleaner.Avoid water log- ging the backing, dry immediately.
Vinyl Type-Clean using mutli-purpose cleaner.
Dry with clean toweling or rags.
Side Cowl Trim Panels-LeathewVinyl-Metal
Types-Use multi-purpose cleaner full strength.
Use a stiff brush and apply to surface, let set two minutes then scrub thoroughly. Clean seams, cracks and beneath beading. Dry with a clean soft towel or rag.
Glove Compartment-Some glove compartments are made of a cardboard type material. Do not waterlog.
Vacuum thoroughly. Clean with upholstery clean- er or vinyl cleaner.
Rubber Mat-Vacuum thoroughly and clean with upholstery cleaner or multi-purpose cleaner. Use toweling or rags to remove dirt and excess cleaner.
Carpeting-Thoroughly vacuum. Mix one pint of upholstery cleaner to one gallon of water. If car- pet is faded, discolored or spotted, add upholstery tint to this solution. To determine the right color shade, add tint in small quantities only. Test by dipping a white rag into solution, wring out and inspect shade. The dye will dry a shade or two darker. With a stiff brush apply solution and scrub carpet vigorously. Lay nap down in one direction. When dry, fluff carpets by rubbing with a dry brush.
Salt Stains-Vacuum carpet thoroughly. Use a so- lution made from water and a heavy concentration of ordinary table salt. Soak the stained area to loosen embedded salt (use a wire brush, if necessary). Wash entire carpet with the recom-
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mended cleaner. Additional washing may be neces- sary for satifactory results. luggage Compartment-Remove all items from compartment. Use a steel brush to loosen rust and caked dirt and vacuum thoroughly. Wash with upholstery cleaner or multi-purpose cleaner and dry with clean toweling or rags.
Cargo-Area (Station Wagon)-Follow same pro- cedure used for Luggage Compartment.
Color Restoration or Change-Tints and dyes should be applied by reliable experienced personnel. Dyes or tints can be applied when stains persist, after cleaning, or a change in color is desired. The instructions for mixing and apply- ing the color must be followed precisely. Use only those recommended for the exact material being worked on. leather and Vinyl Sealers-To material about repair holes cut
1/2 inch larger than area being repaired. Position patch under hole and apply sealer to contacting areas. Apply masking tape over tear to hold edges in place until sealer dries.
After sealer has dried, remove tape and trim all rough edges. Fill visible cracks with sealer.Use a step application procedure in filling deep cracks.
After sealer has thoroughly dried, sand lightly with 400 grade sandpaper until smooth. Apply color to repaired area.
POLISHING-Acrylic Finishes-Polish at least twice a year to remove all foreign film. When polishing use one pad, made from cheesecloth or an old “turkish” towel, to apply polish and anoth- er to remove dried film. Test area by rubbing fin- gers over polished surface. If not thoroughly cleaned, smears of polish will show.
Sand Scratchedverspray-Foreign Material-
Minor conditions can be removed using the fol- lowing procedure:
(1) Using oleum spirits, mineral spirits or kero- sene hand sand affected surface with paper.
No. 600
(2) Remove all sanding sludge.
(3) Machine polish the sanded surface using rub- bing compound until the surface is completely free of scratch marks. Blend with adjacent areas.
(4) Buff surface with a clean lambs wool pad using a liquid type final polish. If the appearance of the polished area is noticeably different than adjacent areas, completely buff the adjacent panels.
If necessary, polish complete side or horizontal surfaces to assure uniform appearance.
( 5 ) Use a clean, soft, cotton cloth, do not use cheesecloth, to hand clean all inaccessible areas.
(6) Remove all polish or rubbing compound from mouldings, medallions, name plates or any other exterior ornamentation.
Bright Metal+When cleaning anodized alumi- num, use care not to rub through the anodized coating. All bright metal should be thoroughtly cleaned at least twice a year.
The product manufacturer recommendations should always be followed. Clean metal thoroughly, removing all traces of cleaner from corners. Apply and rub out a coat of good body wax. During winter months and in areas in which salt is used, do not rub out wax.
Frequent washing of bright metals by steam ne- cessitate more frequent applications of wax.
TIRES
Do not clean tires with scouring powder, steel wool or other abrasive type cleaners. Clean white sidewall tires with a stiff bristle brush and white sidewall cleaner, or multi-purpose cleaner and rinse with clear water. Scuff marks can be dressed down by sanding lightly with $400 sandpaper.
GLASS
Do not use putty knives, razor blades, steel wool, or other metal objects to remove deposits from glass.
Interior glass surfaces, including convertible backlight, should be thoroughly cleaned weekly to remove all traces of smoke and other films.
Exterior glass surfaces, including convertible backlight, are best cleaned with the use of a com- mercially made cleaner. Do not scrape off smears from bugs, road tars or other similar objects, use warm water or the recommended solvents to remove.
During the winter months, snow, ice and frost can be removed with a plastic or rubber type scraper, or with a commercially made solvent.Do not use metal objects to remove deposits from glass.
DRAIN HOLES
The drain holes, in the bottom of cowl plenum chamber, doors and floor sills (rocker panels) should be inspected regularly to insure unobstruct- ed drainage. Remove road tars, mud and other foreign matter immediately. Should bare metal be exposed, surface treat metal and refinish.
The drain holes in the quarter panel well areas are sealed with a removable plastic plug. The plugs should only be removed whenever it is nec- essary to clean or drain fluids from the well area.
LUBRICATION
To maintain ease of operation, the hood, door, deck lid and tail gate hinges should be lubricated with the recommended lubricants at the recom- mended intervals. Refer to the Body Lubrication
Unit for tvm of lubricant and lubrication mints.
- 1
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BODY LUBRICATION 2-1
BODY LUBRICATION
INDEX
Body Maintenance
...................................................
Deck Lid Hinges
Deck Lid Latch
.........................................................
Door Hinges
.......................................................
...............................................................
Door Locks and Linkage
.......................................
4
Door Lock Ratchet and Striker
Door Remote Links
.........................
Page
1
5
5
2
3
.................................................
4
BODY MAINTENANCE
Body and other operating mechanisms should be inspected, and relubricated as needed. This is nec- essary to maintain ease of operation and to pro- vide protection against rust and wear.
Prior to applying any lubricant, wipe the parts clean to remove dust and grit. After lubricating parts, remove excess oil or lubricant.
Relubricate mechanisms as outlined in the fol- lowing paragraphs. Where Lubriplate i s specfied, use a smooth, white body hardware lubricant
Fuel Tank Access Door Hinge
Hood Hinges
...............................................................
Hood Lock and Safety Catch
Lock Cylinders
Tail Gate Door
Tail Gate Wiper Linkage
Window Regulators
............................
.............................
2
..........................................................
..........................................................
......................................
Page
6
2
3
5
6
.................................................
4 conforming to NLGl grade 1. Chrysler Parts
Lubriplate, Part Number 1064768 or equivalent, is i s suitable lubricant. Where Door Ease lubricant specified, use a stainless wax type lubricant
SAFETY CATCH
RELE
NP401
Fig. 1
CONT ACT
AREAS
"
''11 b H O O D LOCK SUPPORT
PIVOT AREA
SAFETY CATCH
Fig. 2
RELEASE HAN
Fig. 3
Except 2/dr H/Top)
N R237
4
HOOD LATCH
RELEASE HANDLE PB96
MyMopar.com
2-2 BODY LUBRICATION
= f ?
?CONTACT AREA
LATCH
-
SLIDINC- r n N i A i
RELEASE
HjNDLE a
HOOD
L
RE1 EASE
NDLE
BAR
SAFETY CATCH
HANDLE
\
Fig. 5
-
PIVOT CONTACT AREA
SAFETY CATCH Fig. 6
-
Hood lock lubrication (Chrysler Models).
\
\
2
\
Fig. 7
- such as Chrysler Parts Door Ease, Part Number
774512
or
equivalent.
HOOD LOCK, RELEASE MECHANISM AND
SAFETY CATCH lubrication of the hood latch release mecha- nisms and safety catch is of vital importance and should be inspected, cleaned and lubricated every 6 months to assure ease of operation and freedom from binding.
All Models
Apply Multi-Purpose Lubricant NLGI grade 2
EP, such as Multi-Mileage Lubricant, Part Num- ber 2525035 or equivalent, sparingly, to all sliding contact areas of latch and release lever, and ends of hood lock release links, if so equipped.
Work lubricant into the lock mechanism until all frictional surfaces are covered. Also apply a film
Fig. 8
-
Hood Hinge Lubrication (Valiant Models) of the same lubricant to the pivot contact areas of the safety catch (Figs. 1, 2, 3, 4, 5, 6 and 7).
Hood Hinges (All Models)
Apply engine oil to all link or hinge pivots and
Lubriplate or equivalent, to gear teeth and sliding contact areas (Figs. 8, 9 and 10).
Door Hinges (All Models)
On all hinges, apply engine oil
(Figs. 11, 12 and 13). to hinge pin ends
On lower hinges, in addition, apply engine oil to spring ends and contact areas.
CAUTION: Avoid lubricant on roller surfaces of hinge arm and roller on front and rear door lower hinges.
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0
BODY LUBRICATION
2-3
Fig. 9
Barracuda Models)
Fig. 10
Chrysler Models)
PIVOT AND ROLLE
R
/
UPPER
SlON SPRING
TACT POINTS
FRONT DOOR LOWER
TORSION SPRl
CONTACT PO
REAR DOOR LOWER
DOOR HINGE LUBRICATION PY813
Fig. I 1
-
Hinge Lubrication (Valiant-Baracuda
Models)
FRONT DOOR
When necessary, apply a thin film of Lubriplate or equivalent, directly to key. Insert key into lock and actuate several times. Wipe excess lubricant from key.
Particular attention should be given to external
Fig. 12
-
Hinge Lubrication (Satellite Models) lock cylinders during fall and winter months to insure protection from water and ice.
Door Lock Ratchet and Striker Bolt
Apply light engine oil, sparingly, to ratchet pivot areas and Door Ease Lubricant or equivalent, to contact area of striker bolt (Fig. 14).
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2-4 BODY LUBRICATION
0
PIN
REAR DOOR UPPER
Fig. 13
T
Imperial Models)
FRONT DOOR LOWER
Fig. 14 Door lock Ratchet ond Striker Bolt
\\
CONTACT AREA
SUPPORT
CONTACT ARE
(EXCEPT CONVERTIBLE) SURFACES
TORSION BAR SLIDE
NPl77C
Fig. 16
Modeis)
Fig. IS Deck l i d latch lubrication
Door Locks and locking Control Linkage (All
Models)
If necessary to inspect operation of and relubri- cate these parts, remove door trim panel. Apply a film of Lubriplate or equivalent, to all pivot and sliding contact areas.
Door Remote Control Link
(AI1
Models)
If necessary to inspect operation of and relubri- cate these parts, remove door trim panel. Apply a film of Lubriplate or equivalent, to all link end pivots.
Window Regulator, Glass Lower Frame (All
Models)
If necessary to inspect operation of and relubri- cate these parts, remove door or quarter trim panel. Apply Lubriplate or equivalent, sparingly, w
W815
Fig. 17
-
Models) to regulator sector gear teeth, assist spring and pivots. Apply same lubricant sparingly, to glass
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BODY LUBRICATION 2-5
,\ fi! q
FASTENER
PB98
Fig. 18
Models) lower frame roller slide tracks and roller and bracket assembly pivot points.
Deck Lid Latch
(AI.
Models)
Apply Lubriplate or equivalent, sparingly, to all pivot and sliding contact surfaces (Fig. 15).
Deck Lid Hinges
(All
Models)
Apply Lubriplate or equivalent, sparingly, to all
Fig. 19
Chrysler and Fury Models) torsion bar support bearing areas and interior sur- face of torsion bar slide (Figs. 16, 17, 18 and 19).
Also, apply same lubricant sparingly, to contact surface of hinge cam slide.
Tail
Gate-Door Lubrication
Apply engine oil sparingly to upper and lower hinge pivot pins. Lubriplate or equivalent, to sup- port links, check strap links, link contact areas and inner pivot or sliding contact surfaces of tail gate and door lock.
LUBRICATION
POINTS
VIEW IN DIRECTION
OF ARROW X
LUBRICATION POINT
UPPER HINGE
PIVOT AND
TORSION BAR h z L O W
- _
E R _ _
-
LOWER HINGE
PIVOT PIN AREAS
BAR CENTER
STRIKER PLATE
'
VIEW IN DIRECTION
OF ARROW W
PBloO
Fig. 20
-
Tail-Gate Door Lubrication (Satellite Models)
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2-6 BODY LUBRICATION
SUPPORT LINK
PIVOT PIN
TORSION BAR
SUPPORT AREA
SPRING WASHER
AND ROLLER
LOWER HINGE
SPRING
QUARTER PANEL
NU262
Fig. 21
-
Tail Gate-Door lubrication (Chrysler-Fury Models)
PIVOT AREAS
CONTACT AREAS latch striker plate and bolt. (Figs.
20
or
21)
Tail Gate Window Wiper Linkage (All
Models)
To lubricate this linkage, remove tail gate trim panel. Apply Lubriplate, or equivalent,sparingly, to the sliding contact areas between the actuator arm and pin, and between the actuating arm and regu- lator sector gear.
CAUTION-Do not contaminate wiper blades with lubricant.
49
Fig 22 Fuel Tank Access Door Hinge (Station Wagon)
Lubricate torsion bar and check arm mechanism with a Multi-Purpose Lubricant NLGI grade
2
EP,such as Multi-Mileage Lubricant Part Number
2525035
or equivalent. Apply stainless wax type stick lubricant such as Chrysler Parts Door Ease
Part Number
774512
or equivalent, to tailgate
Fuel Tank Access Door Hinge Lubrication
(Furyf Chrysler Station Wagon Models)
Apply Multi-Purpose Lubricant, NLGI grade
2
EP, or Multi-Mileage Lubricant, Part Number
2525035
or equivalent, sparingly, to all pivot areas and to spring end contact areas (Fig.
22).
License Plate Bracket Hingef Spring and Pin
Lubrication Points (Fury, Chrysler, Imperial
Models except Station Wagons)
Apply Multi-Purpose Lubricant, NLGI grade
2
EP, or Multi-Mileage Lubricant, Part Number
2525035
or equivalent, sparingly, to all pivot areas.
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0
IMPERIAL CHRYSLER FURY-SHEET METAL DOORS
3-1
SHEET M ETA
L-DO0
R S
INDEX
Page
BUMPERS
...................................................................
10
COWL
...........................................................................
1
Seal-Top Panel
Trim Panel-Side
...................................................
DECK LID
Alignment
Handles-Inside
Outside
Hinge
........................................................
....................................................................
.................................................................
Hinge
..........................................................................
25
Lock
............................................................................
24
Cylinder
..................................................................
25
Manual
....................................................................
25
Vacuum Operated
..............................................
25
Replacement
.........................................................
25
Torsion Bars
.........................................................
25
Weatherstrip
.........................................................
25
DOORS
.........................................................................
14
Alignment
.................................................................
14
Arm Rests
................................................................
15
...................................................................
1
1
24
24
15
18
..........................................................................
1 5
Lock Assembly
..........................................................
1 6
Cylinder
.....................................................................
17
Electric
.......................................................................
18
Solenoids
................................................................
18
Adjustment
.........................................................
18
Replacement
......................................................
18
Lock and Switch
Latch Push Rod
...................................................
Remote Control Switch
......................................
18
........................................................
Latch Replacement
Trim Panels
18
18
..................................................
16
................................................................
15
Watershields
..............................................................
16
Weatherstrips
............................................................
Belt-Outer
.................................................................
Hardtop Door
..........................................................
Roof Rail
...................................................................
Sedan-Station Wagon
.............................................
...................................................................
Windcords
FENDERS
.....................................................................
Alignment
.................................................................
Replacement
............................................................
Wheel house
.............................................................
OUTSIDE AIR INLET VENT
.................................
Control Cable
..........................................................
Door
............................................................................
GRILLE
..........................................................................
HOOD
...........................................................................
Alignment
.................................................................
Hinge
..........................................................................
Lock
............................................................................
Replacement
............................................................
QUARTER PANEL
....................................................
Extensions
................................................................
RADIATOR YOKE SUPPORT
..............................
Air Shield and Cross Bar
TAILGATE
Cylinder
Linkage
..................................................................
...................................................................
Replacement
Trim Panel
Torsion Bar
..................................
...................................................................
Alignment
.................................................................
Lock Assembly
.......................................................
............................................................
...............................................................
..............................................................
Weatherstrips
.........................................................
Page
19
20
19
19
19
20
4
4
1
3
3
3
20
20
6
7
21
3
7 a
3
21
23
23
23
22
23
23
25
COWL TOP PANEL SEAL
SERVICE PROCEDURES
The cowl top panel seal (Fig . 1) is fastened to the panel by retainers moulded into the seal
.
SIDE COWL TRIM PANEL
The side cowl inner trim panel (Fig
.
2) is atta-
(3) Position trim panel under clip at upper front and to cowl side inner panel screws
.
.
Install retaining
(4) Install floor sill inner moulding over panel end and instdl1 screws
. ched to the panel with screws and at the rear lower edge under the floor sill step plate
.
A si-
OUTSIDE AIR VENT CONTROL CABLE lencer pad is used between the trim panel and cowl panel
.
Build-Up and Installation
Replacement
The outside air inlet vent control cable. housing and knob is serviced as an assembly
.
The cable housing shank has two flat edges. indexing with
(1) Position cowl side trim panel extension under windshield garnish moulding and install screw
.
(2) Apply cement to trim panel and position in- sulation on cemented area
.
Hand press to assure positive adhesion and position spring nut on panel
. corresponding edges in the panel and is retained on the panel with a nut at the rear
.
The housing is attached to the vent door bracket with a clip and the coiled cable end is positioned over a pin on the door
.
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3-2 IMPERIAL CHRYSLER FURY-SHEET METAL DOORS
PANEL
I
Fig. 2
-
Side Cowl Trim Panel
Fig. I
-
Cowl Top Panel Seal
Adjus
fmen f
Door adjustment is controlled by the cable hous- ing attachment at the door bracket (Fig. 3). Loo- sen clip screw attaching the housing to the door bracket and push control cable knob to the fully closed position. Holding vent door closed, pull ble housing slack out ca- of door flange. Tighten clip screw and test operation of cable and door.
PLENUM CHAMBER
0
SEAL MUST COVER ALL
MOUNTING HOLES
AROUND PERIMETER
VENT HOUSING
OF
VIEW IN CIRCLE Y
SEAL PERMISSIBLE
OVERLAP WITHOUT
VIEW IN CIRCLE Z
Fig. 3
-
Outside Air Vents
PY13
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0
IMPERIAL CHRYSLER FURY-SHEET METAL DOORS 3-3
VENT DOOR
Removal (Fig. 3)
(1) Remove cowl side trim panel and silencer.
(2) Remove actuator cable housing to door bracket clip.
(3) Slide cable off of pin on door and out of door frame flange.
(4) Remove door to cowl side panel screws.
( 5 ) Remove door and seal assembly and inspect seal for damage.
Insf allofion
(1) Install spring nut to bottom of outside air door housing, if removed.
(2) Position seal in line with outer edge of hous- ing flange (Fig. 3).
(3) Position air door on cowl side panel, align attaching holes, install attaching screws and tight- en progressively.
(4) Insert actuator cable assembly, through hole in door frame flange and install coiled end of ca- ble over pin on door.
( 5 ) Position clip over cable and attach to door bracket.
(6) Adjust vent door cable housing and install trim panel and silencer.
HOOD
LATCH
NU94 OF ARROW Z
Fig. 4
-
Hood Adjustment
ALIGNMEN1
Prior to making any adjustment inspect clearanc- es and alignment of hood sides in relation to cowl, fenders and grille. The cowl adjustment must be made first. Elongated holes in the hinge
(Fig. 4) permit the hood to be moved up, down, fore and aft.
REPLA CEMENl
Fig. 5
-
Hood latch and Release and install bolts loosely.
(2) Align scribe markings on hood with hinge and tighten screws lightly.
(3) Close hood and inspect hood alignment.
(4) Adjust alignment and tighten bolts 180 inch-pounds.
( 5 ) Remove protective coverings.
Removal
(1) Place a protective covering over cowl and fender area.
(2) Mark outline of hinges on hood to aid in installation.
(3) Use extreme care not to permit hood to slide rearward and damage painted surfaces of the cowl and fender areas when removing hood bolts.
Ins ftrllafion
(1) With an assistant, position hood on hinges
LOCK
To adjust lock (Fig. 5), loosen attaching screws and raise or lower until correct adjustment has been obtained. After making any adjustment re- quiring shifting of hood, always inspect hood striker and lock for alignment.
HINGE REPLACEMEN1
The hood hinge (Fig. 4) is attached to the hood by two screws and to the fender splash shield by three screws. Prior to removing the hinge mount- ing screws, prop the hood into the wide open position. The prop should be positioned so the hood cannot move rearward.
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3-4 IMPERIAL CHRYSLER FURY-SHEET METAL DOORS
0
ALIGNMENT
FENDERS
holes in radiator yoke. Install all retainer screws and nuts.
The fender should be adjusted to provide for equal spacing at the cowl, door front edge and door panel top edge. Alignment should be made at bottom of floor sill panel, front of hood and door outer panel upper edge.
(3)
With fender correctly positioned, tighten screws and nuts securely.
(4) Connect head lamp wires and install grille to fender nuts. Connect battery ground strap.
REPLACEMENT (FIGS
6-7-8)
Removal
(1) Disconnect battery ground strap.
(2)
Tape leading edge of front door and cowl to fender area to avoid damaging paint.
(3)
Remove front bumper assembly.
(4) Disconnect head lamp wires and remove grille extension to fender nuts.
( 5 ) Remove fender to cowl, floor sill, wheelhouse and radiator yoke nuts and screws (Fig. 6).
(6) Remove fender assembly and if necessary, mouldings, ornamentation and headlamp assemblies.
Installation
(1) Install head lamps, mouldings and orna- mentation. Carefully position fender on studs at cowl side area and align fender with mounting
WHEEL HOUSE
Remove Wheelhouse Assembly (Fig.
9).
(1) Raise hood and disconnect all brackets and clips attached to the wheelhouse in engine compartment.
(2)
Raise front end of car and remove wheel assembly.
(3)
From underside of fender, remove all wheel- house mounting bolts.
(4) Remove wheelhouse from car.
Replacement
(1) Place housing in position under fender.
(2)
Install mounting bolts loosely.
(3)
Line housing up correctly and tighten mount- ing bolts.
(4) Replace wheel assembly.
( 5 ) Lower front end of car.
(6) Connect all brackets and clips in their proper position on wheelhouse in engine compartment.
SCREW
Fig. 6
-
Fender Altachment-Fury
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3-6 IMPERIAL CHRYSLER FURY-SHEET METAL bOORS
COWL BRACKET
A
COWL u
VIEW IN DlRECl
\
vp&
(RIGHT SIDE)
STRUT MOUNTING
AT DASH
Fig. 8
-
Fender Application-Imperial
FENDER
Fig. 9
-
Wheelhouse Attachment
NU95
REPLACEMENT
RADIATOR YOKE SUPPORT
to yoke support screws (Fig. 10.).
(4) Remove support to frame screws and support.
Removal
(1) Remove radiator assembly.
(2) Remove hood lock striker bar, horn and head lamp wiring from yoke support.
(3) From under the fenders remove wheelhouse lnsf allation
(1) Position yoke support on frame and install frame to support screws finger tight.
(2) From under the fenders, install splash shield
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0
IMPERIAL CHRYSLER FURY-SHEET METAL DOORS
3-7 to support screws finger tight only.
(3) When all screws have been installed, tighten progressively.
(4) Attach horn and light wires to the yoke sup- port with plastic straps.
( 5 )
Install radiator and hoses, fill cooling system and inspect for leaks.
AIR SHIELD
AND
CROSS BAR
Refer to (Fig. 10) for air shield and cross bar attaching points.
HEADLAMP BAFFLE
SUPPORT PLATE
WKILLL L
BRACKET
:J I
VIEW IN DIRECTION
OF ARROW Z
GRILLE LOWER b
\
LOCK VERTICAL
J
SUPPORT BRACKET
AIR SHIELD
\
\ rg)- / ' CROSSMEMBER
NU87
Fig. 10
-
Radiator Yoke Assembly
GRILLE
pushed back against the fenders before securing, in order to avoid stressing and possible fracturing of ALIGNMENT
AND
REPLACEMENT
The grille assembly (Figs. 11, 12, 13, 14 and 15) the die cast metal. With textured grilles care must be held against the vertical lock support and should be used in protecting the grilles from heat during repairs.
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3-8 IMPERIAL CHRYSLER FURY-SHEET METAL DOORS
i
HEADLAMP PLATE
0 fig. I 1
-
Grille Attachment-Fury
Fig. I2
-
Grille Attachment-Sport Fury
PYSS
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0
SCREW AND WASHER
IMPERIAL CHRYSLER FURY-SHEET METAL DOORS
3-9
TEXTURED HEADLAMP BEZEL
Fig. 13
-
Grille Attachment (300 and New Yorker)
P Y l 9
Fig. 14
-
Grille Attachment (Imperial)
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3-10 IMPERIAL CHRYSLER FURY-SHEET METAL DOORS
0
,
LOCK SUPPORT
Fig. 15
-
Grille Attachment (Newport and Custom)
BUMPERS
FRONT
AND
REAR BUMPERS
Refer to (Figs.
16, 17
and
18)
for front and rear bumper attaching points.
NU73A
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IMPERIAL CHRYSLER FURY-SHEET METAL DOORS 3-1 1
SEAL
STEP 'PAD b
TEXTURF PANEL
BRACKET
\
P A D
8 I
& . I
OUTER SUPPORT
\
- _
I
- c -
-.
PLATE
\
LOWER BUMPER
REAR BUMPER
B U ~ P E R
OUTER SUPPORT w
VIEW IN DIRECTION
8
-OF ARRQW z
Fig.
FRONT BUMPER
16
-
Fmnf and Rear Bumper Affachmenf-Fury
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3-12 IMPERIAL CHRYSLER FURY-SHEET METAL DOORS
0
STATION WAGON
REAR BUMPERS
VIEW IN DIRECTION
FRONT BUMPER ATTACHMENT
BUMPER
NEW YORKER
MOULDING
FRONT BUMPERS
Fig.
-
Bumper Attachment (Chrysler)
RETAINER
>
N EWPORT-CUSTOM
CLOSURES
NU63A
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0
IMPERIAL CHRYSLER FURY-SHEET METAL DOORS 3-1 3
FRONT BUMPER
Fig. 18
-
Bumper Attachment (Imperial)
PY325
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3-1 4 IMPERIAL CHRYSLER FURY-SHEET METAL DOORS
DOORS
The service procedures for internal door compo- nents do not include obvious operations, such as removing door or quarter panel trim pane' test- ing operation of windows or inspecting glass fit after adjustments or replacement have been performed.
ALIGNMENT
Up
and Down
Adjustment of the door can be made at either the pillar or door hinge halfs (Fig. 19).
In ond Out
Adjustment is made at the door hinge half.
Adjust only one hinge at a time. Raising outer end of door moves upper part of door forward, when in closed position. Lowering lower part of door moves lower part forward, when in closed position.
Fore and A#
Adjustment is made at the pillar hinge half.
Adjust only one hinge at a time. Raising outer end of door, moves upper part of door into door opening. Lowering outer end of door, moves lower part of door into door opening.
REAR DOOR
Fig.
W F R O N T DOOR NU409
19
-
Door Hinges
LATCH AND STRIKER PIN
The silent type door latch (Fig. 20)) features a rubber isolation of the round striker pin on the door frame and those surfaces acting as stops in- side the latch. The latch assembly is built into a sheet metal pocket on the door face. The striker pin is attached by a single screw which also al- lows for adjusting. Proper torque is 40-60 foot pounds.
0
Fig. 20
-
Door latch and Striker Pin
DOOR REPLACEMENT
block of wood on lifting plate of jack, as near
Fronf Door (All Models) hinge as possible.
(2) Remove door interior trim and hardware.
Removal (3) Scribe a line around upper and lower hinge
(1) With door wide open, place a jack, with a plates on door panel.
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IMPERIAL CHRYSLER FURY-SHEET METAL DOORS 3-15
Fig. 21
-
Window Regulator Handle
On vehicles with electric windows, disconnect the wires from window regulator motor and re- move from door assembly.
(4) Remove hinge screws from door and remove door for further disassembly if necessary.
INSIDE HANDLES
NN605A
Fig. 22
-
Remote Control Handle
HINGE REPLACEMENT
The door hinges (Fig. 19) are attached to the doors by screws accessible from outside. The front door hinges are each attached to the “A” post by three screws.
The rear door upper hinges (on hardtop and sta- tion wagon models), are attached to the b‘”’ post by three screws accessible from the outside. On sedan models, the screws are accessible through an access hole in the
“B”
post.
Ins/cr//otion
(1) With door hardware installed, place door, supported by a padded jack, in position in door opening.
(2) Position hinge plates on door panel and in- stall screws finger tight only.
(3) Adjust jack to align hinge plate scribe marks and tighten screws.
Prior to this installation, on electric window lifts, install wiring in doors and attach to motor and control switch.
(4) Complete door aligning procedure, and install interior trim and hardware.
REAR DOOR (All Models)
Removal
(1) Open door and place a padded jack under door near the hinges.
(2) Remove door interior trim and hardware.
(3)
Scribe aligning marks around hinge plates on door frame.
On vehicles with electric window lifts discon- nect wires from motor and switch and remove from door.
(4) Remove the hinge screws from door and re- move door. lnsf allation
On vehicles with electric window lift, attach wiring to motor and switch prior to installation of trim panel.
(1) With inner hardware installed and supported on a padded jack, position door on hinges.
(2) Install attaching bolts finger tight.
(3) Align hinges with scribe marks and tighten screws.
(4) Test door for alignment and install trim and hardware.
Window Regulator Handle
The window regulator handles are retained on the shaft with an allen set screw (Fig. 21).
The handles should be placed in approximately a horizontal position with the knobs facing forward on the doors and rearward on the quarter panel.
Remote Control Handle
The remote control handle (Fig. 22) is attached to the control unit with a screw at the rear inner end.
ARM RESTS
The arm rests are retained by two metal screws inserted at the bottom of the arm rest base. The pad and base can be separated and if necessary, the pad may be retrimmed.
TRIM PANELS
Door Trim Panel Replacement
(1) Remove inside handles and arm rests.
(2) Remove screws attaching trim panel to door inner panel.
(3) Insert a wide blade screw driver next to the retaining clips between trim panel and door frame.
Snap retaining clips out of door panel and remove panel.
(4) Before installing trim panel, inspect condition of watershield (Fig. 23).
( 5 ) Align trim panel retaining clips with holes of door frame and bump into place with heel of hand.
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3-18 IMPERIAL CHRYSLER FURY-SHEET
VIEW IN DIRECTION
METAL DOORS
0
(3) Adjust lock assembly.
Lock and Switch Replacement
(1) Disconnect lock switch wires (front door only).
(2) Disconnect solenoid link at lock lever.
(3) Remove screws attaching lock and switch as- sembly to door and remove from door.
(4) Remove switch from lock assembly.
FRONT DO%R AR DOOR
Fig. 28
-
Outside Door Handle
HANDLE
NU402
Installation
(1) Position key actuated switch on lock assem- bly and install screw.
(2) Position lock and switch assembly inner face and install screws. on door
(3) Connect solenoid link to lock lever.
(4) Connect lock switch wires (front door only) and test lock operation.
L
atch Push Rod
The latch push rod (Fig. 26) is positioned through an opening in the door belt area approxi- mately at the front end of the arm rest position on 2 door models. On 4 door models the push rod is located approximately above the latch (Fig.
25).
ELECTRIC DOOR LOCKS
All doors may be locked or unlocked electrically.
Refer to the Electrical Group for test proce- dures and wiring diagrams.
Remote Control Switch Replacement
The remote control switch (front doors only)
(Fig. 27) is attached to the door inner face with one screw. The remote control push rod is atta- ched to the switch with a “push-on’’ type retainer.
OUTSIDE HANDLE-FRONT DOOR
SOLENOID
Adjustment
(1) Loosen solenoid to mounting bracket screws
(Fig. 27).
(2) Push lock lever to down position and slide solenoid to full down position in mounting bracket.
(3) Raise lock lever to up position, extending solenoid rod to maximum up position.
(4) Tighten solenoid to mounting bracket screws and test operation of lock.
Removal
(1) With door glass in up position, remove han- dle attaching nuts from mounting studs (Fig. 28) and link from handle to lock.
(2) Lift handle up and remove from door.
Installation
(1) Position handle into door opening and engage handle to lock link.
(2) Attach retaining nuts and test handle operation.
OUTSIDE HANDLE-REAR DOOR
REPLACEMENT
Removal
(1) Disconnect solenoid link at solenoid (Fig. 27)
(2) Remove solenoid lead wires.
(3) Remove solenoid to mounting bracket screws and remove solenoid assembly.
Installation
(1) Position solenoid on mounting bracket and install mounting screws. DO NOT TIGHTEN.
(2) Connect link to solenoid rod and connect wires.
Removal
(1) With door open and glass in up position, remove link retainer at handle connector (Fig. 28).
(2) Depress outside handle release button and remove link from handle connector.
(3) Remove handle to door nuts.
Installation
(1) Position handle in door and install mounting nuts.
(2) Depress handle button and position link over
.connector on handle.
(3) Install retainer over link and connector.
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WEA THERSTRIPS AND WINDCORDS
Sedan and Station Wagon Models
(1) Apply lower half of weatherstrip, starting at number one index hole and using fasteners for lo- cating and ending at number 2 index hole.
(2) Apply a 1/8 inch bead of cement to weath- erstrip seating area on door upper half.
(3) Install upper half of weatherstrip on door, indexing at the upper corners.
(4) Work weatherstrip from index points to a point midway between them. lock pillar.
(4) Make sure lip of weatherstrip dovetails into groove of lock pillar seal and install seal on lock pillar. Door Weatherstrips
Make sure all old weatherstrip particles and ce- ment are removed. Avoid puckering or stretching of weatherstrip.
Hardtop
Front door
(1) Apply a 1-8 inch bead of cement on weatherstrip.
(2) Position and attach moulded end of weather- strip with fasteners.
(3) Index and install weatherstrip on door, using fasteners as a locating point and working from hinge pillar side of door completely around to
Hardtop Rear Door
(1) Index and install weatherstrip on door by inserting fasteners in door and install from top of hinge pillar side of door completely around to lock pillar
(2) Make sure lip of weatherstrip dovetails into groove of hinge pillar seal and install seal.
(3) Make sure lip of weatherstrip dovetails into groove of door upper ornament seal and install seal.
Roof Rail Weatherstrip
Refer to Figure 29 for attaching points and me- thods of cementing.
The weatherstrip retainers are adjustable through use of elongated attaching holes. The weatherstrip can be moved in or out for the best possible fit and seal along the top edge of the vent frame, door and quarter glass.
The glass up-stop must be adjusted so a fully raised glass just curls the outer lip of weatherstrip against the inner lip. ,
When the up-stop, roof rail weatherstrip and glass are properly adjusted, the outer lip of weath-
SEALER
A T H ~ I
2 DOOR
VIEW IN DIRECTION
OF ARROW A
Fig. 29
-
Roof Rail Weatherstrip
NU408
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3-20 IMPERIAL CHRYSLER FURY-SHEET METAL DOORS
0
REAR DOOR
. . .
-.
-
-
AIR CONDITIONING ONLY
STATION WAGON
VIEW IN DIRECTION OF ARROW
-
Fig. 30
V
-
-
Door Windcords erstrip will seal along the top edge of the glass and the inner lip
Of weatherstrip will seal along the upper inside edge of glass.
Outer Belt Weatherstrip
The door outer belt weatherstrips are retained in the door panel with spring type retainers.
Windcords
Refer to Figure and method
30
for windcord starting points of attachment.
QUARTER PANEL EXTENSIONS
Refer to Figures 31 and 32 for attachment appli- cations of the quarter panel extensions.
D SEAL
PANEL
Fig. 31
-
Quarter Panel Extension-Station Wagon
PY9
Fig. 32
-
Quarter Panel Extension-Except Station
Wagon
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IMPERIAL CHRYSLER FURY-SHEET METAL DOORS 3-21
Station Wagon Models
TAI L
are equipped with a
“two-way” tail gate that can be opened as a swingout type door or in the conventional tail gate manner. The sequence of adjusting the link- age should be followed, as outlined in this service manual, to ascertain correct locking and releasing operations.
ALIGNMENT (Fig. 33)
Lower window before making any adjustments.
Vertical Adjustment
(1) Hinge Pin Adjustment. a. From underside of body on left side loosen pin lock nut. b. At top of pin, just under hinge pivot, adjust pin to proper height then tighten lock nut. Proper adjustment is obtained when bushings on body and gate halves of upper hinge are just touching.
(2) Striker Adjustment. a. Loosen plate screws and striker be moved up or down. so plate can
GATE
b. Tighten plate and striker at desired position.
Both upper and lower strikers should be ad- justed to carry equal weight of tailgate.
In and Out Adjustment
(1) Lower Hinge Support Plate. a. Loosen three bolts from left underside of body. b. Adjust tail gate to desired position and tighten bolts.
There isn’t any in and out adjustment for up- per hinge.
(2) Upper and Lower Striker Adjustment. a. Follow procedure outline used in vertical adjustment.
L ateral Adjustment
(1) Upper Hinge Body Half a. Remove bottom trim strip from left rear window. b. Remove left rear floor trim and cover. c. Lower left rear quarter trim.
CHECK BRACKET
ARROW Z
Fig. 33
-
Tailgate Assembly
TORSION BAR
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3-22 IMPERIAL CHRYSLER FURY-SHEET
d. Reaching through opening in body pillar loosen four bolts on the upper hinge (body half). e. Adjust upper hinge to desired position. f. Tighten bolts and replace cover, lower quar- ter trim and window trim.
(2) Lower Hinge Support Plate. a. Use in and out adjustment procedure.
Door Sag Compensation
Care must be taken in making this adjustment to avoid the outer edges of tail gate rubbing against body.
This can be accomplished by moving upper hinge (body half) laterally closer to body pillar and by moving lower hinge support plate laterally towards the center of body. (See lateral adjustment procedure to accomplish this.)
REPLACEMEW
Removal
Remove trim panel and disconnect terminals at control switch. Disconnect wiper and washer elec- trical leads.
(1) Remove check arm torsion bar guide from pillar guide plates.
(2) Support tail gate on jacks or stands.
(3) Loosen hinge pivot pin locking screws (Fig.
33).
METAL DOORS
(4) Use a pencil and outline hinge plate position on pillar post for future assembly.
( 5 ) Remove hinge plate attaching bolts from pil- lar post.
(6) Slide hinge plate and torsion bar in through guide toward center of tail gate.
(7) Lower tail gate down and out of body opening.
Installation
(1) With torsion bar and hinge plates pushed in toward center of tail gate, engage hinge plates into lower opening of body.
(2) Attach hinge plate attaching bolts into pillar posts and locate hinge plates in relation to previ- ous marked positions.
(3) Tighten attaching bolts firmly enough to hold position and inspect alignment.
(4) Close tail gate and center in opening.
( 5 ) Attach torsion bar bracket to pillar post.
(6) Open tail gate and tighten locking screws on hinge pivot pin.
(7) Connect electrical leads and install trim panel.
(8) Operate tail gate window and inspect alignment. fY
RIGHT SIDE
/ ’
Fig. 34
-
Lock Linkage Adiustmenh
NR496
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IMPERIAL CHRYSLER FURY-SHEET METAL DOORS 3-23
Fig. 35
-
Rear Header Wedhersfrip
TRIM
PANEL
The tail gate trim panel is attached with metal screws. Clean all foreign material from the seating area of the trim panel before installing.
Fig. 36
-
Rear Header Weofhersfrip Retainer glass restraining bracket.
(6) Install link into release regulator mechanism and upper left latch remote lever clip.
(7) Install link into lock remote lever.
(8) Take up all play in latch remote lever and release regulator mechanism arm and adjust link threaded end to this point.
(9) Install link into upper right lock remote le- ver and test operation of tail gate and door assembly.
LOCK
To replace the lock assembly (Fig. 33) remove trim panel glass and glass runs. The lock assembly is retained on tail gate by screws accessible at end of tail gate.
L
OCK CYLINDER
The tail gate lock cylinder assembly is retained on the outer panel with a horseshoe type retainer
(Fig. 33).
LOCK LINKAGE
TORSION BAR
Removal
(1) Remove trim panel from tail gate.
(2) Remove screws attaching torsion bar clamp to tail gate pillar (Fig. 33) and remove clamp.
(3) Remove torsion bar bearing retainer and bearing.
(4) Remove screws attaching torsion bar and hinge to tail gate.
( 5 ) Remove torsion bar from hinge.
Installation and Adjustment (Fig. 34).
The lower right to upper right latch link and upper right lock to release regulator mechanism arm link can only be adjusted to three total turns from nominal position for all release, interlocking and latch engaging operations.
(1) Inspect locks to make certain they are in the fully latched position.
(2) Install link to lower right latch detent clip, raise upper right lock actuator until it contacts upper latch lock detent.
(3) Adjust threaded portion of link until aligned with clip hole of actuator and insert link into clip.
(4) Connect link to upper right lock remote con- trol lever and to release regulator mechanism actuator.
( 5 ) Install link from release regulator arm to the
Installation
(1) Lubricate torsion bar at right hinge area and at torsion bar bearing area.
(2) Install hinge on torsion bar and insert tor- sion bar into tail gate.
(3) Position hinge to tail gate and install mount- ing screws. Tighten screws.
(4) Install bearing and bearing retainer on tor- sion bar (Fig. 33). Tighten retainer nut.
( 5 ) Position clamp over end of torsion bar and from outside end of tail gate install attaching screws.
(6) Install tail gate trim panel.
Rear Header Weatherstrip
The roof rear header weatherstrip is a press fit in the retainer (Fig. 35). Position the ends first to form a seal with the quarter pillar runs.
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3-24 IMPERIAL CHRYSLER FURY-SHEET METAL DOORS
0
Rear Header Weafhersfrip Refainer
The roof rear header weatherstrip retainer is at- tached to the header with “pop” rivets (Fig.
36).
The seal has adhesive applied to one side which attache it to the retainer. Trim the ends of the seal flush with the retainer.
The rear air deflector (Fig.
38)
used on station wagon models is mounted on the roof by inserting the deflector studs through holes drilled in the panel and securing with sealing type nuts from
Fig. 37
-
Pillar Weatherstri‘Re fainer
NUT AND SEAL
The tail gate upper pillar, retainer, seal with weatherstrip is retainer on the pillar with screws
(Fig.
37).
and Seal.
Fig. 38
-
Roof Rear Air Deflector the car interior. Tighten the nuts inch-pounds.
75-115
DECK LID
ALIGNMENT
The deck lid hinge (Fig.
39)
to lid attaching holes are slightly oversize, allowing slight to and fro, and, in and out adjustment.
REPLACEMENT
The deck lid is attached to each hinge by two screws. An assistant’s aid is recommended when replacing lid to prevent it sliding rearward and damaging paint, also to aid in aligning of hinge screw holes when installing.
LOCK REPLACEMENT
The deck lid lock (Fig. 40) is attached to the deck lid by two screws. Scribe location of lock mounting flanges to aid in installation. On vacuum actuated units, disconnect vacuum hose.
Adjus fmen f
Vertical adjustment of lock is made at the atta-
Fig. 39
-
Deck Lid Hinge and latch
NU68
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0
RETA
DECK LID
LATCH
IMPERIAL CHRYSLER FURY-SHEET METAL DOORS 3-25
Llt
OF ARROW Z VIEW IN DIRECTION OF ARROW Y PY83
Fig. 40
-
Deck l i d Lock and Cylinder
Installation ching screws and side adjustment is made at the striker attaching bolt.
Cylinder Replacement
(1) Position hinge on bracket pin and install a new spring nut.
The lock cylinder is retained by a spring steel
(2)
Install deck lid, connect torsion bar and in- spect alignment.
VACUUM ACTUATED DECK LID LOCKS ;TORSION BAR
The vacuum actuated deck lid lock release sys- Removal tem (Fig. 41) consists of vacuum tank mounted Use care when removing torsion bar as it is un- over the right front wheel housing, a push button der a load. Release load from torsion bar slowly control switch and a vacuum actuated diaphragm and remove from support bracket. assembly connected to the lock. Vacuum is sup- (1) Remove torsion bar (Fig. 42) from adjust- plied to system from intake manifold. Rubber hos- ment slot. es are used to connect component units. (2) Push bar out of roller in hinge arm and re-
If failure of the system is accompanied with a move from hinge support. rough engine idle, remove hose from manifold fit- /nstcr//rrt;on ting tube and plug end of the tube. If engine idle (1) Position torsion bar into hinge support and improves noticeably, inspect hoses for possible insert end into roller in hinge arm. leaks. (2) Hook torsion bar into support bracket.
Should System fail to Operate entirely, remove hose at the release diaphragm in deck lid and
(3) Wind bar and insert end into center adjust- ing slot. running, actuate button in glove box while a help- er observes gauge. If no reading can be obtained, inspect for a pinched hose. A reading of less than
16 inches will indicate a leak in the system.
HINGE
Remo vu1
(4)
( 5 )
Place lid in various open positions and test tension.
Adjust bars until deck lid stays in open position,
WEA ;THERSTR/PS
Apply an even continuous coat of cement to en-
(1) Remove deck lid assembly and disengage tor- sion bar from hinge (Fig. 42) being removed.
(2)
Remove hinge to hinge bracket spring nut and remove hinge. tire weatherstrip contact surface of deck lid open- ing (Fig. 43). Install weatherstrip, make sure weatherstrip molded corners are correctly positioned.
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3-26 IMPERIAL CHRYSLER FURY-SHEET METAL DOORS
VACUUM TUBE
VIEW IN CIRCLE X
WITH AUTOMATIC
TEMPERATURE CONTROL
Fig. 41
-
Vacuum Actuated Deck l i d Lock
OF ARROWZ
0
Fig. 42
-
Deck l i d Torsion Bar
Fig.
VIEW IN CIRCLE Y
VIEW IN CIRCLE X
43
-
Deck l i d Weatherstrip
NP114
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0
SATELLITE-SHEET METAL DOORS 3-27
SATELLITE
INDEX
Page
Outside Air Vent
......................................................
27
With Heater
Hood
............................................................
2 8
..............................................................................
29
Alignment
.................................................................
29
Replacement
............................................................
29
Removal
....................................................................
2 9
Installation
...............................................................
3 0
Hood Leveling Bumper
........................................
29
Lock
............................................................................
3 0
Hood Adjusting Screws
......................................
3 0
Carburetor Outside Air
.......................................
3 0
Fender‘s
........................................................................
3 0
Alignment
.................................................................
3 0
Replacement
............................................................
3 0
Removal
....................................................................
3 0
Installation
...............................................................
3 0
Radiator Yoke Support
Replacement
Removal
..........................................
35
............................................................
35
Installation
Bumper’s
Doors
....................................................................
35
Alignment
...............................................................
......................................................................
Bumper’s (Except Station Wagon)
Rear Bumper Station Wagon
Fore and A f t
.................
3 4
...........................
35
Grille
..............................................................................
35
Grille Attachment
.................................................
35
.............................................................................
35
35
U p a n d D o w n
.........................................................
35
...........................................................
Door Latch Striker Adjustment
.........................
3 4
35
35
35
Door and Latch Adjustment
...............................
35
Latch Link
Page
...................................................................
41
Door Lock Cylinder Linkage
................................
39
Lock Cylinder
Door Trim Panel Installation
...............................
3 8
Weatherstrips
Tailgate
Door Sag
...................................................................
Torsion Bar
.............................................................
Remote Control
Outside Handle
Vertical Adjustment
In and Out Adjustment
Roof Air Deflector
......................................
3 9
.........................................................
3 8
.........................................................
3 9
Front Door Latch Locking Control
Door Trim Panel Replacement
............................................................
40
Door Weatherstrips
..............................................
Roof Rail Weatherstrips
...................
.........................
........................................................................
41
.............................................
3 8
38
40
40
41
..............................................................
41
Lock Linkage Adjustments
...............................
41
................................................
41
Lateral Adjustment
...............................................
41
4 1
44
Tailgate Weatherstrips
.......................................
43
Deck Lid
......................................................................
Alignment
4 5
.................................................................
45
Replacement
............................................................
45
Hinge Replacement
..............................................
4 5
Removal
....................................................................
4 5
Installation
...............................................................
4 6
Torsion Bar Replacement
.....................................
4 3
Removal
....................................................................
4 3
Installation
...............................................................
Deck Lid Lock Cylinder
Deck Lid Weatherstrip
4 3
......................................
4 5
..........................................
4 6
SERVICE PROCEDURES
COWL PANELS
OUTSIDE AIR INLETS
Control Cable
On air conditioned equipped vehicles. only the left vent door i s used
.
Attachment
The control cables are attached to the instrument panel lower flange with screws (Fig
.
1)
.
The lower end of the cables are retained bn a mounting bracket with a clip and screw (Fig
. 2) .
The right cable “looped” end is positioned on the air door control crank arm (Fig
.
2)
.
The left cable is held on the crank arm with a spring type retainer (Fig . 3) .
Routing- with Heater
Route cables rearward of heater support brace. under heater control cables and defroster hoses to the instrument panel attaching points on right side of steering column (Fig
.
3) .
CONTROL CABLE
Fig
.
1
.
6
NR131
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3-28 SATELLITE-SHEET METAL DOORS
With Air Conditioning (Left door only]
Route cables behind steering column support bracket, through spot cooler duct hole in brake pedal bracket, under speedometer cable and around air conditioning outlet duct to instrument panel attachment holes on right side of steering column (Fig. 4).
Attachment
(1) At lower end of cable, remove screw and clip retaining cable on mounting bracket (Fig. 2).
(2) Push control knob in fully and rotate air door control crank arm to the fully closed position.
(3) Position clip over cable and on mounting bracket. Install screw, tighten securely and test cable operation.
Fig. 2
-
Control Cable Adjustment
0
Fig. 3
-
Control Cable
OUTSIDE
AIR
DUCTS
(Fig.
5)
Vehicles equipped with a heater include the right side duct in the heater housing. Vehicles without a heater have a separate duct assembly for the right side. The left side duct assembly is the same for all models.
Without Heater
The outside air duct assemblies are attached to the plenum opening. The right duct is retained by two hook type rods positioned over the plenum opening flange and held to brackets on the base of the duct with screws (Fig. 5 ) .
The left duct assembly is attached directly to the plenum by positioning the duct over the plenum weld studs and securing with nuts.
With Heater
The right duct, part of the heater housing, is attached to the plenum with a single hook type rod positioned over the plenum flange and secured to the duct base with a screw (Fig. 5).
NR129
Fig.
SPEAKER OUTLET
4 \
’
4
-
Control Cable with Air Conditioning
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SATELLITE-SHEET METAL DOORS
3-29
BUMPER
NR164
Fig. 5
-
Outside Air Duct
HOOD
ALIGNMENT
Prior
to
making any hood adjustment, inspect clearances and alignment of hood sides in relation
Fig. 7
-
Hood leveling Adiustment
to cowl, fenders and grille. The cowl adjustment must be made first.
REPLACEMENT
Rem0 val
(1)
Place a protective covering over cowl and fender area.
YOKE STRiKER
Fig. 6
-
Hood Adiustment
FENDEK
SHIELD PB272
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3-30 SATELLITE-SHEET METAL DOORS
SAFETY
CATCH
PY233
Fig. 8
-
Hood Lock and Striker
(2) Mark outline of hinges on hood to aid in installation (Fig. 6).
(3) With an assistant, remove hinge-to-hood atta- ching bolts and remove hood assembly. Use ex- treme care not to permit hood to slide rearward and damage painted surfaces of the cowl and fender areas. lnst allation
(1) With an assistant, position hood on hinges and install hinge to hood bolts. Do not tighten.
(2) Align scribe markings on hood with hinge and tighten screws lightly.
(3) Close hood and inspect hood alignment.
(4) Adjust the alignment (Figs. 6 and 7) as nec- essary and tighten the hood to hinge bolts 180 inch-pounds.
( 5 ) Remove protective covering from cowl and fender area.
LOCK
To adjust the lock (Fig. 8) loosen the attaching screws and raise or lower until the correct adjust- ment has been obtained. After making any adjust- ment that requires a shifting of the hood, always inspect the hood striker and the lock plate assem- bly for alignment.
TORSION BAR REPlACEMENT
(1) Disengage the torsion bar roller from its seat on hood hinge by forcing the roller end of bar to the rear and raising hood fully.
(2) Disengage left hand torsion bar roller from hood hinge.
(3) Remove hood assembly.
(4) Remove torsion bars from center support and remove bars from end reinforcements.
( 5 ) Lubricate torsion bar rollers and install on hinges.
(6) Install hood assembly and adjust alignment.
HINGE REPlACEMENT
The hood hinge (Fig. 6) is attached to the hood by two screws and to the fender splash shield by three screws. Prior to removing the hinge mount- ing screws, prop the hood into the wide open position. The prop should be positioned so the hood cannot move rearward.
CARBURETOR AIR SYSTEM
The carburetor air system (Fig. 9) is available on
Plymouth Road Runner, GTX is the “Air
Grabber”-a vacuum-operated air scoop in the hood ducted directly to the air cleaner. This sys- tem is standard with the “hemi” engine and op- tional on the high-performance 383 and 440 CID engines. The driver can open or close the air scoop when the engine is running. It closes auto- matically when the engine is shut off.
FENDERS
A
MGNMENT
The fender should be adjusted to provide for equal spacing at the cowl, door front edge and door panel top edge. Alignment should be made at bottom of floor sill panel, front of hood and door outer panel upper edge.
REPlA CEMENT
Removal
(1) Disconnect battery ground strap.
(2) Tape leading edge of front door and cowl to fender area to avoid damaging paint.
(3) Remove front bumper assembly.
(4) Disconnect head lamp wires and remove nuts attaching grille extension to fender.
( 5 ) Remove nuts and screws attaching fender to cowl, floor sill, wheelhouse or splash shields and radiator yoke (Figs. 10 and 11).
(6) Remove fender assembly and if necessary re- move fender mouldings, ornamentation and head light assemblies.
Instaltation
(1) Install head lamps, mouldings and ornamen- tation if removed.
(2) Carefully position fender on studs at cowl side area and align fender with mounting holes in radiator yoke. Install all mounting screws and re- tainer nuts.
(3) With fender correctly positioned, tighten all screws and nuts securely making certain fender is aligned at cowl and hood areas.
(4) Connect head lamp wires and install grille to fender nuts. Connect the battery ground strap.
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0
SATELLITE-SHEET METAL DOORS 3-35
IMPACT PAD
GRILLE
ALIGNMENT
AND
REPLACEMENT
Refer to (Fig. 14) for grille attaching points. The grille must be held against the front face of the fenders at the outer edges to avoid stressing or fracturing the grille. Care must be taken to pro- tect the textured grille from high temperature dur- ing repairs.
DOORS
The service procedures for internal door compo- nents do not include obvious operations, such as removing door or quarter panel trim panels, test- ing operation of windows or inspecting glass fit after adjustments or replacement have been performed.
SUPPORT BUMPER PB267
Fig. 13
-
Rear Bumper Station Wagon Models
RADIATOR YOKE SUPPORT
REPLA CEMENT
Removal
(1) Drain radiator and remove hoses from radiator.
(2) Remove radiator attaching screws and radiator.
(3) Remove hood lock striker bar, horn and headlamp wiring from yoke support.
(4) From under the fenders remove the wheel- house to yoke support attaching screws.
(5) Remove support to frame attaching screws and remove radiator yoke support from engine compartment.
ALIGNMENT
Up and Down
Adjustment of the door can be made at either the pillar or door hinge halfs. (Fig. 15).
In and Out
Adjustment is made at the door hinge half. Adjust only one hinge at a time. Raising outer end of door moves upper part of door forward, when in closed position. Lowering lower part of door moves lower part forward, when in closed position.
Fore and
Aft
Adjustment is made at the pillar hinge half.
Adjust only one hinge at a time. Raising outer end of door, moves upper part of door into door opening. Lowering outer end of door, moves lower part of door into door opening.
Installation
(1) Position yoke support into the engine compartment. Install the frame to yoke support screws finger tight.
(2) From under the fenders, install splash shield to yoke support screws finger tight only.
(3) When all attaching screws have been installed, tighten progressively.
(4) Attach the horn and lamp wires to the yoke support with the plastic straps.
(5) Install radiator, hoses, fill cooling system and inspect for leaks.
STRIKER AND ROTOR
The door strikers (Fig. 15) are attached to the pillars. Oversize holes permit up and down and in and out movement. Fore and aft adjustment is made by adding or removing shims between the striker and post. The striker plate should be ad- justed to lift the door slightly.
AIR SHIELD AND CROSS BAR
Refer to (Figs. 10 and 11) for air shield and cross bar attaching points.
BUMPERS
ATTACHMENT
Refer to (Fig. 12 and 13) for bumper attaching points.
DOOR REPLACEMENT
Front Door (All Models)
Removal on vehicles with electric windows, disconnect the wires from window regulator motor and re- move from door assembly.
(1) With door in wide open position, place a jack, with a block of wood or pad on lifting plate of jack, as near hinge as possible. (This will hold weight of door as hinge bolts are loosened.)
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3L36 SATELLITE-SHEET METAL DOORS
0
/
BOLT GRILLE ATTACHMENT
-
SEDAN
BEZEL
GRILLE ATTACHMENT- HARDTOP
Fig. 14
-
Grille Attachment
P B n o
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SATELLITE-SHEET METAL DOORS 3-37
\
FRONT DOOR LATCH
PY458
Fig. 16
-
Door Striker
REMOTE CONTROL
Fig. IS
-
Door Hinge Atfachment
(2) Remove door interior trim and hardware.
(3) Scribe a line around upper and lower hinge plates on door panel.
(4) Remove hinge attaching screws from door and remove door for further disassembly if necessary.
(1) With door inner hardware installed, place door in position in door opening, supported by a padded jack.
On electric window lifts, install wiring in doors and attach to motor and control switch.
(2) Locate door hinge plates on door panel and install hinge attaching screws finger tight only.
(3) Adjust jack to align hinge plate scribe marks and tighten attaching screws.
(4) Complete door aligning procedure, and install door interior trim and hardware.
REAR DOOR
(All
Models)
Removal
On vehicles with electric window lifts discon- nect wires from motor and control switch and remove from door prior to door removal.
(1) Open rear door and place a padded jack un- der door near the hinges.
(2) Remove door interior trim and hardware.
(3) Scribe aligning marks around hinge plates on door frame.
(4) Remove hinge attaching screws from door and remove door from body.
Installation
(1) With rear door inner hardware installed, sup- port door on a padded jack and position door on hinges.
(2) Install attaching bolts finger tight.
(3) Align hinges with scribe marks.
(4) Tighten attaching screws and test door for alignment.
Fig. 17
-
Remote Control Handle
NN605A
( 5 ) Install door interior trim and hardware.
On vehicles with electric window lift, insert wiring into the door and attach wiring to motor and control switch prior to installation of trim panel.
HINGE REPLACEMENT
The door hinges (Fig. 15) are attached to the doors by screws accessible from outside. The front door hinges are each attached to the three screws.
“A”
post by
The rear door upper hinges (on hardtop and sta- tion wagon models), are attached to the
“B”
post by three screws accessible from outside. On sedan models, the screws are accessible through an ac- cess hole in the “B” post.
INSIDE HANDLES
Window Regulator Handle
The window regulator handles are retained on the shaft with an allen set screw. The handles should be positioned on the shaft approximately in a horizontal position with the knobs facing rearward.
Remote Control Handle
The remote control handle (Fig. 17) is attached to the control unit with a screw at the rear inner end.
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03-38 SATELLITE-SHEET METAL DOORS
ANTI-RATTLER
VIEW A
Fig. 19
-
Rear Door Locking Mechanism
NN546
Fig.
CONTROL ~ ~ 4 0 2
18
-
Front Door Locking Mechanism
ARM RESTS
The arm rests are retained by two metal screws inserted at the bottom of the arm rest base. The pad and base can be separated and if necessary, the pad may be recovered.
TRIM PANELS
DOOT
Trim Panel Replacement
(1) Remove inside handles and arm rests.
(2) Remove screws attaching trim panel to door inner panel.
(3) Insert a wide blade screw driver between trim panel and door frame next to retaining clips and snap retaining clips out of door panel. Re- move trim panel.
(4) Before installing door trim panel, inspect condition of watershield.
( 5 ) Be certain the escutcheon spring is placed on the regulator shafts.
(6) Align trim panel retaining clips with holes of door frame and bump into place with heel of hand.
(7) Install trim panel to door screws.
(8) Install escutcheon washer, handles and arm rest.
LOCK ASSEMBLY
Remote Control (Manual)
Removal
(1) Raise door glass.
I
CONTROL
NN545
Fig. 20
-
Rear Door Locking Control
(2) Remove screws attaching remote control base to door panel (Figs. 18 and 19).
(3) Remove link from remote control lever.
(4) Remove control through large opening in door.
Installation
(1) When installing the remote control assembly, coat parts with lubriplate.
(2) Install assembly through door opening and connect link to the control lever.
(3) Install attaching screw and test operation control. of
LOCK REPLACEMENT
Removal
(1) Disconnect handle to lock link (Figs. 18 and
19) from lock by pulling link outward at lock.
(2) Disconnect locking lever rod (front door
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a
SATELLITE-SHEET METAL DOORS
3-39 only) from lock assembly (Fig. 18).
(3) Disconnect lock control rod from lock assem- bly (Fig. 20).
(4) Remove screws attaching lock assembly to door.
( 5 ) Rotate lock assembly and disconnect remote control link when removing lock,
(6) Lubricate all moving points of lock assembly.
Installation
(1) Position lock assembly in door and connect remote control link to lock lever.
(2) Install lock retaining screws.
(3) Connect handle to lock link.
(4) Connect locking lever rod (front door only) to lock assembly.
( 5 ) Connect locking lever rod and remote control link to lock.
L
OCK CYLINDER
Removal
(1) With window in the up position, disconnect cylinder link (Fig. 21) from clip on lock lever (4 door only) and from cylinder.
(2) On 2 door models disconnect lock link from clip on lock lever, remove link control bracket mounting screws and remove cylinder link from cylinder.
(3) Remove retainer inder from door. from cylinder body and cyl-
Installation
(1) Position cylinder in door and install retainer on cylinder body.
(2) Connect the cylinder link to cylinder arm and to clip on lock lever (4 door models).
(3) On (2 door models) connect cylinder link to cylinder, position link bracket on door face and install attaching screws. Connect lock link to lock.
OUTSIDE HANDLE-FRONT DOOR
Removal
(1) With door glass in up position, remove door handle attaching nuts from mounting studs (Fig.
21) and link from handle to lock.
(2) Lift handle up and remove from door.
Installation
(1) Install handle into door opening. Engage link from handle to lock.
(2) Attach retaining nuts and test operation of the handle.
%
ATTACHING NUTS
VIEW IN DIRECTION OF
ARROW Z
Fig. 2 1
-
Lock Cylinder and Outside Door Handle
P 8404
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3-40 SATELLITE-SHEET METAL DOORS
REAR DOOR
Removal
(1) With door open and glass in up position re- move retainer from link at handle connector.
(2) Lift outside handle and remove link from handle connector.
(3) Remove nuts attaching handle to door and remove handle.
Installation
(1) Position handle in door and install mounting nuts.
(2) Lift handle and position link over connector on handle.
(3) Install retainer over link and connector.
WEA THERSTRIPS AND WINDCORDS
0
(2) Apply a 1/8 inch bead of cement to weath- erstrip seating area on door upper and lower areas.
(3) Install upper half of weatherstrip on door, indexing at the upper comers.
(4) Work weatherstrip from index points to a point midway between them. Avoid puckering or stretching of weatherstrip.
Hardtop-Models
(1) Apply a coat of cement to weatherstrip con- tact area on door inner and outer panels at belt line and to contact surface of weatherstrip.
(2) Position pillar seal on weatherstrip, making sure lip of weatherstrip dove tails into groove of seal and install screws.
(3) Install weatherstrip on door, indexing at top of door at belt line with two fasteners.
Door Weatherstrips
Make sure all old weatherstrip particles and ce- ment are removed before installing new weatherstrip.
Sedan and Station Wagon Models
(1) Apply lower half of weatherstrip, starting at hinge face at belt line, working fasteners into holes in shut face of doors.
Roof Rail Weatherstrip
Refer to Figure 22 for the attaching points and methods of cementing.
The weatherstrip retainers are adjustable through the use of elongated attaching holes. The weather- strip can be moved in or out for the best possible fit and seal along the top edge of the frame, door glass and quarter glass.
The glass up-stop must be adjusted so the fully raised glass just curls the outer lip of weatherstrip
GLASS BLOW-OFF RETAINER
ROOF SIDE
DRAIN TROUGH
VIEW IN DIRECTION OF ARROW X m a
GLASS MUST BE\
POSIT ION
RETAINER
VIEW IN CIRCLE Y
QUARTER PANEL
OF ARROW W OF ARROW V
Fig. 22
-
Roof Rail Weatherstdp
OF ARROW Z PB274
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0
SATELLITE-SHEET METAL DOORS 3-4 1
against the inner lip
When the up-stop, roof rail weatherstrip and glass are properly adjusted, the outer lip of weath- erstrip will seal along the top edge of the glass and the inner lip of weatherstrip will seal along the upper inside edge of glass.
TAILGATE
Station Wagon Models are equipped with a “two way” tailgate that can be opened as a swing-out type door with the glass in the raised or lowered position. The tailgate can be opened in the con- ventional tailgate manner.
The sequence of adjusting the linkage should be followed as outlined in this manual, to ascertain correct locking and releasing operations.
Vertical Adjustment
1. Hinge pin adjustment, Fig. 23.
A. On the lower left side loosen the pin lock nut.
B. Adjust the pin to proper height. Proper ad- justment is obtained when the bushings on the body and gate halves of upper hinge are just touching after the adjustment has been made, tighten lock nut.
2. Striker adjustment.
A. Loosen the plate and striker so that the plate screws and striker plate can be moved up or down.
B. Tighten plate and striker at desired position.
BOTH THE UPPER AND LOWER STRIKERS
SHOULD BE ADJUSTED TO CARRY EQUAL
WEIGHT OF THE TAILGATE.
In and Out Adjustment
1. Loosen the three lower hinge attaching nuts and adjust the tailgate to the desired position by removing or installing the necessary shims and then tighten bolts. The slotted holes in the lower hinge also provides side to side adjustment.
2. Upper and lower striker adjustment use same procedure as vertical adjustment. against the body.
REPLACEMENT
Removal
Remove trim panel and disconnect terminals at control switch. Disconnect electrical leads.
(1) Remove check arm and torsion bar guide from pillar guide plates.
(2) Support tailgate on jacks or stands.
(3) Loosen hinge pivot pin locking screws (Fig.
23).
(4) Use a pencil and outline hinge plate position on pillar post for future assembly.
( 5 ) Remove hinge plate attaching bolts from pil- lar post.
(6) Slide hinge plate and torsion bar in through guide toward center of tailgate.
(7) Lower tailgate down and out of body opening.
Installation
(1) With torsion bar and hinge plates pushed in toward center of tailgate, engage hinge plates into lower opening of body.
(2) Attach hinge plate attaching bolts into pillar posts and locate hinge plates in relation to previ- ous marked positions.
(3) Tighten attaching bolts firmly enough to hold position and inspect alignment.
(4) Close tailgate and center in opening.
( 5 ) Attach torsion bar bracket to pillar post.
(6) Open tailgate and tighten locking screws on hinge pivot pin.
(7) Connect electrical leads and install trim panel.
(8) Operate tailgate window and inspect alignment.
TRIM PANEL
The tailgate trim panel is attached with metal screws. Clean all foreign material from the seating area of the trim panel before installing.
Lateral Adjustment
1. Lateral adjustment can be made at the upper hinge by removing or installing shims as necessary.
2. Elongated slots in the lower hinge provide lat- eral adjustment of the tailgate.
Door Sag
This adjustment can be made by moving the up- per (body half) laterally closer to the body pillar and by moving the lower hinge toward the center of the car.
CARE must be taken in making this adjustment to avoid the outer edges of the tailgate rubbing
LOCK AND CYLINDER
To replace the lock assembly (Fig. 24) remove trim panel glass and glass runs. The lock assembly is retained on tailgate by screws accessible at end of tailgate. The lock cylinder assembly is retained on the outer panel with a horseshoe type retainer.
LOCK LINKAGE
Installation and Adjustment (Fig.
24)
The lower right to upper right latch link and upper right lock to release regulator mechanism arm link can only be adjusted to three total turns from nominal position for all release, interlocking
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0
SATELLITE-SHEET METAL DOORS 3-43
and latch engaging operations.
(1) Inspect locks to make certain they are in the fully latched position.
(2) Install link to lower right latch detent clip, raise upper right lock actuator until it contacts upper latch lock detent.
(3) Adjust threaded portion of link until aligned with clip hole of actuator and insert link into clip.
(4) Connect link to upper right lock remote con- trol lever and to release regulator mechanism actuator.
( 5 ) Install link from release regulator arm to the glass restraining bracket.
(6) Install link into release regulator mechanism and upper left latch remote lever clip.
(7) Install link into lock remote lever.
(8) Take up all play in latch remote lever and release regulator mechanism arm and adjust link threaded end to this point.
(9) Install link into upper right lock remote le- ver and test operation of tailgate and door assembly.
TORSION BAR
Removal
(1) Remove trim panel from tailgate.
(2)
Remove screws attaching torsion bar clamp to tailgate pillar (Fig.
23)
and remove clamp. and
(3)
Remove torsion bar bearing retainer bearing.
(4) Remove screws attaching torsion bar hinge to tailgate.
( 5 ) Remove torsion bar from hinge. and lnsf
alla
fion
(1) Lubricate torsion bar at right hinge area and at torsion bar bearing area.
(2)
Install hinge on torsion bar and insert sion bar into tailgate. tor-
(3) Position hinge to tailgate and install mount- ing screws. Tighten screws.
(4) Install bearing and bearing retainer on tor- sion bar (Fig. 23). Tighten retainer nut.
TAIL
GA
TE WEA THERSTRIPS
The Roof Header Seal (Fig.
25),
is cemented to the header and tailgate pillars.
The Roof Rail Retainer is attached to the Head- er and Pillars by screws.
The Tailgate Glass opening has both inner and outer weatherstrips. The inner consists of two weatherstrips that are a compression fit at the top center of opening.
The Outer Tailgate opening weatherstrip is one
I 1 P-
LEFT SIDE
RIGHT SIDE
Fig. 24
- lock linkage Adiustments
’
NR496
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3-44 SATELLITE-SHEET METAL DOORS
0
VIEW IN CIRCLE W
SEAL
VIEW IN DIRECTION
OF ARROW Y
VIEW IN CIRCLE V
Fig. 25
-
Tailgate Weatherstrip
VIEW IN CIRCLE X PB403
P Y l l V V l E W IN CIRCLE Z
Fig. 26
-
Roof Air Deflector piece and indexes with the lower tailgate opening weatherstrip which is a two piece weatherstrip.
Fig. 27
-
Deck Lid Hinge and Latch
NU68
ROOF REAR AIR DEFLECTOR
The rear air deflector (Fig. 26) used on station wagon models is mounted on the roof by inserting the deflector studs through holes drilled in the panel and securing with sealing type nuts from the car interior. Tighten the nuts 75-115
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0
LINK
/
CLIP
I
GASKET
/
LOCK
DECK LID’
~
SATELLITE-SHEET METAL DOORS 3-45
LATCH
LI
VIEW IN DIRECTION
OF ARROW 2
Fig. 28
VIEW IN DIRECTION OF ARROW Y
-
Deck Lid Lock and Cylinder
PY83 screws. An assistant’s aid is recommended when
NUT replacing lid to prevent it sliding rearward and damaging paint, also to aid in aligning of hinge screw holes when installing.
LOCK
REPLACEMENT
The deck lid lock (Fig.
27)
is attached to the deck lid by two screws. Scribe location of lock mounting flanges to aid in installation.
LUBRKATION inch-pounds.
Fig. 29
-
Deck Lid Torsion Bar
DECK LID
Adjustment
Vertical adjustment of lock is made at the atta- ching screws and side adjustment is made at the striker attaching bolt.
Cylinder Replucement
The lock cylinder is retained by a spring steel
“U” shaped slip (Fig. 28).
ALIGNMENT
The deck lid hinge (Fig.
REPLACEMENT
27)
to lid attaching
The deck lid is attached to each hinge by two
HINGE holes are slightly oversize, allowing slight to and Removul fro, and, in and out adjustment. (1) Remove deck lid assembly and disengage tor- sion bar from hinge (Fig.
29)
being removed.
(2) Remove hinge to hinge bracket spring nut and remove hinge.
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3-46 SATELLITE-SHEET METAL DOORS
0 der a load. Release load from torsion bar slowly and remove from support bracket.
(1) Remove torsion bar (Fig. 29) from adjust- ment slot.
(2) Push bar out of roller in hinge arm and re- move from hinge support.
VIEW IN CIRCLE Y
VIEW IN CIRCLE X
Fig. 30
-
Deck Lid Weathentrip
NP114
Installation
(1) Position hinge on bracket pin and install a new spring nut.
(2) Install deck lid, connect torsion bar and in- spect alignment.
TORSION BAR
Removal
Use care when removing torsion bar as it is un-
Installation
(1) Position torsion bar into hinge support and insert end into roller in hinge arm.
(2) Hook torsion bar into support bracket.
(3) Wind bar and insert end into center adjust- ing slot.
(4) Place lid in various open positions and test tension.
( 5 ) Adjust bars until deck lid stays in open position.
WEA THERSTRIPS
Apply an even continuous coat of cement to en- tire weatherstrip contact surface of deck lid open- ing (Fig. 30). Install weatherstrip, make sure weatherstrip molded corners are correctly positioned
.
VACUUM TUBE
Fig. 31
-
Vacuum Actuated Deck Lid Lock.
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BARRACUDA-SHEET METAL-DOORS 3-47
VACUUM ACTUATED DECK LID LOCKS
The vacuum actuated deck lid lock release tem (Fig sys-
.
31) consists of a vacuum tank mounted over the right front wheel housing. a push button control switch the glove box and a vacuum actu- ated diaphragm assembly connected to the lock
.
Vacuum is supplied to system from intake manifold
.
Rubber hoses are used to connect com- ponent units
.
If failure of the system is accompanied with a rough engine idle. remove hose from manifold fit- ting tube and plug end of the tube
.
If engine idle improves noticeably. inspect hoses for possible leaks
.
Should system fail to operate entirely. remove hose at the release diaphragm in deck lid and connect a vacuum gauge to hose
.
With engine running. actuate button in glove box while a help- er observes gauge
.
If no reading can be obtained. inspect for a pinched hose
.
A reading of less than
16 inches will indicate a leak in the system
.
BARRACUDA
Outside Air Vents
Page
....................................................
40
With Heater
............................................................
48
Shelf Trim Panel
Scuff Plate
Radiator Yoke Support
Replacement
Removal
Installation
Bumper's
...................................................
...............................................................
48
Cowl Seal t o Cowl Panel
..................................
4 9
Cowl Side Trim Panel
.........................................
4 9
Hood
..............................................................................
4 9
Alignment
.................................................................
49
Replacement
............................................................
49
Removal
Installation
...............................................................
Hood Leveling Bumper
Lock
........................................
4 9
............................................................................
Hood Adjusting Screws
Hood Top Ornament
Carburetor Outside Air Hood Seal
Fender's
..................
.........................................................................
............................................................
49
49
Alignment
..................................................................
5 2
Replacement
.............................................................
5 2
Removal
.....................................................................
52
Installation
....................................................................
5 2
Urethane
................................................................
48
49
5 0
5 0
51
5 1
5 2
..........................................
5 2
...............................................................
................................................................
Front Bumper Sub-Assembly
5 2
5 2
5 2
Front and Rear Supports
...................................
5 3
Front Bumper Sub-Assembly
............................
5 3
............................
5 3
Steel
.........................................................................
5 3
Rear Bumper-Steel or Urethane
Sub-Assembly
.............................................................
Rear Bumper-to Car
Grille
5 3
5 3
................................................
5 3
..............................................................................
5 4
Alignment and Replacement
Page
............................
5 4
Grille Assembly t o Car
Grille Panel Air Shield
.......................................
5 4
55
Doors
.............................................................................
55
Alignment
.................................................................
Up and Down
55
Fore and A f t
.........................................................
55
...........................................................
55
Door Latch Striker Adjustment
.........................
55
Door and Latch Adjustments
L a t c h L i n k
.............................
55
...................................................................
5 6
Door Lock Cylinder Linkage
................................
5 6
Lock Cylinder
..........................................................
5 6
Remote Control
......................................................
5 6
Outside Handle
Installation
Stone Deflector
Deck Lid
Alignment
Replacement
Removal
Installation
.......................................................
Front Door Latch Locking Control
Door Trim Panel Installation
Door Trim Panel Moulding
Ash Receiver t o Panel
............................................................
6 0
Hinge Replacement
....................................................................
5 7
5 7
...............................
5 7
................................
5 7
Door Trim Panel Name Plate
Quarter Panel Airshield
Quarter Trim Panel Moulding
.................
...........................
5 7
........................................
5 7
...............................................................
Quarter Panel Trim
.................................................
Folding Top Pocket Panel Assembly
Pocket Panel Installation
.....................................
5 9
............................
6 0
........................................
60
......................................................
......................................................................
..............................................
5 8
5 8
5 8
6 0
6 0
6 0
6 0
6 0
...............................................................
6 0
Torsion Bar Replacement
Removal
Installation
.....................................
6 0
....................................................................
6 0
...............................................................
6 0
Deck Lid Lock Cylinder
......................................
6 1
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3-48 BARRACUDA-SHEET METAL-DOORS
FRAME HOOK
0
Fig. I
-
Outside Air Vents
Fig. 2
-
Shelf Trim Panel
OUlSlDE
AIR VENlS
(Fig.
1)
SPRING NUT
PY445
Fig. 3
-
Scuff Plate window defogger or rear speaker or both.
( 3 ) Insert fastener into retainer on shelf trim panel.
(4) Position and align shelf trim panel to metal shelf panel and snap in place.
With Heater
The left side vent is attached to the cowl assem- bly and the right side vent is part of the heater unit (Fig. 1). Vents are not available with air conditioning.
Shelf lrim Panel (Fig.
2)
(1) Place shelf trim panel face side down on bench.
(2) Remove gated section of silencer for rear
Scuff Plate (Fig.
3)
(1) Assemble spring nut to quarter trim panel.
(2) Position scuff plate to body side sill and se- cure with screws.
Dash Liner Installation (Fig.
4)
(1) Remove gated section for jobs with manual transmission and gated hole for windshield washer foot pump.
(2) Position liner assembly to dash panel and secure with fastener.
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0
BARRACUDA-SHEET METAL-DOORS 3-49
Fig. 4
-
Dash liner Installation Fig. 5
-
Cowl Seal
Cowl Seal to Cowl Panel (Fig.
5>
Position seal assembly to hood panel and fasteners, align fasteners to holes in cowl top pan- el and secure by inserting fasteners into holes.
Cowl Side-Trim Panel (Fig.
6>
(1) Assemble spring nut to cowl trim panel.
(2) Apply cement to felt side of silencer, and cowl side trim rear.
(3) Position cemented surface of silencer to panel, cowl side trim assembly. Press down firmly to obtain proper adhesion.
(4) Place assembly to cowl side inner panel.
Align holes and secure with screw.
SILENCER
PY441
COWL SIDE PANEL
TRIM PANEL SILENCER
Fig. 6
-
Cowl Side Trim Panel
ALIGNMENT
Prior to making any hood adjustment inspect clearances and alignment of hood sides in relation to cowl, fenders and grille. The cowl adjustment must be made first.
REPLACEMENT
Removal
(1) Place a protective covering over cowl and fender area.
(2) Mark outline of hinges on hood to aid in installation.
(3) With an assistant, remove hinge-to-hood bolts
(Fig. 7) and remove hood assembly. Use care not to permit hood to slide rearward and damage painted surfaces of the cowl and fender areas.
HOOD
Installation
(1) With an assistant, position hood on hinges and install bolts. Do not tighten.
(2) Align scribe markings on hood with hinge and tighten screws to hold in positon.
(3) Close hood and inspect alignment.
(4) Adjust alignment (Figs. 7) tighten bolts and remove protective coverings.
HOOD
LEVELING BUMPER REAR (Fig. 8)
For position and installation of bumper see (Fig. 8).
LOCK
To adjust lock (Fig. 9) loosen attaching screws and raise or lower until correct adjustment has been obtained. After making any adjustment that requires shifting of hood, always inspect hood striker and lock plate alignment.
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3-50 BARRACUDA-SHEET METAL-DOORS
HOOD
I
HINGE
REINFORCEMENT a
VIEW IN DIRECTION
OF ARROW Z
HOOD
- "
SAFETY CATCH
Fig. 7
-
Hood Application
H
Fig. 8
-
Hood Leveling Bumper's
Fig. 10
-
Hood Adjusting Screws and Bumpers
Fig. 9
-
Hood Lock and Striker
HOOD
ADJUSllNG SCREWS AND BUMPERS
(Fig.
10)
For ADJUSTING screws and locations
of
bump- ers
to
fender and hood extension see (Fig.
10).
HOOD 10P ORNAMENl
(Fig.
11)
(1)
Sub-assembly
(4)
spacers, one
to
each comer stud. Spacer can be rubber tubing.
(2) Position spacer and ornament assembly to hood panel, secure with springnuts on leading studs.
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BARRACUDA-SHEET METAL-DOORS 3-51
ORNAMENT-HOOD TOP
HOOD
FRESH AIR OPENING
VIEW IN CIRCLE "Z"
PY472
Fig. 11
-
Hood Top Ornament
CARBURETOR OUTSIDE AIR HOOD SEAL
(Fig.
12)
To
replace outside air hood seal, remove attach- ing screws from inner hood panel (Fig. 12).
FENDERS
VIEW IN DIRECTION OF ARROW Z
Fig. 12
-
Carburetor Outside Air Hood Seal
PW22
FENDER SHIELD
\
VIEW IN
DIRECTION OF ARROW Z
Fig. 13
-
Fender Application
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3-52 BARRACUDA-SHEET METALDOORS
ALIGNMENT
The fender should be adjusted to provide for equal spacing at the cowl, door front edge and door panel top edge. Alignment should be made at bottom of sill panel, front of hood and door outer panel upper edge.
0 grille extension to fender nuts.
( 5 ) Remove fender to cowl, floor sill, wheelhouse and radiator yoke nuts and screws (Fig. 13).
(6) Remove fender assembly and if necessary, mouldings, ornamentation and headlamp assemblies.
REPLACEMENT
Removal
(1) Disconnect battery ground strap.
(2) Tape leading edge of front door and cowl to fender area to avoid damaging paint.
(3) Remove front bumper assembly.
(4) Disconnect head lamp wires and remove
Installation
(1) Install head lamps, mouldings and ornamentation. Carefully position fender on studs at cowl side area and align fender with mounting holes in radiator yoke. Install all retainer screws and nuts.
(2) With fender correctly positioned, tighten screws and nuts securely.
(3) Connect head lamp wires and install grille to fender nuts. Connect battery ground strap.
REPLACEMENT
RADIATOR YOKE SUPPORT
Removal
(1) Drain and remove radiator.
(2) Remove hood lock striker, horn and head lamp wiring from yoke support.
(3) From under fenders remove splash shield to yoke support screws.
(4) Remove support to frame screws and support.
Installation
(1) Position yoke support on frame and install screws finger tight.
(2) From under fenders, install splash shield to yoke support screws finger tight only.
(3) When all screws have been installed, tighten progressively.
(4) Attach horn and light wires to yoke support with plastic straps.
( 5 ) Install radiator and hoses, fill cooling system and inspect for leaks.
LOCK WASHER
BUMPERS
ONT
MPER BRACE
SCREW AND WASHER
NUT^
I
LOCK WASHER
PLAIN WASHER
I .
?(PLAIN WASHER
NUT
URETHANE
'
7-1
1
Fig. 14
-
Front Bumper Supports-Steel and Urethane
Fig.
+ r y
URETHANE BUMPER
PY439
I5
-
Front Bumper Subassembly-Ure thane
FRONT AND REAR BUMPER
Refer to Figures 14 thru 19 for front and rear bumper attaching points.
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0
BARRACUDA-SHEET METAL-DOORS 3-53
Front Bumper Supports-Steel and Urethane
(Fig. 17)
For positioning of supports to bumper and body, see (Fig. 14).
Front Bumper Sub-Assembly-(Urethane)
(Fig. IS)
(1) Loose assemble bumper support outer, right and left, and inner, right and left.
(2) Secure supports with plain washer, lock washer, and nut.
(3) Loose assemble inner to outer support at rear upper flange with bolt and nut.
(4) Tighten items 2 and 3.
Front Bumper Sub-Assembly (Steel) (Fig.
16)
(1) Loose assemble bumper support and support inner, right and left. .
(2) Secure bolt, plain washer, lock washer, and nut to support.
(3) Loose assemble inner to outer support at rear upper flange with bolt and nut.
(4) Tighten item 2 and 3.
( 5 ) Loose assemble guard brace between right and left inner supports with bolt and nut.
OLT d4
FENDER
HEADLAMP OPENING
FENDER
SIDE RAIL
I
PLAIN WASHER
Fig. 16
-
Front Bumper Subassembly-Steel
OCK WASHER
Fig. 17
-
Front Bumper to Car-Steel or Urethane
(6) Assemble bumper guard sub-assembly, right and left, to front bumper with bolt, plain washer and lock washer.
(7) Tighten item 6.
(8) Loose assemble screw and washer to guard brace, nut and washer.
(9) Tighten item 5 , right and left.
(10) Tighten item 9, right and left.
SUPPORT \
RlGHT,AND LEFT
UllT
PLAIN WASHER
I
WASHER
.
I LLL
NUT
% -
SUPPORT
RIGHT AND LEFT
RETAINER nrr,
\
BUMPER
PREAR
/ m c , . , c '3RCEMENT
I
-LIMPER
Front Bumper to Cat-Steel or Urethane
(Fig. 17)
(1) Position front bumper to front side rails, right and left.
(2) Loose assemble bolt and washer assembly front bumper support to frame.
(3) Position bumper to sheet metal right and left.
(4) Position bumper to front side rail and tighten.
LOCK WASHER
LOCK WASHER
'
EAR URETHANE
BUMPER p y m
Fig. 18
-
Rear Bumper Subassembly-Steel or Urethane
Rear Bumpet-Steel or Urethane
Sub-Assembly (Fig. 18)
(1) Assemble rear bumper guard to bumper with reinforcement.
(2) Use plain washer, lock washer and nut for rear bumper guard to bumper and tighten.
(3) Loose assemble right and left support to rear bumper with bolt, plain washer, lock washer and nut, and tighten.
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3-54 BARRACUDA-SHEET METAL-DOORS
0
(4) Assemble rear bumper support to frame with. retainer.
Rear Bumpet-Steel or Urethane to Car
(Fig.
19>
(1) Position rear bumper, steel, or urethane, to car.
(2) Install plain washer and nut to rear bumper support and frame.
(3) Position assembly to quarter panel and deck opening, lower panel, drain trough.
(4) Tighten nut and bolts.
( 5 ) Assemble rear bumper guard to guard bracket.
(6) Secure guard support to bumper guard. Se- cure to underbody side rail with screw and washer.
ALIGNMENT AND REPLACEMENT
GRILLE ASSEMBLY TO CAR (Fig.
20)
(1) Position radiator grille assembly to car.
BUMPER GUARD
PY435
Fig. 19
-
Rear Bumper Application to Car-Steel or
Urethane
GRILLE
( 2 ) Screw and washer-secure reinforcement
. center
( 3 ) Screw and washer-mount to radiator grille mounting reinforcement.
RETAINER
Fig. 20
-
Grille to Car
PB210
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0
BARRACUDA-SHEET METAL-DOORS 3-55
(4) Screw and washer-install to radiator grill outer mounting reinforcement, and to radiator grille upper panel.
( 5 ) Tighten screws.
(6) Connect terminal wire to headlamp wiring harness.
GRILLE PANEL AIR SHIELD (Fig.
21)
For installation of Air Shield to car see (Fig.
2 1).
Fig. 21
-
Grille Panel Air Shield
PB211
DOORS
The service procedures for internal door compo- of door moves lower part forward in closed nents do not include obvious operations, such as position. removing door or quarter panel trim panels, test- ing operation of window or inspecting glass fit af- DOOR LATCH STRIKER ADJUSTMENT (Fig. ter adjustments or replacement have been performed.
23)
The latch assembly is built into a sheet metal pocket on the door face. The striker pin is atta-
ALIGNMENT ched by a single screw which also allows for adjusting. Torque the striker pin screw 50 foot-pounds. Up and Down
Adjustment of the door can be made at either the pillar or door hinge halfs (Fig.
22).
DOOR AND LATCH ADJUSTMENTS
Fore and Aft end of door moves upper part of door forward, when in closed position. Lowering the lower part
(1) Check all doors for contour and spacing, and all door lock strikers for proper relation to locks.
Adjustment is made at the pillar hinge half. Fit and readjust as follows:
Adjust only one hinge at a time. Raising outer
(2)
Open doors.
(3)
Loosen door latch striker (Fig.
23).
(4) Loosen the necessary hinge bolts to suit each door as follows: (Fig.
22).
(a) For front door upper and lower hinge
TAPPING PLATE
Fig. 22
-
Door Hinges Fig. 23
-
Door Latch Striker Adjustment
PY458
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3-56 BARRACUDA-SHEET METAL-DOORS
.
I
0
HANDLE ASSEMBLY
Fig. 24
- latch link
HANDLE ASSEMBLY
Fig. 25
-
Door Lock Cylinder linkage
PY463
ACC
HO
@’
Fig. 26
SCREW AND
SCREW A N D
- lock Cylinder-Door lock
Fig. 28
-
Outside Handle-latch link
(body half) (forward most bolt).
(b) For front door upper and lower hinge
(body half) (rear most bolt).
(c) For front door upper and lower hinge (door half) (2) upper and (3) lower bolts.
( 5 ) Readjust and fit doors to door openings for alignment of contour lines and belt surfaces.
(6) Secure previously loosened hinge bolts (Fig.
22).
(7)
Readjust door latch striker.
(8) Tighten and retorque striker to pounds (Fig.
23).
(9) Close doors.
40 to 60 foot
Fig. 27
-
Remote Control
LATCH LINK (Fig. 24)
Assemble link, front door latch (Fig. of handle assembly, (close clip).
24)
to lever
DOOR LOCK CYLINDER LINKAGE (Fig. 25)
(1) Connect link front door latch key cylinder to lever portion of key cylinder.
(2) Insert lower end of link (item $1) into latch locking lever retainer.
LOCK CYLINDER-DOOR LOCK (Fig. 26)
(1) Place handle assembly (front door outside) face down.
(2) Position cylinder assembly to handle assembly.
(3) Position spacer to cylinder and handle assembly.
(4) Secure cylinder with screws.
REMOTE CONTROL
(Fig.
27)
(1) Assemble seal-thru door panel access hole and position to remote control lever, press to secure.
(2) Position control assemblv to attaching holes in door.
(3)
Secure with screw and washer.
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BARRACUDA-SHEET METAL-DOORS 3-57
SCREW
- = $
REST
INNER PANEL
Fig. 29
-
Front Door Latch Locking Control
FOR
WI
Fig. 30
-
Door Trim Panel Installation
PY457
PY455
Fig. 31
-
Door Trim Panel Moulding
OUTSlm HANDLE-LATCH LINK (Fig. 28)
(1)' Assemble gasket to handle and link assembly.
(2) Position handle and gasket assembly to door outside panel.
(3) Secure with nut and washer.
(4) Insert lower end of link (part of handle assembly) into latch lever release and close clip.
Fig. 32
-
Door Trim Panel Name Plate
DOOR TRIM PANEL MOULDING
(Fig.
31)
(1) Place door trim panel on bench.
(2) Position, align and insert tabs in moulding.
(3) Insert into holes in door trim panel.
(4) Bend over tabs behind trim panel.
FRONT DOOR LATCH LOCKING CONTROL
(Fig.
29)
(1) Position front door latch to front door inside panel-thru access hole.
(2) Secure with screw and washer.
DOOR
TRIM
PANEL INSTALLATION (Fig. 30)
(1) Position and hook door trim panel to inner panel, align bottom of trim panel to fastener holes, tap in place.
(2) Secure each end with screws.
(3) Secure at arm rest with screws.
For cars equipped with electic window lift, thread wire thru cut out in trim panel before positioning to inner panel.
DOOR
TRIM
PANEL NAME PLATE
(Fig. 32)
(1) Position door trim panel on bench.
(2) Insert name plate to holes in trim panel. Se- cure with nuts.
QUARTER PANEL AIRSHIELD (Fig.
33)
Installation
(1) Apply sealer adhesive to airshield.
(2) Install weatherstrip assembly to holes in quarter panel with clips.
(3) Apply weatherproof tape to weatherstrip, quarter panel, and side sill.
(4) Apply adhesive around window regulator in weatherstrip and immediately apply air shield.
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3-58 BARRACUDA-SHEET METAL-DOORS
0
Fig. 33
-
Quarter Panel Air Shield
DUST BOOT FASTENER
POCKET PANEL
Fig. 34
-
Quarter Trim Panel-Hardtop
QUARTER PANEL TRIM
INER BRACKET
ELECTRIC WINDOW
SWITCH RETAINER py526
QUARTER TRIM PANEL INSTALLA TION (Fig.
Fig. 35
-
Pocket Panel Assembly-Convertible
34’
(1)
Position quarter trim panel, align holes to FOLDING TOP POCKET PANEL ASSEMBLY quarter inner panel.
(2) Secure top with screws.
(3)
Secure bottom to floor pan with screw.
(Fig.
35’
(1) Punch out opening for electric window lift switch retainer if applicable.
(2) Position panel assembly on bench.
(3)
Position fastener stud dust boot into holes in
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BARRACUDA-SHEET METAL-DOORS
3-59
QUARTER
TRIM PANEL
Fig. 37
-
Trim Panel Moulding
Fig. 36
-
Pocket Panel Installation-Convertible pocket panel and secure with nut.
(4) Assemble moulding upper and lower to pock- et panel.
( 5 ) Bend tabs.
(6) Position and install retainer assembly - tric window lift switch and bend tabs. tabs.
(7) Assemble bracket to floor.
(8) Secure with screw and washer.
(9) Insert ash receiver into bezel and snap secure.
POCKET PANEL INSTALLATION
(Fig. 36)
(1) Insert bulb into socket on existing wire as- sembly and turn to secure.
(2) Install panel into body and snap bulb and
ASH RECEIVER
BRACKET PY524
Fig. socket into rib
38
-
Ash Receiver to Panel of pocket panel.
(3) Route electric window lift wiring thru hole in pocket panel.
(4) Position and align pocket panel to quarter inside panel with front edge over lock pillar weld flange and secure to quarter inside panel with screw.
QUARTER
OUTSIDE PANEL
CROSS MEMBE
Fig. 39
-
Stone Deflector
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3-60 BARRACUDA-SHEET METAL-DOORS
0
( 5 ) Secure pocket panel to floor pan with screw.
(6) Assemble screw rear seat top panel. screw.
(3) Position ash receiver to quarter trim panel with press in place.
QUARTER TRIM PANEL
MOULDING
(Fig. 37)
(1) Place quarter trim panel on bench.
(2) Align and inserf tabs in moulding to holes in quarter trim panel.
(3) Bend tabs.
(4) Repeat operation to assemble lower moulding.
ASH RECEIVER TO PANEL (Fig. 38)
(1) Place quarter trim panel on bench.
(2) Position bracket to trim panel, secure with
STONE DEFLECTOR (Fig. 39)
(1) Assemble rear stone deflector J-nuts.
(2) Assemble the rear stone deflector with screw and washer and with nut and washer.
(3) Then tighten the nut and washer.
(4) Assemble reinforcement stone deflector to rear cross member, with screw and washer to rear cross member reinforcement.
( 5 ) Tighten screw.
DECK LID
Alignment hinge brackets are welded in place and are not adjustable.
(2) Use care when disengaging a torsion bar
The deck lid hinges (Fig. 40) permit only slight a s it i s under a load. Disengage torsion bar adjustment at the hinge attaching points. The roller from hinge being removed.
(3) Remove spring nut retaining hinge to hinge bracket (Fig. 40) and remove hinge.
Replacement
The deck lid is attached by two screws on each side. An assistant's aid is recommended when replacing, to prevent it sliding rearward and da,m- aging the paint and also to aid in aligning of the hinge screw holes when installing.
Installation
(1) Use a new spring nut and install hinge.
(2) Install deck lid and connect torsion bars.
(3) Test deck lid adjustment.
TORSION BAR REPLACEMENT
Hinge Replacement
Removal
(1) Remove the deck lid.
Removal
(1) Remove torsion bar (under spring load) from adjustable slot (Fig. 41).
(2) Unwind torsion bar and remove from support bracket.
(3) Push torsion bar out of roller in hinge arm and remove from hinge support.
(1) Insert bar into hinge support and position end of bar into hinge arm roller.
(2) Hook torsion bar into support bracket, and position end of bar into first adjusting slot.
(3) Move deck lid to various open positions and
%
LUBRICATION
TORSION BAR HIN
POSITIONING SLO
NRlOl
Fig. 40
-
Deck l i d Hinge and Torsion Bar
VIEW " A '
Fig. 41
-
Deck l i d Torsion Bar Adiustment
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BARRACUDA-SHEET METAL-DOORS 3-61
LOCK CYLINDER il
PANEL
RETAINER
RELEASE LEVER
RELEASE
LINK LOCK
CYLINDER
LEVER
VIEW IN DIRECTION
OF ARROW B
D
Fig. 42
-
Deck Lid Lock Cylinder
PY470
CLIP
VIEW IN
DIRECTION OF ARROW A
LATCH LEVER
SCREW
RELEASE
Fig. 43
LINK
LATCH SUPPORT '
// 1 / '11
-
Deck Lid Lock-Latch Link and Latch
PY465
SCREW AND
Fig. 44
-
Lock Cover Replacement test tension of torsion bars.
(4) Adjust bars progressively until lid stays in open position.
DECK LID LOCK CYLINDER (Fig.
42)
(1) Assemble gasket to deck lid lock cylinder.
(2) Assemble gasket and deck lid lock cylinder to attaching hole in deck lid opening lower panel.
(3) Engage quill into deck lid latch and secure with retainer (deck lid lock cylinder).
DECK LID LOCK, LATCH LINK AND LATCH
ADJUSTMENT (Fig. 43)
(1) Assemble deck lid latch release lever clip to latch assembly.
(2) Assemble link thru clip and release lever of latch assembly.
(3) Disassemble screws and remove deck lid slave latch.
(4) Position latch and link assembly to attaching holes in deck lid lower panel latch support.
( 5 ) Snug assembly with screws removed.
(6) Adjust latch position for flush alignment of deck lid quarter panel.
(7) Secure screws.
(8) Assemble clip to link cylinder lever.
(9) Assemble link thru clip and release lever of link cylinder.
PY468 LOCK SHiELD HOUSING
45
-
Lock Linkage Shield-Deck Lid
L OCK COVER REPLACEMENT (Fig. 44)
(1) Position gasket to medallion assembly of deck lid lock cylinder and position over lock bezel and thru attaching holes.
(2) Secure with nuts.
LOCK LINKAGE SHIELD (Fig. 45)
(1) Position shield to support deck opening lower panel and housing quarter panel.
(2) Secure with screw and washer.
DECK LID WEATHERSTRIP (Fig. 46)
(1) Apply a coat of adhesive to weatherstrip contact surfaces.
(2) Install weatherstrip so that joint will be lo- cated at bottom of deck lide opening. (Avoid puckering or stretching of weatherstrip around corners). Trim ends to overlap .25. Apply adhesive to butt surfaces and install under compression to provide a watertight joint.
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3-62 VALIANT-SHEET METAL-DOORS
OUTSIDE
QUARTER PANEL
DECK LID
WEATHERSTRIP
\
/9====7
L..-.I
0
VIEW IN
DIRECTION OF ARROW Z
DECK LID
WEATHERSTRIP
’
VIEW IN CIRCLE Y
Fig
.
46
.
SHEET METAL-DOORS
VALIANT
INDEX
BUMPERS
Page
...................................................................
67
DECKLID
....................................................................
7 2
Alignment
.................................................................
7 2
Hinge 7 2
Lock-Adjustment
-Cylinder
.................................................
7 3
..............................................................
7 3
-Replacement
Torsion Bars
............................................................
Weatherstrips
DOORS
.........................................................................
Alignment
.....................................................
.........................................................
.................................................................
7 3
7 3
7 3
68
68
Arm Rests
................................................................
7 0
Ha ndles-I nside
......................................................
6 9
Remote Control
Handles-Outside
Rear
Hinge
...................................................
7 0
...................................................
7 1
Front
........................................................................
7 1
..........................................................................
Latch and Striker Pin
Lock Assembly
Cylinder
..................................................................
Trim Panels
7 1
69
.........................................
69
69
7 1
.............................................................
7 0
Weatherstrips
.........................................................
7 1
Door (Except Sedan)
Page
............................................
72
Sedan
......................................................................
71
Outer Belt
Roof Rail
..............................................................
7 2
................................................................
72
Windcords
FENDERS
................................................................
Alignment
.................................................................
65
Replacement
............................................................
OUTSIDE AIR VENTS
GRILLE
Alignment
.................................................................
Replacement
HOOD
............................................
...........................................................................
Alignment
.................................................................
Hinge
..........................................................................
Replacement
Torsion Bars
Trim Panels
............................................................
...........................................................
72
65
65
6 3
68
68
68
63
6 3
6 3
6 3
65
7 0
Weatherstrips
......................................................
7 1
RADIATOR YOKE SUPPORT
..............................
6 7
Air Shield and Cross Bar
..................................
6 7
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VALIANT-SHEET METAL-DOORS 3-63
SERVICE PROCEDURES
OUTSIDE AIR V E N T m g .
1)
Vehicles equipped with a heater include the right side duct in the heater housing. Vehicles without a heater have a separate duct assembly for the right side. The left side duct assembly is the same for all models.
Without Heater
The outside air duct assemblies are attached to the plenum opening. The right duct is retained by two hook type rods positioned over the plenum opening flange and held to brackets on the base of the duct with screws (Fig. 1).
The left duct assembly is attached directly to the plenum by positioning the duct over the plenum weld studs and securing with nuts.
With Heater
The right duct, part of the heater housing, is attached to the plenum with a single hook type rod positioned over the plenum flange and secured to the duct base with a screw (Fig. 1).
0 WITHOUT HEATER
Fig.
RIGHT DUCT
1
-
Outside Air Vents
HOOD
NR165
ALIGNMENT
Prior to making any hood adjustment, inspect clearances and alignment of hood sides in relation to cowl, fenders and grille. The cowl adjustment must be made first.
REPLACEMENT
Removal
(1) Place a protective covering over cowl and fender area.
(2) Mark outline of hinges on hood to aid in installation.
(3) With an assistant, remove hinge-to-hood bolts
(Fig. 2) and remove hood assembly. Use extreme care not to permit hood to slide rearward and damage painted surfaces of the cowl and fender areas.
Installation
(1) With an assistant, position hood on hinges and install hinge to hood bolts. Do not tighten.
(2) Align scribe markings on hood with hinge and tighten screws lightly.
(3)
Close hood and inspect alignment.
(4) Adjust alignment (Fig. 2 and 3) as necessary and tighten hood to hinge bolts 180 inch-pounds.
( 5 ) Remove protective covering from cowl and fender area.
To adjust the latch (Fig. 4) loosen the attaching screws and raise or lower until the correct adjust- ment has been obtained. After.making any adjust- ment that requires a shifting of the hood, always inspect the hood striker and the lock plate assem- bly for alignment.
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3-64 VALIANT-SHEET METAL-DOORS
0
BUMPER
1
Fig. 3
-
Hood leveling Adiustment
79
- - J
NUT
Fig. 2
-
Hood Adiusfment
PY24
4
HOOD SAFETY
GRILLE
CROSSBAR
SCREW
Fig. 4
-
Hood latch and Release Handles.
SCREW
PY23
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0
VALIANT-SHEET METAL-DOORS 3-65
(3) Remove hood assembly.
(4) Remove torsion bars from center support and remove bars from end reinforcements.
( 5 ) Lubricate torsion bar rollers and install on hinges.
(6) Install hood assembly and adjust alignment.
NK914 B
Fig. 5
. REINFORCEME
-
Hood Torsion Bar's
HINGE REPLACEMENT
(1) Disengage torsion bar roller from hood hinge.
(2) Scribe hinge location on hood and remove hinge to hood screws.
(3) Support hood at hinge area.
(4) Remove hinge stud spring nuts from studs
(Fig. 2) and remove hinge.
( 5 ) Lubricate hinge stud areas with lubriplate and position hinge on studs.
(6) Using a socket with putty placed on end, position a new spring nut on putty and position on stud. Press spring nuts on studs using a screw driver. TORSION BAR REPLACEMENT
(1) Disengage the torsion bar roller (Fig. 5 ) from its seat on hood hinge by forcing the roller end of bar to the rear and raising hood fully.
(7) Remove hood support and position hinge on hood.
(8) Install hinge to hood screws and tighten to
(2) Disengage left hand torsion bar roller from 180 inch pounds after alignment has been hood hinge. accomplished.
(9) Engage torsion bar roller with hood hinge.
ALIGNMENT
FENDERS
(6) Remove fender assembly and if necessary re- move fender mouldings, ornamentation and head
The fender should be adjusted to provide for light assemblies. equal spacing at the cowl, door front edge and door panel top edge. Alignment should be made lnstullution at bottom of floor sill panel, front of hood and (1) Install head lamps, mouldings and ornamen- door outer panel upper edge. tation if removed.
(2) Carefully position fender on studs at cowl
REPLACEMENT
Removal
(1) Disconnect battery ground strap.
(2) Tape leading edge of front door and cowl to fender area to avoid damaging paint.
(3) Remove front bumper assembly.
(4) Disconnect head lamp wires and remove nuts attaching grille extension to fender.
( 5 ) Remove nuts and screws attaching fender to cowl, floor sill, wheelhouse or splash shields and radiator yoke (Fig. 6). side area and align fender with mounting holes in radiator yoke. Install all mounting screws and re- tainer nuts.
(3) With fender correctly positioned, tighten all screws and nuts securely making certain fender is aligned at cowl and hood areas.
(4) Connect head lamp wires and install grille to fender nuts. Connect the battery ground strap.
AIR SHIELD
AND
CROSS BAR
Refer to (Fig. 7) for air shield and cross bar attaching points.
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3-66 VALIANT-SHEET METAL-DOORS
HOOD BUMPER ADJUST b
DASH PANEL
SHIM
0
Fig. 6
-
Fender Aftachmenf
FRAME MEMBER
BRACE
YOKE
UPPER
OF ARROW Z
PY262
Fig. 7
-
Air Shield and Crossbar
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0
BUMPERS
ATZACHMENT
Refer to (Figs. 8 and points.
9) for bumper attaching
VALIANT-SHEET METAL-DOORS 3-67
PY263
Fig. 8
-
Front Bumper Applications
RADIATOR YOKE SUPPORT
REPLACEMENT
Removal
(1) Drain radiator and remove hoses from radiator.
(2) Remove radiator attaching screws and radiator.
(3) Remove hood lock striker bar, horn and headlamp wiring from yoke support.
(4) From under the fenders remove the wheel- house to yoke support attaching screws.
( 5 ) Remove support to frame attaching screws and remove radiator yoke support from engine com part men t
.
Installation
(1) Position yoke support into the engine compartment. Install the frame to core support screws finger tight.
(2) From under the fenders, install splash shield to yoke support screws finger tight only.
(3) When all attaching screws have been installed, tighten progressively.
(4) Attach the horn and lamp wires to the yoke support with the plastic straps.
( 5 ) Install radiator, hoses, fill cooling system and inspect for leaks.
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3-68 VALIANT-SHEET METAL-DOORS
e
GRILLE
held against the front face of the fenders at the
A
L
IGNMENT AND REPLA CEMENT outer edges to avoid stressing or fracturing. Cau-
Refer to (Fig. 10) for grille attaching points. tion should be used in protecting textured grilles
Align grille to frame opening. The grille must be from high temperature during repairs.
Fig. 10
-
Grille Assembly
DOORS
The service procedures for internal door compo- nents do not include obvious operations, such as removing door or quarter panel trim panels, test- ing operation of windows or inspecting glass fit after adjustments or replacement have been performed.
ALIGNMENT
Up and Down
Adjustment of the door can be made at either the pillar or door hinge halfs (Fig. 11).
In and Out
Adjustment is made at the door hinge half.
Adjust only one hinge at a time. Raising outer end of door moves upper part of door forward, when in closed position. Lowering lower part of door moves lower part forward, when in closed position. Fig. 11
-
Door Hinge Attachment
PY261
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3-70 VALIANT-SHEET METAL-DOORS
a
W
Fig. 13
NN605A
-
Remove Control Handle install hinge attaching screws finger tight only.
(3) Adjust jack to align hinge plate scribe marks and tighten attaching screws.
(4) Complete door aligning procedure, and install door interior trim and hardware.
Fig. 12
-
Latch and Striker Pin
REAR DOOR (All Models)
Fore and AH
Adjustment is made at the pillar hinge half.
Adjust only one hinge at a time. Raising outer end of door, moves upper part of door into door opening. Lowering outer end of door, moves lower part of door into door opening.
Removal
(1) Open rear door and place a padded jack un- der door near the hinges.
(2) Remove door interior trim and hardware.
(3) Scribe aligning marks around hinge plates on door frame.
(4) Remove hinge attaching screws from door and remove door from body. LATCH AND STRIKER PIN
The silent type door latch (Fig. 12) features a rubber isolation of the round striker pin on the door frame and those surfaces acting as stops in- side the latch. The latch assembly is built into a sheet metal pocket on the door face. The striker pin is attached by a single screw which also al- lows for adjusting. Proper torque is 40-60 foot pounds.
DOOR REPLACEMENT
Installation
(1) With rear door inner hardware installed, sup- port door on a padded jack and position door on hinges.
(2) Install attaching bolts finger tight.
(3) Align hinges with scribe marks.
(4) Tighten attaching screws and test door for alignment.
( 5 ) Install door interior trim and hardware.
Front Door
Removal
(1) With door in wide open position,
P1ac.c a jack, with a block of wood or Dad on lifting d a t e of jack, as near hinge as possi6le. (This wik i o l d weight of door a 1s hinge bolts are loosened.)
(2) Remove doc or interior trim and hardware.
(3) Scribe a lii ne around upper and lower hinge plates on door p tanel.
(4) Remove h inge attaching screws from door and remove d oor for further disassembly if necessary.
Installation
(All
Models)
.
.
(1) With door inner hardware door in position in door opening, padded jack.
(2) Locate door hinge plates on door panel and
+INGE REPLACEMENT
The door hinges (Fig. 11) are attached to the d loors by screws accessible from outside. The front
“A” post by three screws.
The rear door upper hinges are attached to the
“B” post by three screws accessil access hole in the
“B”
post.
INSIDE HANDLES
Window Regulator Handle
The window regulator handles
2 ire retained on
The handles
.. -
,
.
. . . _ ipproximately in installed, place a honzontal position with the knobs facing supported by a rearward.
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VALIANT-SHEET METAL-DOORS 3-71
Remote Control Handle
The remote control handle (Fig. 13) is attached to the control unit with a screw at the rear inner end. hand.
(7)
Install trim panel to door screws.
(8) Install escutcheon washer, handles and arm rest.
LOCK ASSEMBLY
ARM RESTS
The arm rests are retained by two metal screws inserted at the bottom of the arm rest base. The pad and base can be separated and if necessary, the pad may be recovered.
TRIM PANELS
Rem0 ve Control(Manual)
Removal
(1) Raise door glass.
(2) Remove screws attaching remote control base to door panel (Fig. 13 and 14).
(3) Remove link from remote control lever.
(4) Remove control through large opening in door.
Replacement
(1) Remove inside handles and arm rests.
(2) Remove screws attaching trim panel to door inner panel.
(3) Insert a wide blade screw driver between trim panel and door frame next to retaining clips and snap retaining clips out of door panel. Re- move trim panel.
(4) Before installing door trim panel, inspect condition of watershield.
( 5 ) Be certain the escutcheon spring is placed on the regulator shafts.
(6) Align trim panel retaining clips with holes of door frame and bump into place with heel of
Installation
(1) When installing the remote control assembly, coat parts with lubriplate.
(2) Install assembly through door opening and connect link to the control lever.
(3) Install attaching screw and test operation of control.
L
OCK REPLACEMENT
Removal
(1) Disconnect handle to lock link (Fig. 14) from lock by pulling link outward at lock.
LOCKING ROD
REAR DOOR
DOOR HAND
FRONT DOOR
Fig. 14
-
Front and Rear Door locking Mechanism
VIEW IN DIRECTION OF ARROW A
DOOR LATCH LINKAGE
PY271
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3-72 VALIANT-SHEET METAL-DOORS
0
'\
NR192
Fig. 15
-
Door Lock Cylinder
.
(2) Disconnect locking lever rod (front door only) from lock assembly.
(3) Disconnect locking rod link from lock.
(4) Remove screws attaching lock assembly to door.
( 5 ) Rotate lock assembly and disconnect remote control link when removing lock.
(6) Lubricate all moving points of lock assembly.
Installation
(1) Position lock assembly in door and connect remote control link to lock lever.
(2) Install lock retaining screws.
(3) Connect handle to lock link.
(4) Connect locking lever rod (front door only) to lock assembly.
( 5 ) Connect locking lever rod and remote control link to lock.
L OCK
CYLINDER
Removal
(1) With window in the up position, disconnect cylinder link (Fig. 15) from clip on lock lever (4 door only) and from cylinder.
(2) On 2 door models disconnect lock link from clip on lock lever, remove link control bracket mounting screws and remove cylinder link from cylinder.
(3) Remove retainer from cylinder body and cyl- inder from door.
Ins tat fat ion
(1) Position cylinder in door and install retainer on cylinder body.
(2) Connect the cylinder link to cylinder arm and to clip on lock lever (4 door models).
(3) On 2 door models connect cylinder link to cylinder, position link bracket on door face and install attaching screws. Connect lock link to lock.
Fig. 16
-
Front Door Handle
0UlSI.DE HANDLE-FRONl DOOR
Removal
(1) With door glass in up position, remove door handle attaching nuts from mounting studs (Fig.
16) and link from handle to lock.
(2) Lift handle up and remove from door.
Installation
(1) Install handle into door opening. Engage link from handle to lock.
(2) Attach retaining nuts and test operation of the handle.
OUlSlDE HANDLE-REA R DOOR
Removal
(1) With door open and glass in up position re- move retainer from link at handle connector.
(2) Depress outside handle release button and remove link from handle connector.
(3) Remove nuts attaching handle to door and remove handle.
Installation
(1) Position handle in door and install mounting nuts.
(2) Depress handle button and position link over
(3) Install retainer over link and connector.
WEA 1HERSlRIPS AND WINDCORDS
Door Weatherstrips
Make sure all old weatherstrip particles and ce- ment are removed before installing new weatherstrip.
Sedan Models
(1) Apply lower half of weatherstrip, starting at hinge face at belt line, working fasteners into holes in shut face of doors.
(2) Apply a 1/8 inch bead of cement to weath- erstrip seating area on door upper and lower areas.
(3) Install upper half of weatherstrip on door, indexing at the upper corners.
(4) Work weatherstrip from index points to a
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0 point midway between them. Avoid puckering or stretching of weatherstrip.
All Models (Except Sedan)
(1) Apply a coat of cement to weatherstrip con- tact area on vent wing, door inner and outer pan- els at belt line and to contact surface of weatherstrip.
(2) Position pillar seal on weatherstrip, making sure lip with two fasteners.
VALIANT-SHEET METAL-DOORS 3-73
strip can be moved in or out for the best possible fit and seal along the top edge of the vent frame, door glass and quarter glass.
The glass up-stop must be adjusted so the fully raised glass just curls the outer lip of weatherstrip against the inner lip.
When the up-stop roof rail weatherstrip and glass are properly adjusted, the outer lip of weath- erstrip will seal along the top edge of the glass and the inner lip of weatherstrip will seal along the upper inside edge of glass. Roof Rail Weatherstrip
Refer to Figure 17 for the attaching points and methods of cementing.
The weatherstrip retainers are adjustable through the use of elongated attaching holes. The weather-
Outer Belt Weatherstrip
The door outer belt weatherstrips are retained in the door panel with spring type retainers.
Fig.
-
Roof Rail Weatherstrip
DECK LID
also to aid in the aligning of the hinge screw holes when it is installed.
Alignment
The deck lid hinges (Fig. 18) permit only a very slight adjustment at the deck lid to hinge attach- ing points.
Hinge Replacement
Removal
Replacement
(1) Remove the deck lid assembly.
(2) Disengage the torsion bar roller from hinge
The deck lid is attached to the hinges by two being removed. Use care when disengaging torsion screws on each side. An assistant’s aid is recom- bar as it is under a load. mended when replacing the deck lid to prevent it (3) Remove spring nut (Fig. 18) retaining hinge from sliding rearward and damaging the paint and to hinge bracket and remove hinge.
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3-74 VALIANT-SHEET METAL DOORS
0
‘--
Fig. 18
-
Deck l i d Torsion Bar
NRl9l
Fig. 19
-
Deck l i d lock
Installation
(1) Insert bar into hinge support.
(2) Insert end of torsion bar into roller in hinge arm.
(3) Hook torsion bar into support bracket.
(4) Wind torsion bar and insert end of bar into first adjusting slot.
( 5 ) Place deck lid in various open positions and test tension of torsion bars.
(6) Adjust torsion bars progressively until deck lid stays in open position.
VIEW IN CIRCLE X
Fig. 20
-
YIEW IN CIRCLE Y
NPll4
Deck l i d Weofherstrip
Installotion
(1) Use a new spring nut and install hinge on hinge bracket.
(2) Install deck lid assembly and connect torsion bar.
Torsion Bar Replacement
Removal
(1) Remove torsion bar (underspring load) from adjustment slot (Fig. 18).
(2) Unwind torsion bar.
(3) Unhook torsion bar from support bracket.
(4) Push torsion bar out of roller in hinge arm and remove from hinge support.
Lock Replacement
The deck lid lock assembly (Fig. 19) is attached to the deck lid by two screws. Scribe the location of the lock mounting flanges to aid in installation.
Lock Adjustment
Vertical adjustment of the deck lid lock is made at the lock attaching screws. The side adjustment is made at the striker attaching bolts.
Lock Cylinder
The deck lid lock cylinder (Fig. 19) is retained in the body by a spring steel “U” shaped clip at- tached from within the body.
Weatherstrip
Apply an even continuous coat of cement to en- tire weatherstrip contact surface ing (Fig. of deck lid open-
20) and install weatherstrip. Make sure molded comers of weatherstrip are correctly positioned.
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INTERIOR T R I M AND SEATS 4-1
INTERIOR T R I M AND S E A T S
INDEX
CONSOLE
Page
....................................................................
18
COVER MATERIAL INSTALLATION
FLOOR COVERING
FRONT SEAT BACK LATCH
GLOVEBOX
Installation
Installation
.................
...............................
...............................................................
14
Installation
...............................................................
1 4
Removal
....................................................................
GARNISH MOULDINGS
........................................
1
...............................................................
2
GLOVE BOX LOCK
.................................................
2
...............................................................
18
1
14
2
3
Removal
....................................................................
2
HEADLINING
..............................................................
4
Fabric Type
..............................................................
4
Hard Board Lining
LINING SECTION
.....................................................
Installation
Removal
................................................
...............................................................
6
6
7
....................................................................
6
POWER SEATS
.........................................................
1 8
RECLINING SEAT MECHANISM
Bucket Type
REPLACEMENT
Front Seat
Rear Seat Back
.......................
.........................................................
................................................................
Page
1 2
............................................................
12
Installation
...............................................................
12
17
1 7
SAFETY BELTS
SEATS
......................................................
17
Rear Seat Cushion
...............................................
17
.........................................................
7
..........................................................................
1 2
Adjustment
..............................................................
12
SHELF TRIM PANEL
..............................................
7
Installation
...............................................................
7
Removal
....................................................................
7
SIX W A Y MANUAL SEAT
STATION WAGON
...................................
16
..................................................
Cushion
.....................................................................
Second Seat Back
17
1 8
................................................
1 7
Second Seat Cushion
..........................................
1 7
Third Seat Back
....................................................
1 8
Third Seat Back And Cover Panel
................
18
SERVICE PROCEDURES
INTERIOR TRIM
GARNISH MOULDINGS
When removing a garnish moulding that is over- lapped by an adjoining moulding, loosen the end attaching screw to prevent possible damage to both mouldings.
To assure correct alignment when installing the mouldings install the screws finger tight, align moulding at each end and tighten screws. Use care not to draw screws down too much or the moulding will be damaged at the screw holes.
Removal and installation procedures for the gar- nish mouldings are covered with the related component.
Floor Covering
To remove the rear floor covering it is necessary to remove the front seat assembly and the rear seat cushion. The front seat mounting brackets are positioned on top of both front and rear floor covers. The rear floor covering is positioned under the front covering.
On units equipped with consoles, the carpet must be assembled over the floor pan mounting brackets and/or shifting lever. The body wiring is posi- tioned through the holes in the carpet. The front edge of carpet is positioned under the rubber flap
Fig. 7
-
Glove Box
-
Valiant
Fig. 2
-
Glove Box
-
Satellite
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4-2 INTERIOR T R I M AND SEATS
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Fig. 3
-
Glove Box
-
Fury
Fig. 4
-
Glove Box Door
-
Valiant
NP568A
BUMPER-@
/--
Fig. 5
-
Glove Box Door
-
Satellite
NR349 on the cowl trim panel. With air conditioning, the carpet front edge must be positioned on front of the air conditioning housing flange and secured with the floor air outlet retainer bracket.
Glove
Box
The glove box is a one piece folded type (Figs.
1, 2, and 3).
Fig. 6
-
Glove Box Door
-
Fury
(3) Install glove box door assembly and attaching screws at top.
Glove Box Assembly (Barracuda)
The glove box is a two piece assembly.
(1) Position upper and lower assemblies together with screws. (Fig. 7).
(2) Install lamp lens.
(3) Position glove box to inner panel and secure with screws.
(4) Secure hinge to door.
( 5 ) Install glove box door bumpers to panel.
(6) Install glove box door lock latch catch to panel.
Removal
(1) Remove glove box door (Figs. 4, 5 , and 6).
(2) Remove screws attaching box to top and side areas of opening (Figs. 1, 2 and 3).
(3) Remove glove box from under and to rear of instrument panel.
/nstaflation
(1) From rear of instrument panel, position glove box in opening, making sure screw mounting holes are aligned.
(2) Install attaching screws at sides to hold in position.
Glove Box Lock
Prior to installing lock cylinder make sure tum- bler is in a retracted position and key inserted,
Removal is fully
(1) Open glove box door and put latch lever into lock position, insert key and turn to lock position (Fig. 8).
(2) Remove key and with a small pointed tool or screw driver depress tab located in lock hous- ing slot.
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INTERIOR T R I M AND SEATS 4-3
(3) Keep tab in depressed position insert key into lock and turn slightly to remove key cylinder.
Installation
(1) Install latch assembly to inner panel of glove box door.
(2) Insert lock and key into latch through glove box face. Turn key to unlatch lock and remove key.
(3) Depress tab and complete cylinder installation.
(4) Install glove box spring lock catch to upper flange of instrument panel.
( 5 ) Close door and align to panel, open door and tighten all screws.
Fig. 7
-
Glove Box Assembly -Barracuda
EY
BU
SECTION A-A
Fig. 8
-
Glove Box lock
-
ALL
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4-4 INTERIOR T R I M AND SEATS
EW
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Fig. 9
-
Glove Box Attachment
-
Chrysler
-
Imperial
Glove Box
- -
Imperial lnsiallaiion
Refer to Figure 9 for the glove box attaching points. The glove box consists of an upper and lower section and are attached into a single unit with screws.
HEADLINING
Rem0 vat-Fabric Type
(1) Remove rear seat cushion, dome light, bezel
A,!
4 DOOR
- W
NR347
Fig. I I
-
Listing Wire Retainers and lens, sun visors, rear view mirror and coat hooks.
(2) Remove headlining from cemented areas at windshield header and rear window opening.
(3) Remove headlining from under shelf panel.
(4) Using a dull bladed putty knife, disengage fabric from side rail retainer (Figs. 10, 11 and 12)
LISTING
WIRE RETAINER
HARDTOP
'
LISTING
WIRE RETAINER
REAR WINDOW
UPPER RETAINER
REAR WINDOW
SIDE RETAINER
Fig. 10
- listing Wire Retainers
HARDTOP
NU291
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INTERIOR T R I M AND SEATS 4-5
down and out. Work only small areas at a time.
( 5 ) Remove headlining at the windshield header and from fasteners at rear window area (Figs. 10 and 12).
(6) Remove listing wires from side rail retainers and support wire from rear listing wire (Figs. 13 and 14).
(7)
Remove all foreign material and cement from windhsield header area and rear window opening areas.
(8) Remove listing wires from headlining and insert in comparable listing of new liner.
Installation
(1) Trim excess listing material even with edges of headlining.
(2) Locate centerline of lining at front and rear ends, cut a small notch as an aid in maintaining headlining alignment during installation.
(3) Locate and mark the centerline points of windshield and rear window openings.
(4) Center headlining at rear window and insert rear listing wire to retainer clips on roof rail extensions.
NR346
Fig. 12
-
Rear Window Area Retainers by gently forcing material up and
( 5 ) Hook rear listing wire to wire supports and stretch material sufficiently to remove all wrinkles off of retainers while maintaining front to rear alignment. The and while maintaining pressure on fabric, pull same amount of material should hang down at
(UNDERSIDE SHOWN)
VIEW IN CIRCLE X h
Fig. 13
-
SOH Headlining
VIEW IN DIRECTION
OF ARROW Y VIEW IN CIRCLE Z
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4-6 INTERIOR T R I M AND SEATS
0 both sides.
(6) Insert remaining listing wires into roof side rail retainers following same cautions as in step 5.
(7) Apply cement to windshield header area and when cement becomes tacky, start at centerline area of windshield and position headlining on ce- mented area.
(8) Using a dull putty knife, secure liner on barbs at header area, do not install material at top of windshield posts making sure there are no wrinkles and fabric seam is straight.
(9) Locate sun visor mounting bracket screw holes in header and cut holes in headlining slight- ly larger than attaching screws.
(10) Install sun visors and tuck in cqrners of headlining at top of windshield posts.
(1 1) Locate rear visor mirror bracket screw holes, cut holes in fabric slightly larger than screws and install mirror.
(1 2) When installing headlining at side rail retainers, work only a small section at one time to make certain seams are straight and material is free of wrinkles.
(13) Using a dull putty knife and working alter- nately from side to side, install headlining on side rail retainers.
(14) Apply cement at rear window opening and to quarter panel area, and after cement becomes tacky, install headlining starting at top center and working outward and down the sides.
(15) Install rear seat cushion and coat hooks.
(16) Locate dome light opening cut out sufficient material for correct installation. Install dome lamp, bezel and lens.
HARD BOARD LINING
Retainer Moulding Replacement
The individual hard board headlining sections are held in position with semi-flexible type plastic mouldings (Figs. 15 and 16) forced over the re- tainer sections of the roof bows. Starting at either outer end, remove end cap and pry the moulding off retainer. When installing moulding make cer- tain it is fully seated and evenly spaced from side to side. Install end caps in retainer and over moulding ends.
Lining Section
To remove either the front or rear headlining sections, remove the windshield or rear window garnish mouldings and the one bow moulding at the panel inner edge.
Removal
(1) Remove plastic mouldings (Figs. 15 and 16)
OF ARROW W
RETAINER
QUARTER PANEL
(UNDERSIDE SHOWN)
Fig. 14
-
Soft Headlining
VIEW IN DIRECTION
OF ARROW Y
PY78
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OF RAIL
INTERIOR T R I M AND SEATS 4-7
PANEL # l \
PANEL #3\
PANEL #2,
A
ROOF RAIL
\
SPA'tK
--
PANEL
MOULDING
VIEW IN CIRCLE X
\ \
I
LSCREW
A
FINISH
MOULDING
UNER
Fig. s
OF ARROW V
IS
-
Hard Board Panel
-
Station Wagon
PANEL
VIEW IN DIRECTION
PP
D V 7 7 on roof bows.
(4) Install mouldings on bow retainers and caps over ends.
/ p 1 .
<--
- -
SIDE RAIL
RETAINERS
Fig. 16
-
Hard Board Headlining at edges of section being removed.
FASTENER
NN376
(2) Using a fibre tool force liner section off roof bow and out of side retainers.
(3) Inspect liner section for damaged edges.
Installation
(1) Position liner section on side retainers and in alignment with mating surface of roof bow.
(2) Push section up at center to seat it in side retainers.
(3) Align edges of section with moulding retainer
SAFETY BELTS
Refer to Figures 17 through 22 for methods and areas of attaching the safety belts.
SHELF TRIM PANEL
Removal
(1) Remove rear seat cushion and back.
(2) Remove defogger outlet and rear window side garnish mouldings.
(3) Loosen cemented edges of trim panel.
(4) Raise trim panel at front and remove retain- ers from shelf panel.
( 5 ) Slide trim panel forward and up to remove.
(6) Raise front edge of silencer pad and using a putty knife separate the silencer from cement. Re- move silencer.
(7) Remove all cement from shelf panel.
Installation
(1) Apply cement to same areas of shelf panel from which old cement was removed and install silencer pad.
(2) Install retainers in new trim panel.
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4-8 INTERIOR T R I M AND SEATS
(3) Slide trim panel into position and press re- tainers into shelf panel holes.
(4) Apply cement to shelf panel end extensions
0
and press into position.
(5) Install defogger outlet and window side gar- nish mouldings and rear seat assembly.
HARD TOP
VIEW IN CIRCLE X
STATION WAGON
’ .
VIEW IN DIRECTION OF ARROW Y
Fig.
VIEW IN CIRCLE Z
-
Front Seat Shoulder Belts
PY80
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4-10 INTERIOR T R I M AND SEATS
f i
BUCKET SFAT WITH
, I . . . . s .
CENTER ! CENTER
I
LAP BELT
(NOT USED ON BUCKET SEATS
WITH OR WITHOUT CONSOLE)
I
ALL BENCH SEAT APPLICATIONS
Fig. 20
-
Fmni S e d lap Beth
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INTERIOR T R I M AND SEATS 4-11
ANTI-RATTLE WASHER
VIEW IN CIRCLE U
VIEW IN CIRCLE W
VIEW IN CIRCLE X
NU20A
Fig. 21
-
Rear and Third Seat Lap Belts
STATION W A G O N
Fig. 22
-
Rear Seat Shoulder Belts
REINFORCEMENT
OUTER LAP BELT
VIEW IN CIRCLE X
SHOULDER BELT
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4-12 INTERIOR T R I M AND SEATS
0
SEATS
ADJUSTMENT
To raise or lower the front seat (Figs. 23 thru
26) loosen the adjuster mounting bolt nuts, under the floor pan, and remove or install shims be- tween the adjuster base and floor pan.
To move seat “fore or aft” reposition the adjus- ter mounting bolts in the adjuster base.
RECLINING SEA T MECHANISM
For east of assembling, the following procedures should be performed in sequence as listed.
BUCKET TYPE (Fig.
27)
(1) Before pad support, and cover are assembled, attach lever release to front recliner.
(2) Insert upper end of cable into hole in lever.
Attach cable and latch to front spring and cover using screw.
(3) Install spacer on rod end of adjuster (Figure
27). (Seat Cannot Be Assembled Without Spacer),
(4) Insert adjuster into back of recliner with clevis end on bracket and rod end protruding
ALLEN SCREW
CENTER CUSHION
Fig. 23
-
Front Seat Adjuster
-
Valiant
CENTER CUSHION
Fig. 24
-
Front Seat Adjuster
-
Satellite
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INTERIOR TRIM AND SEATS 4-13
SEAT FRAME
SEAT FRAME
Fig. 25
-
Front Seat Adiuster
-
Fury
KNOB
ADJUSTER\
I
T
I
I
I
I
3 t A I
'
ADJUSTABLE
(BUCKET)
-SCREW AND WASHER
HAND TIGHTEN
SCREW
AND WASHER
BELT
!
TWO WAY ADJUSTABLE SEAT
/NUT
Fig. 26
-
Front Seat Adiuster
-
Barracuda
FLOOR PAN
("C" MEMBER) v
BOLT/
-
LAP BELT TO FLOOR
(TYPICAL APPLICATION)
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4-14 INTERIOR T R I M AND SEATS
FRONT SEAT
BACK LEVER RELEASE
ING AND COVER
\
USTING WASHER
PIN
SPRl r i o d
WASHER
PY15
Fig. 27
-
Reclining Seat
-
Bucket Type through the opening in bottom recliner.
( 5 ) Align holes of clevis in adjuster, with hole in bracket on front recliner. Drive pin spring through bracket and sides of clevis on adjuster.
(6) Cut clearance hole in side facing of that the release handle shaft is accessible. cover so
(7) Place handle release on wire release. Slide release and washer spring onto the handle shaft, secure in place with ring retainer.
(8) Position pivot brackets on back spring. Align holes, and drive pin spring through holes in pivot bracket on each side of recliner.
(9) Position rod end of adjuster in corresponding stanchion on base and drive pin spring through holes in stanchion and rod.
(10) With recliner, cover, base and seat cushion assembled put back spring and cover in position.
Compress clip to free wire release. Press handle down as far as possible. Insert shim between ad- justing washer and cam and move lever release down until cam presses shim against adjusting washer. Release clip and remove shim.
(11) With handle in released position move re- cliner back spring and cover forward, as far as possible, and remove spacer.
(12) Raise and lower front recliner back spring and cover. Check operation and adjustment.
(13) Move front recliner forward. Pull flap on front recliner over base, and place hog ring to front recliner.
(14) Place inner end
Attach end of spring in latch pivot. of spring on forward tab of latch.
Slide latch and washer spring over latch pivot shaft and secure with ring retainer.
(15) Attach cable and latch to base using screw in lower attaching bracket.
(16) Attach cable and latch to zig-zag element, in front recliner using hog ring.
(17) Raise lever in front seat back to operate latch on cable. Check operation and alignment.
FRONT
SEA T BACK LA TCH-(Except
Barracuda)
All two door vehicles incorporate latches to pre- vent the seat back from falling forward (Fig. 28).
Removal
(1) Remove snap ring and flat washer from pi- vot pin.
(2) Remove end of spring from latch and re- move latch assembly.
(3) Remove spring from groove of pivot pin.
(4) Remove knob and clip from end of latch. lnst allation
(1) Position spring on pivot pin and align inner end of spring in pivot groove.
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(2) Install latch assembly on pivot pin and insert outer end of spring in notch on latch.
(3) Install flat washer and retainer firmly against latch assembly.
(4) Install clip and knob on latch.
Front Seat Back latch-Barracuda(Fig. 29)
(1) Install latch to back spring assembly before spring is trimmed. Insert bolt through back spring and into latch. (See view in direction of arrow Z).
(2) Trim back spring assembly.
(3) Install shield to trimmed back spring.
(4) Screw bumper assembly into back spring to
INTERIOR T R I M AND SEATS 4-15
KNOB
SCREW
/
ATTACHING
ESCUTCHEON
I
/‘ATERIAL
SEAT BACK
SET SCREW
Fig. 28
RELEASE LATCH CABLE
-
Front Seat Back Latch
-
Except Barracuda
HINGE ARM COVER
DIRECTION OF
(LOCK POSITION)
Fig. 29
-
Front Seat Back Latch
-
Barracuda within .87 in. of lower edge of lower cross mem- ber of back spring.
( 5 ) Fasten plate to trimmed cushion spring by inserting screw through plate and into cushion spring. Note difference in position for bucket seat and bench seat (See view in direction of arrow Y)
(6) Mount striker assembly to trimmed cushion spring by inserting bolt through slot in striker and hole in spacer and into tapping plate in cushion spring. Note: Difference in striker assembly and quantity of spacer required for bucket and bench seat. Striker assembly should be positioned so that bolt will be in mid-way position of slot.
(7) Mount trimmed back spring to trimmed cushion spring by installing pivot bolt through large hole in “Hockey Stick” and hole in washer and into weld nut in cushion spring.
(8) Attach cover to back spring by inserting screw through cover and into back spring. Note:
Difference in cover for bucket and bench seat.
(9) Attach cover to back spring by inserting screw through cover and into back spring.
Note: Rod on back side of buttun in cover passes through hole in “Hockey Stick.”
(10) Check operation of seat back latch by fold- ing back rearward to engage lock latch with rod on striker. Then press button on cover inboard. It
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4-16 INTERIOR T R I M AND SEATS
SEAT BACK
SEAT CUSHION\
0
CROSS MEMBER
CROSS MEMBER
PY697
Fig. 30
-
Six Way Manual Seat
-
Barracuda
SEAT BACK
Fig. 31
-
Reclining Seat Mechanism
-
4 Door Models should release the latch and allow the seat back to be folded forward. If latch does not engage rod, move striker forward. If latch does not disen- gage from rod, remove spacer and check operation of latch and re-position bumper as required.
Six Way Manual Seat (Fig. 30)
The plate should be mounted prior to carpet installation.
(1) Install plate assembly to floor pan.
(2) Install screw to plate.
(3) Install seat to floor pan after carpet installation.
(4) Install spacer to inboard holes of front and rear crossmembers.
( 5 ) Secure with nut to studs.
4 Door Models
Make certain spacer is installed on rod end of
Fig. 32
-
Rear Seat Cushion and Back adjuster assembly (Fig. 3
l),
otherwise seat cannot be assembled.
(1) Insert adjuster and cable assembly into rear of seat back, with clevis end of bracket and rod end protruding through hole in bottom facing of seat back.
(2) Route cable between edge of bottom facing and back spring frame of seat back. Do not use hole for adjuster rod.
(3) Position adjuster clevis end in bracket on seat back and secure with spring pin.
(4) Position seat back on cushion, with shoulder bolt on right side and pivot pin and push nut on left side.
( 5 ) Position cable to rear of seat cushion.
(6) Position adjuster rod end in cushion bracket and secure with spring pin.
(7) Slide fibre washer, release handle and spring washer over release shaft and secure in place with retaining ring.
(8) Push retainer pin through hole in release handle, slide eye of adjuster cable over pin and fasten with cotter pin.
(9) Slide retaining clip over cable housing and fasten to side of seat cushion with two screws fin- ger tight only.
(10) Insert .060 inch shim between release handle and bottom of seat cushion. Push release handle down firmly against shim and pull cable housing through retaining clip (away from handle) to re- move all slack.
(11) Tighten screw to lock sheath in retaining clip and remove shim.
(12) Raise seat back to upright position and move spacer from rod end of adjuster. re-
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/
INTERIOR T R I M AND SEATS 4-17
Fig. 33
-
Second Seat Back
PY96
PY97
Fig. 34
-
Second Seat Chshion tangs on the upper edge of the seat frame being positioned over hangers on the shelf panel. The lower edge of the seat back incorporates two met- al straps which are attached to mounting brackets welded to the rear floor pan.
STA
TION
WAGON-SECOND SEA
T
BACK
Removal
(1) Remove screws attaching seat back to hinge assemblies (Fig. 33).
(2) Release catches from seat back and remove assembly.
Installation
(1) Position seat back on hinge assemblies.
(2) Install hinge to seat back screws.
(3) Test engagement of seat back catches and adjust as necessary. Fig. 35
-
Third Seat Back and Cushion
(1 3) Test operation of mechanism.
REPLACEMENT
Front Seat
The front seat cushion is an integral part of the seat frame. All seat frames are attached to the adjusters by studs and nuts. Remove nuts from adjuster mounting bolts, under floor pan and re- move seat.
Rear Seat Cushion
The rear seat cushion is held in place (Fig. 32) by inserting the rear edge of the cushion under the seat back. The front lower frame of the seat incorporates retainers which fit into slotted brack- ets welded to the floor pan.
Rear S e d Back
The rear seat back (Fig. 32) is held in place by
SECOND SEAT CUSHION
Removal
(1) Raise rear floor hinged panel at rear of seat cushion assembly (Fig. 34) to expose seat cushion to floor pan attaching screws.
(2) Remove screws attaching cushion to floor pan.
(3) Move cushion slightly rearward to disengage locking bars at front bottom side of cushion and remove cushion.
Installation
(1) Place cushion in position, making certain locking bars at bottom are engaged in brackets on floor pan.
(2) Raise hinged portion of floor, at rear of seat cushion, and install screws attaching cushion mounting straps to floor pan.
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4-18 INTERIOR T R I M AND SEATS
THIRD SEAT BACK
Removal
(1) With third seat back in the UP position
(Fig. 3 5 ) remove the seat hinge links screws.
(2) Remove seat back and support panel assembly.
(3) The seat back cushion is retained with screws to the seat back panel.
Installation
(1) Position back cushion on back panel and in- stall retainer screws.
(2) Position seat back and support panel assem- bly on hinge links and install retaining screws.
CUSHION
The third seat cushion (Fig. 35) is attached to hinges which in turn are attached to the quarter inner panels by screws.
Removal
(1) Remove screws attaching hinges to quarter inner panel.
(2) Remove rear seat cushion assembly.
Installation
(1) Position cushion assembly on rear floor pan.
(2) Install hinges on quarter inner panel and tighten securely.
(3) Test seat operation, inspect fit and alignment.
THIRD SEAT BACK AND COVER PANEL
Refer to Figure 35 for the attaching points and method of attachment for the third seat back and cover panel assembly.
POWER SEATS
Refer to the Electrical Group for tests, wiring diagrams and complete servicing procedures.
COVER M A TERIA
L
INSTAL LA TION
Prior to installing the original or new cover, make certain the spring pad (where used) and pad cover are centered on the spring and are firmly attached. Make certain all buttons dnd medal- lions (where used) are pulled down securely and locked in position.
As an aid in attaching the cover correctly, mark the areas on the spring where the original cover was attached with hog rings, screws or drive nails.
CONSOLE
Consoles (Fig. 37 and 38) are attached to weld- ed brackets on the floor pan tunnel with screws and bolts. To loosen the rear mountings, raise, the carpet lower edges to expose the screw and bolt.
All other attaching screws are accessible from within the console.
R PAN BRACKET
VIEW IN CIRCLE S
VIEW IN CIRCLE U
D SEAT BACK
VIEW IN CIRCLE Z
VIEW IN CIRCLE V
REAR FLOOR PAN
COVER PANEL
RD SEAT BACK
ELEASE HANDLE
HANDLE FLOOR
INNER REAR PANEL
VIEW IN DIRECTION
OF ARROW Y VIEW IN CIRCLE Z fig. 36
-
Third Seat Back and Cover
OF ARROW T
SEALING WASHER
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INTERIOR T R I M AND SEATS 4-19
FINISH
PLATE
XREW
-
&NUT FRONT FINISH PLATE
Fig. 37
-
Console Attachment
-
Barracuda
CONSOLE ASSEMBLY
PY286
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Fig. 38
-
Console Adaptation
-
Chrysler
-
Plymouth
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EXTERIOR LIGHTING 5-1
ELECTRICAL
CONTENTS
Convertible Top
Electric Locks.......
Exterior Lighting
Power Seats
..............................................
....................................................
Page
53
40
1
50
Power Window, Power Vents
Specifications
Tailgate Washer..
Wiring
.....................
..............................................................
Page
46
57
54
62
HEADLIGHTS
INDEX
Compensating the Aimers
Measuring Headlight Aim
....................................
Page
2
General Information
................................................
1
Headlight Sealed-Beam Replacement
...............
4
3
Mounting and Adjusting the Aimers
...............
3
PraAiming Instructions
Service Diagnosis
.........................................
Page
2
1
Testing Aimer Calibration
....................................
3
Visual Headlight Adjustment4Without
Aimers)
.........................................................................
4
GENERAL INFORMATION
road, ditches, etc. On low beam, only the number two (2) bulbs operate.
Dual Headlight System
The dual headlight system consists of four sealed beam bulbs. The two outboard bulbs are of the two filament type for low and high beam. These bulbs are identified by a numeral (2) molded in the lens. The two inboard bulbs have only one filament and are marked by a numeral (1) molded in the glass.
The bulbs cannot be installed wrong as the mounting lugs for the number one ber two (2)
(1) and num- bulbs are offset at different angles.
On high beam, the number 1 bulbs provide the high intensity “reach” down the highway and the off focus filament in the number 2 light provides the “body” light which illuminates the side of the
Condition
HEADLIGHTS DIM (engine running above idle)
Single Headlight System
The single beam system consists of two sealed beam bulbs. The bulbs are the two filament type for low and high beam and are marked by a number 2 molded in the lens.
The low beam is intended for use in congested areas and on highways when meeting other vehi- cles within a distance of 500 feet. The high beam is intended primarily for distant illumination and for use on the open highway when not meeting other vehicles.
Manual on and off operation is controlled by a switch mounted on the instrument panel while manual operation of the high-low beam is con- trolled with a foot operated dimmer switch mounted on the left side of the floor pan.
SERVICE DIAGNOSIS
Possible Cause
(a) High resistance in lighting circuit.
(b) Faulty sealed beam units.
(c) Faulty voltage regulator.
Correction
(a) Test lighting circuit including ground connection. Make necessary repairs.
(b) Replace sealed beam units.
(c) Test voltage regulator and alternator. Make necessary repairs.
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5-2 EXTERIOR LIGHTING
Condition
LIGHTS FLICKER
LIGHTS BURN OUT
FREQUENTLY
LIGHTS WILL NOT LIGHT
HEADLIGHTS DIM (engine idling or shut off)
0
SERVICE DIAGNOSIS
Possible Cause
Loose connections or damaged wires i n lighting circuit.
Light wiring insulation damaged producing momentary short.
High voltage regulator setting.
Loose connections in light circuit.
Discharged battery.
Loose connections in lighting circuit.
Burned out lamps.
Open or corroded contacts in headlight switch.
Open or corroded contact in dimmer switch.
Partly disc ha rged battery.
Faulty battery.
High resistance in light circuit.
Faulty sealed beam units.
Corroded battery terminals.
Correction
Tighten connections and check for damaged wiring.
Test wiring and replace damaged wires. or tape
Test and replace voltage regulator if necessary.
Tighten connections.
Recharge battery and correct cause.
Tighten connections.
Replace bulbs or sealed beam unit.
Replace headlight switch.
Replace dimmer switch.
Charge battery.
Test battery. Replace if necessary.
Test headlight circuit including ground connection. Make necessary repairs.
Replace sealed beam units.
Clean terminals.
SERVICE PROCEDURES
assume its normal position.
PRE-AIMING INSTRUCTIONS
(1) Test dimmer switch operation.
(2) Observe operation of high beam indicator light mounted in instrument cluster.
(3) Inspect for badly rusted or faulty headlight assemblies. These conditions must be corrected be- fore a satisfactory adjustment can be made.
(4) Place vehicle on a level floor.
( 5 ) Adjust front suspension height as necessary.
(6) Inspect tire inflation.
(7) Rock vehicle sideways to allow vehicle to
(8) If gasoline tank is not full, place a weight in trunk of vehicle to simulate weight of a full tank
(6 1/2 pounds per gallon).
(9) There should be no other load in vehicle other than driver or substituted weight of approxi- mately 150 pounds placed in driver’s position.
(10) Remove each headlight trim panel. Do not remove sealed beam retainer rims.
(1 1) Thoroughly clean headlight lenses.
COMPENSATING THE AIMERS
(1) Place transit on floor in line with vertical centerline of right front wheel (Fig. 1). Place split image target in like position at right rear wheel.
(2) Adjust range screw on transit until target split image coincides or merges into one unbroken line. Make sure that the line of sight i s perpen-
Fig. I-Determining Slope o f Floor dicular from the eye to the viewing port of the transit and that the target image i s centered in viewing port of transit.
(3) Turn dial on side of transit until bubble in spirit level is centered.
(4) When bubble is centered, note “plus” or
“minus” reading on compensator scale. This figure indicates degree of slope of floor and must be transferred to each aimer.
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EXTERIOR LIGHTING
5-3
- -
Fig. 2-Adiusting Floor Level Compensators
KU433A
Fig. 3-Checking Aimer Calibration
HORIZONTAL ADJUSTING
VERTICAL ADJUSTING
SCREW
SCREW
\
Fig. 4Mounting and Adlusting Aimers
( 5 ) With a screw driver, turn adjusting slot of floor level compensator in each aimer, until cor- rect plus or minus figure (or fractional part) ap- pears in proper window, Fig. 2.
TESTING AlMER CALIBRATION (Fig. 3)
(1) Using carpenter or stone mason level of known accuracy, locate a true vertical plate glass window or smooth surface.
(2) Set DOWN-UP pointer on DOWN 2.
(3) Set RIGHT-LEFT pointer and floor level com- pensator at “0”.
(4) Secure aimers to glass or smooth surface three to five feet apart so split image targets can be located in viewing ports.
( 5 ) If bubble is centered in glass dial, vertical calibration is correct. If bubble is not centered, make DOWN-UP adjustment by rotating level ad- justing screw until bubble is centered in spirit level.
(6) The horizontal aim is correct if targets on opposite aimers are aligned in viewing ports. If targets are not aligned in viewing ports, rotate mirror adjusting screw until target split image be- comes aligned.
MOUNTING AND ADJUSTING THE AIMERS
(1) While holding an aimer in alignment with lens of one headlight on 2 headlamp models or the number (2) lens on 4 headlamp models, bring aimer up to and against headlight lens. Make cer- tain that headlight lens pads are making full contact with aimer mounting flange and that aimer target is facing inboard.
(2) Push release lever forward (to expel air from suction cup) and while holding aimer firmly against headlight aiming pads, slowly pull release lever back until spring lock engages in the slot,
(Fig. 4).
(3) Mount second aimer on other side of vehicle, in same manner.
(4) On each aimer, set pointer to numeral
DOWN side of the DOWN-UP scale.
2 on
(5) On each aimer, position the pointer, of the
RIGHT-LEFT scale, at 2-RIGHT.
MEASURING HEADLIGHT AIM
Horizontal Test
Turn the RIGHT-LEFT scale knob until the split image is in alignment. If the RIGHT or LEFT
PORTION of scale exceeds the following values, the lights should be aimed.
Values given represent inches a t 25 feet.
No. 1 Unit
No.2Unit
Left
. . . . . . . . . . . . . . . . . .
4
. . . . . . . . . . . . . . . . . .
0
Right
4
4
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5-4 EXTERIOR LIGHTING
VERTICAL ADJUSTMENT SCREWS
0
I
~ ~ 3 8 8 ~
NF689C
HORIZONTAL ADTUSTMENT SCREWS
Fig. SHeadlight Adiusting Points
Fig. &low Beam Adiustment Pattern
Vertical Test
Turn DOWN-UP scale knob until the spirit level is centered. If DOWN or UP portion of the scale exceeds the following values, the lights should be aimed.
No. 1 Unit
No. 2 Unit
. . . . . . . . . . . . . .
. . . . . . . . . . . . . .
1/2 to 3-1/2 down
1/2 to 3-1/2 down
Horizontal Adjustment
(1) With pointer of RIGHT-LEFT scale still set
2-RIGHT, sight through aimer viewing port. Make sure that line of sight is perpendicular from eye to viewing port of aimer and that target image is centered in viewing port of aimer.
(2) While sighting through viewing port of aimer, turn horizontal adjusting screw on headlight until split target image line merges into one un- broken line. To remove backlash, be sure to make a final adjustment by turning headlight horizontal adjusting screw in a clockwise direction, (Fig. 5).
(3) Make horizontal adjustment on other side of vehicle in same manner.
Fig.7-High Beam Ad/ustment Pattern
NP273A
Remove aimers by releasing spring lock at rear
(bottom) of aimer and pushing release lever forward. Do not attempt to remove the aimers by pulling away from headlight lens-slide suc- tion cup downward and away from lens.
(4) Install headlight trim panels.
Vertical Adjustment
(1) Turn vertical adjusting screw on headlight in counterclockwise direction to bring bubble of spirit level on aimer to vehicle side of center. Use care to avoid disturbing installed position of aimers.
Then turn screw clockwise until bubble is centered for correct aim and elimination of backlash.
(2) Make vertical adjustment on other side vehicle in same manner. of
(3) Inspect target alignment on each side and readjust the horizontal aim, if necessary.
Proceed to adjust number (1) bulbs on dual headlight systems by repeating outlined procedure.
SEALED BEAM REPLACEMENT (ALL
MODELS)
The lens, filament and reflector are sealed into one unit which can be removed as follows:
(1) Remove screws from headlight bezel and re- move bezel.
(2) Remove screws from interior retaining ring, and remove ring. Do not disturb headlight aimer screws.
(3) Pull out sealed beam unit and unplug connector, pulling straight off.
(4) Install new sealed beam unit.
( 5 ) Install unit retaining ring.
(6) Aim the headlight and install headlight bezel.
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EXTERIOR LIGHTING 5-5
VISUAL HEADLIGHT ADJUSTMENT
Low Beam
Place vehicle on a known level floor 25 feet from aiming screen or light colored wall.
Four lines are required on screen or wall (Fig.
6).
(a) A horizontal line at the level of centers of headlights, number 2.
(b) A center vertical line which must be lined up with center of hood, number 4.
(c) A vertical line on left of screen or wall in line with center line of left headlight, number 3.
(d) A vertical line on right of screen or wall in line with center line of right headlight, number 5 .
Remove headlight door. Adjust top adjusting screw for vertical adjustment, adjust side screw for horizontal adjustment. (See Fig. 5.)
Adjust low beam of headlights to match the pat- terns in Figure listed below:
6 and the corresponding numbers
(1) Lower beam pattern of both headlights.
(2) Horizontal line at level of headlight centers.
(3) Vertical line in line with center of left headlight.
(4) Vertical line in line with center of hood.
( 5 ) Vertical line in line with center of right headlight.
High Beam
Adjust high beam of headlights to match the patterns in Figure bers listed below:
7 and the corresponding num-
(1) High beam pattern of both headlights.
(2) Horizontal line at level of headlight centers.
(3) Vertical line in line with center of left headlight
.
(4) Vertical line in line with center of hood.
( 5 ) Vertical line in line with center of right headlight.
AUTOMATIC HEADLIGHT BEAM CHANGER
combination dimmer-over-ride type foot switch
GENERAL INFORMATION
mounted on the conventional dimmer switch
The automatic beam changer is an automatic location. headlight control unit which senses the light inten- The over-ride foot switch replaces the standard sity from approaching vehicles and automatically adjusts the headlights to a high or low beam. foot dimmer switch. One position of the over-ride foot switch provides automatic control of the
The automatic beam changer will dim the head- lights when an oncoming car with headlights on low beam is seen at a distance of approximately
1200 feet. The unit will return the headlights to high beam within approximately one-half second after the approaching car has passed.
Major components of the automatic beam chan- ger are: a photo-amplifier unit, a power relay, a foot switch, a sensitivity control (driver control), and an interconnecting wire harness (Fig. 1).
The photo-amplifier unit combines a light sensing optical device and a transistorized amplifier into one unit with sufficient power to operate a power relay for switching headlight beams. The unit is mounted under the hood just ahead of the radia- tor cradle assembly. A level assembly for use in setting correct vertical aim is attached as part of the unit. Do Not Disturb Factory Calibration of level.
The power relay is a single pole, double throw twelve volt unit which provides for switching the headlight beams. The upper beam position is the
“normally closed” position. The power relay is mounted on the front floor pan just above the headlight beams. The other position provides low beam only.
In the automatic position, partially depressing the foot switch provides an over-riding high beam as long as the switch is held in this position. Auto- matic operation is restored when the driver releas- es the foot switch.
An in-line 4 ampere fuse is also incorporated into the wire harness. If this fuse should blow, the circuit will revert to manual control of the headlight beams by means of the foot switch.
A sensitivity control is located on the instrument panel to the right of the light switch. See Fig. 1 and Headlamp Sentinel and Headlamp Dimmer
Wiring diagrams under “Wiring Diagrams.” This unit provides a driver sensitivity adjustment. Ro- tating the knob clockwise increases sensitivity and headlights will switch to low beam when an ap- proaching car is farther away. Rotating the knob counterclockwise toward the word off decreases sensitivity, allowing an approaching car to come nearer before switching occurs. The extreme coun- terclockwise position of the control is an “Of€” position and gives manual control of the headlight beams by means of the foot switch.
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5-6 EXTERIOR LIGHTING
PHOTO-
5
OFF
DRIVER CONTROL
(SENSITIVITY CONTROL]
MAKE SURE UNIT IS
GROUNDED TO CAR
BODY BEFORE TURNING
SYSTEM ON
1
I
GYIBLK
FOOT DIMMER
SWITCH
I
COLOR CODE
~~
BLK BLACK
DGN DARK GREEN
GY GRAY
GY/BLK* GRAY WITH BLACK STRIPE
N.C.
LBL LIGHT BLUE
LGN LIGHT GREEN
N.C NO CONNECTION
TO HEADLAMP-UPPER
BEAM FILAMENTS
TO
HEADLAMP
SWITCH
R RED
V VIOLET OR PURPLE v/w*
VIOLET WITH WHITE STRIPE
SEE NOTE t
TO HEADLAMP LOWER
BEAM FILAMENTS
\Fu WHITE OR NATURAL
I
*
I
WITH TRACER
SYMBOLS f WIRES CROSSING (NO SPLICE)
4
TERMINAL
<
PUSH-ON CONNECTOR-FEMALE TERMINAL
3.1
+.;
MALE TERMINALS
*:
FEMALE TERMINAL
I-
NOTE-POWER RELAY CONTAINS DAMPENING DIODE TO PROTECT PHOTO-AMPLIFIER FROM POWER RELAY SURGES
DURING SWITCHING.
CAUTION-REPLACE POWER RELAY WITH EXACT PART NUMBER ONLY, SUBSTITUTION OF
PART NUMBER WILL PROBABLY RESULT IN A RUINED PHOTO-AMPLIFIER.
N U W
Fig. I-A ufomafic Headlamp Beam Changer Wiring Diagram-Schematic
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EXTERIOR LIGHTING 5-7
Place the vehicle in a well lighted area. Start the engine and operate at fast idle (Note this transis- torized unit does not require a warm-up time).
Trouble shoot the wiring, foot switch, driver sensi- tivity control and power relay with a 12 volt bat- tery and test lamp equipped with a number 53 bulb (one candle power). The test procedures must be performed in the sequence as outlined below:
(1) Set the sensitivity control knob to approxi- mate center of its rotation.
(2) Turn the headlight switch “On”; headlights should remain on lower beam in both positions of the foot dimmer switch. If not see “Condition 1.”
(3) Depress foot switch slightly. If high beams come on, the switch is in “Automatic” position. If high beams do not come on, completely depress and release foot switch to put it in “Automatic” position. Depressing foot switch slightly should cause lights to switch to high beam. If not see
“Condition 2”.
(4) With the foot switch in “Automatic” position, cover the photo-amplifier with a black cloth; headlights should switch to high beam. If not see “Condition 3”.
( 5 ) Remove the black cloth from the photo-amplifier; headlights should return to low beam. If not see “Condition 4”.
(6) With headlights on “Automatic” lower beam, rotate driver control counterclockwise to “off’ position; headlights should switch to high beam. If not see “Condition 5.”
(7) Fully depress foot switch to the manual position; headlights should switch to low beam. If not see “Condition 6”.
Condition
SERVICE DIAGNOSIS
Possible Cause Correction
WHEN HEADLIGHT SWITCH IS
TURNED “ON”, AND LOW
BEAM IS NOT OBTAINED IN
BOTH POSITIONS OF FOOT
DIMMER SWITCH.
(a) Driver control rotated t o “off“ position.
(b) Loose or wrong connection a t foot switch, power relay, and driver control or photo-amplifier connectors.
(c) Incomplete ground on photo-a m pl if ier.
(d) Poor ground a t power relay or defective power relay.
(a) Set control t o center of rotation and check owner understanding.
(b) See Fig. 1 and check all connections.
(c) Check ground.
(d) (1) check ground.
(e) Blown fuse.
(f) Defective connection control. t o driver control or defective driver
(2) Replace defective power relay.
(e) See Fig. 1 and continuity check
(f) for blown fuse.
See Fig. 1 and continuity check for:
FOOT SWITCH FAILS TO
GIVE OVERRIDE HIGH BEAM
WHEN SLIGHTLY DEPRESSED.
(9) Faulty photo-amplifier.
(a) Faulty foot switch.
HEADLIGHTS DON’T GO
HIGH BEAM WHEN
PHOTO-AMPLIFIER IS IN
TO
COMPLETE DARKNESS (WITH
FOOT SWITCH IN
AUTOMATIC POSITION)
(b) Driver control not grounded.
(c) Faulty photo-amplifier.
(a) Wrong connection a t power relay.
(b) Faulty photo-amplifier.
(1 ) Defective connection.
(2) Open driver control.
(9) Replace faulty photo-amplifier.
(a) Ground L-9 (Dark Green) wire a t foot switch; if lights go to high beam, replace foot switch.
(b) Check ground.
(c) Replace photo-amplifier.
(a) Check for reversed connection a t power relay.
(b) Disconnect photo-amplifier a t three way connector. If headlights switch t o high beam replace faulty photo-amplifier.
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Condition
SERVICE DIAGNOSIS
Possible Cause Correction
(a) Aim photo-amplifier.
HEADLIGHTS FAIL TO GO TO
LOW WHEN MEETING OTHER
HEADLIGHTS.
(a) Photo-amplifier improperly aimed.
(b) Loose, disconnected or broken photo-amplifier wiring.
(c) Blown fuse.
(d) Faulty foot switch wiring.
(e) Faulty wiring.
(f) Faulty photo-amplifier.
(b) Check all connectors. See
Figure 1.
(c) Replace fuse. Correct condition causing fuse t o blow.
(d) Check for loose connections or open circuit in foot switch wiring. Replace if necessary.
See Figure 1.
(e) Check wiring for open circuit, loose or incorrect connections.
(f) Replace faulty photo-amplifier.
HEADLIGHTS ON
“AUTOMATIC” LOWER
BEAM, ROTATING DRIVER’S
C 0 T R 0 L
COUNTERCLOCKWISE
“OFF” POSITION,
TO
HEADLIGHTS WILL NOT
SWITCH TO HIGH BEAM.
HEADLIGHTS FAIL TO GO TO
LOW BEAM WHEN FOOT
SWITCH IS COMPLETELY
DEPRESSED TO MANUAL
POSITION.
(a) Faulty ground on drivers control.
(a) Faulty wiring i n foot switch circuit.
(b) Faulty foot switch.
(a) Check ground t o instrument panel.
(a) Inspect for loose connections or open circuit, in wiring from foot switch t o power relay.
SERVICE PROCEDURES
(b) Replace faulty foot switch.
PHOTO-AMPLIFIER (Fig. 2)
Aiming
Performance of the automatic beam changer is dependent on the proper vertical adjustment of the photo-amplifier. If the unit is aimed too low, re- flected road light from the car’s own headlights will cause the unit to “Hold” the headlight on lower beam.
(1) Place the vehicle on level floor.
(2) Check tire inflation: tire pressure should not vary more than 3 to 5 pounds.
(3) Rock the vehicle sideways to allow the springs and other suspension parts to assume nor- mal position.
(4) Fuel tank must be at least half full with trunk empty except for spare tire.
( 5 ) Raise car hood.
(6) Adjust vertical aiming screw at front of pho- to-amplifier unit until level bubble is centered,
(Fig. 3). Always make final adjustment while turning screw clockwise.
Removal
(1) Disconnect battery ground cable.
(2) Disconnect photo-amplifier harness at connector.
(3) Remove two screws attaching photo-amplifier mounting bracket to radiator grille yoke bracket brace (Chrysler), fender headlamp mounting plate
(Imperial) and remove photo-amplifier and mount- ing bracket to work bench for disassembly.
(4) Remove the adjusting screw from the photo-ampli fier.
( 5 ) Remove the tension spring and remove the photo-ampli fier.
Installation
(1) Position the photo-amplifier on the mounting bracket and install adjusting screw.
(2) Install the tension spring.
(3) Install the photo-amplifier and support brack- et to fender headlamp mounting plate (Imperial); radiator grille yoke bracket brace (Chrysler).
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I
VIEW IN DIRECTION
OF ARROW A -
VIEW IN DIRECTION OF ARROW
Fia. 2-Photo-Amplifier Installed
1
B NU537
FOOT DIMMER
NU540A
Fig. 4-Power Relay
Fig. 3-Aiming the Scanner
Tighten screws to
10 inch-pounds.
35 inch-pounds plus or minus
(4) Aim photo-amplifier see “Aiming”.
( 5 ) Connect harness at connector.
(6) Connect battery ground cable and test opera- tion of system.
POWER RELAY (Fig. 4)
Removal
(1) Disconnect battery ground cable.
(2) Disconnect harness from relay.
(3) Remove two screws attaching relay to dash panel and remove relay.
Inst allation
(1) Position relay on dash panel and install the two attaching screws.
(2) Connect harness connector at relay.
(3) Connect battery ground cable and test opera- tion of system.
FOOT SWITCH
Removal
(1) Disconnect battery ground cable.
(2) Raise carpet and disconnect wire harness connectors from switch.
(3) Remove the switch mounting screws and re- move switch. lnsf allation
(1) Connect wire harness connectors to switch.
(2) Position switch on floor pan and install atta- ching screws.
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(3) Connect battery ground cable and test opera- tion of system.
SENSITIVITY CONTROL SWITCH
REPLACEMENT
This switch is coaxial with the Safeguard Senti- nel Time Delay Control Switch. For replacement see instructions under “Safeguard Sentinel.”
SAFEGUARD SENTINEL LIGHTING SYSTEM
INDEX
Amplifier
General Information
Photocell
......................................................................
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Page
1
1
3
o
1 3
Service Diagnosis
Tests
Time Delay Control Switch
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Page
10
1 2
1 2
GENERAL INFORMATION
The Safeguard Sentinel Lighting System is a light sensing device that automatically controls the use of the driving lights after the ignition key is turned on. The system automatically activates the taillights and the headlights when the light intensi- ty outside the car requires road illumination. If light intensity reaches a point (selected by the driver with the sensitivity control located on the photocell), when the lights are no longer needed, the Sentinel turns them off. In periods of darkness, the headlights and taillights will remain on and the back-up lights will come on for a pe- riod of from one to three minutes after the igni- tion key is turned off depending on the desired setting of the Time Delay Control Switch. The system can be disconnected at anytime by turning the knob to “OFF”. Use of the driving lights is then controlled by the headlight switch.
Three units control the system. See “Wiring
Diagrams”. The time control switch is mounted on the lower part of the instrument panel adjacent to the headlight switch. Turning the knob on acti- vates the system. The headlight switch remains turned off. Rotating the control knob clockwise increases the period of time the driving lights re- main on after the ignition key is turned off.
The photocell, mounted on the top left side of the instrument panel pad, may be adjusted by the driver to automatically determine when the degree of light outside of the car will require the use of the driving lights. Turning the control clockwise decreases the sensitivity of the cell to light. Rotat- ing the knob counterclockwise increases the sensi- tivity and will turn the lights on earlier.
The amplifier is mounted under the right side of the instrument panel on the heater plenum cham- ber flange. This unit receives the signals from the photocell and control knob and activates the head- light circuit accordingly. The entire Safeguard cir- cuit is grounded through the Time Delay switch.
When the switch is in the “OFF” position, a mal- function of any of the sentinel components cannot interfere with normal operation of headlight switch see “Wiring Diagram”.
The backup lights will light regardless of the position of the time control switch when the head- light switch is turned on with the ignition key off.
They will go out when the ignition key is turned on.
The circuit breaker in the headlight switch pro- tects the headlight circuit during normal manual operation. When the Safeguard time control switch is turned on, the headlight switch is by-passed.
Therefore a second circuit breaker, mounted in the amplifier, protects the headlight circuit.
Before any tests are made, it should be deter- mined that all ually first. It driving lights are operating man- is important that the steps in the service diagnosis be performed in the sequence shown for each condition. Refer to “Wiring
Diagrams” for wiring circuits.
SERVICE DIAGNOSIS
Condition Possible Cause
LIGHTS FAIL TO LIGHT
AUTOMATICALLY IN PERIODS
OF DARKNESS
(a) Loose connections.
(b) Poorly grounded time control switch.
Correction
(a) Test continuity of all circuits and repair as necessary.
(b) Remove switch bezel and clean paint from instrument panel under bezel.
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EXTERIOR LIGHTING 5-1 1
SERVICE DIAGNOSIS
Condition Possible Cause
(c) Faulty time control switch.
Correction
(d) Faulty photocell.
(e) Faulty amplifier.
(c) Jump white wire (X-7) a t switch t o a good ground. If lights light, replace switch.
(d) Remove X-19 wire (gray) from black connector. Connect connector and if lights light replace photocell.
(e) Disconnect multiple connector a t amplifier and jump from red
(X-17) t o blue (X-5) in body wiring side of connector. If lights light, replace amplifier.
(a) Instruct owner in the proper use of system.
LIGHTS FAIL TO TURN OFF
AUTOMATICALLY IN PERIODS
OF LIGHT
(a) Photocell covered up.
(b) Loose connections in photocell circuit.
(c) Faulty photocell.
(d) Faulty amplifier.
(b) Check and tighten wire connector at photocell.
(c) Test photocell by jumping gray
(X-19) and black (X-20) wires a t amplifier multiple connector.
Replace photocell if lights go off.
(d) Disconnect multiple connector a t amplifier. If lights go out, replace amplifier.
(a) Test circuit for short and replace fuse.
LIGHTS TURN OFF
IMMEDIATELY AFTER
IGNITION SWITCH I S TURNED
OFF
(a) Taillight fuse blown.
LIGHTS REMAIN ON TOO
LONG AFTER IGNITION
SWITCH I S TURNED OFF
(b) Short circuit between X-16 and
X-8 wires of time control switch.
(c) Faulty time control switch.
(b) Repair as necessary.
(d) Faulty amplifier.
(a) Loose connection in yellow wire
(X-16) or light green wire (X-8).
(c) Test with switch known t o be good. (Be sure t o ground switch.) Replace if necessary.
(d) Test with amplifier known t o be good. Replace i f necessary.
(a) Repair as necessary.
(b) Faulty time control switch.
BACKUP LIGHTS FAIL
LIGHT
TO
BACKUP LIGHTS LIGHT
MANUALLY BUT
DURING
NOT
TIME DELAY
(c) Faulty amplifier.
(a) Loose wire connections.
(b) Open windshield wiper circuit breaker.
(c) Faulty amplifier.
(a) Faulty amplifier.
(b) Test with switch known t o be good. (Be sure t o ground switch.) Replace if necessary.
(c) Test with amplifier known t o be good. Replace if necessary.
(a) Test continuity of violet wire
(X-9) and violet wire with white tracer (8-2). Repair as necessary.
(b) Test operation of windshield wipers. If inoperative, test for short circuit and repair as necessary.
(c) Jump violet wire (X-9) t o violet wire with white tracer (B2A) at amplifier. If backup lights light, replace amplifier.
(a) Disconnect violet wire with white tracer (8-2) a t amplifier.
I f lights turn off, replace amplifier.
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5-12 EXTERIOR LIGHTING
Boq
AMPLIFIER ASSEMBLY
0
NU535
Fig. 1-Photo Cell Installation
TESTS
Before testing any part of the Safeguard Sentinel
Lighting System, it should first be determined that the exterior lighting system of the vehicle is oper- ating properly. Turn on the headlights, and visual- ly test the operation of the lights. The backup lights should light regardless of the position of the time control switch or the gear selector and go out when the ignition key is turned on.
After testing the manual operation of the light- ing system, inspect the multiple connectors at the amplifier, the photocell and the time control switch to be sure they are tight and making good contact. If connections are tight, continuity of the entire wire harness should be tested with an ohmmeter.
Should the automatic operation fail, test the time control switch for a good ground. Place a jumper wire from the switch bezel or knob to a good body ground and test the operation of the system.
If the system operates properly, remove the switch bezel and clean the paint from the instrument panel, under the bezel, and reinstall the bezel.
The photocell amplifier and control switch are not to be serviced. If one or the other is defective, it should be replaced.
Photocell (Fig.
1)
If the lights fail to light automatically after dark, test the photocell by covering with a dark cloth.
Start the engine, turn on the time control switch and turn off the headlight switch. If the head- lights and taillights do not light within a few seconds, uncouple the muliple connector at the
Fig. 2-Ampiifier tnstaiiation amplifier. Remove the gray wire connector leading to the body wiring and recouple the connector. If the lights light, replace the pho- tocell and reinstall the gray wire connector.
Should the lights fail to automatically turn off at day break, shine a bright light into the photocell.
Rotate the cap to the centered position between the “Early” and “Late” position. If the lights light, the cap was rotated too far blocking off light to the cell through the window in the cap
(Fig. 1). Instruct the owner in the proper use of the Safeguard Lighting System.
If the sensitivity adjustment of the cap still fails to correct the operation, test the photocell by placing a jumper wire from the gray wire (X-19) to the black wire will close the photocell circuit and the lights should turn off. If they do, replace the photocell.
Time Delay Control Switch
Always test the time delay control switch for a good ground to the instrument panel before condemning the switch.
Ground the switch by connecting a jumper wire from the knob of the switch to a good body ground. Test the operation of the system. If the system operated properly, remove the switch bezel and clean the paint from the panel so a good contact will be made when the bezel is installed.
If the lights fail to turn off automatically after the ignition is turned off and the photocell test is positive, test the switch by jumping the yellow wire switch. If the lights turn off, replace the switch.
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EXTERIOR LIGHTING 5-13
Should the lights turn ignition key is turned off immediately after the off, (no time delay) regard- less of the time control setting, inspect the tail- light fuse. If the fuse is not blown; test for short in switch.
See “Instrument Cluster Removal”, Electrical
Group 8. After removing the cluster bezel proceed as follows:
(1) Rotate knob till set screw is visible, loosen set screw and remove knob.
(2) Remove bezel nut with Tool C-3824 and re- move switch from back of bezel. Amplifier
Should the lights fail to light automatically, and the photocell and switch tests are positive, the amplifier should be tested as follows:
Remove the amplifier from the heater plenum chamber flange and disconnect the multiple con- nector (Fig. 2). Place a jumper wire from the red wire connector on the body wiring side. light, replace the amplifier.
Should the lights fail to turn off
If the lights automatically at day break and the photocell and time delay switch tests are positive, disconnect the multiple connec- tor at the amplifier. If the lights go out, replace the amplifier.
Failure of the lights to turn when the ignition key is turned turn off automatically off or the lights off immediately regardless of time control setting of the switch, test with an amplifier known to be good. If lights operate properly, replace the amplifier.
PHOTOCELL
Removal
(1) Disconnect battery ground cable.
(2) Remove steering column cover and left spot cooler hose from distribution duct if air condition- ing equipped.
(3) From under panel, disconnect photocell con- nector (black and gray wires (Fig.
l),
and remove tinnerman clip from photocell base with a small screw driver. Pull photocell up through mounting hole, cut wires and remove.
Installation
(1) From top of instrument panel, feed photocell wires through mounting hole.
(2) Hold photocell in place on panel, press tin- nerman clip on photocell base from under panel
(Fig. 1).
(3) Install connector insulator on wire terminals.
(4) Couple connectors and install steering column cover.
( 5 ) Install left spot cooler hose to distribution duct if air conditioning equipped.
(6) Connect battery ground cable and test opera- tion of light system.
TIME DELAY CONTROL SWITCH
Removal
To service the time delay control switch, it is necessary to remove the instrument cluster bezel.
Installation
(1) Position switch in bezel and install bezel nut with Tool C-3824.
(2) Position knob on switch and tighten set screw.
(3) Install instrument cluster bezel as outlined in
“Instrument Cluster Installation” in Electrical,
Group 8.
AMPLIFIER
Removal
Remove the two nuts retaining the amplifier bracket to the right fresh air vent flange and low- er assembly far enough to disconnect multiple connector. Remove two self tapping screws from bracket to separate from amplifier.
Installation
Assemble the bracket to the amplifier with the two self tapping screws and bolt the assembly to the right fresh air vent flange. Connect the multi- ple connector and the battery ground cable. Test the operation of the Sentinel.
ROAD LAMPS-BARRACUDA
Removal (Right or Left)
(1) From under front bumper disconnect lamp wires at connector and ground connection (Fig. 1).
BOLT NUT ASSEMBLY r
Fig. I-Rood lamp Mounting
PY928
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Fig. 24-d Lamp Aiming Chad
(2) Remove one nut and washer attaching lamp to lamp mounting bracket and remove lamp assembly.
Installation
(1) Position lamp on mounting bracket and in- stall attaching nut and washer.
(2) Connect wire at connector and to ground.
(3) Check road lamp aiming.
ROAD LAMP AIMING (Fig. 2)
Place the vehicle on a level area 25 feet from an aiming screen or light colored wall.
(1) Inspect tires for proper inflation.
(2) If the gas tank is not full, place a weight in trunk of vehicle to simulate the weight of a full tank of gas. (Gas is 6-1/2 pounds per gallon).
(3) Adjust front suspension to proper height.
(4) Rock the vehicle sideways to allow vehicle to assume its normal position.
Draw two road lamp aiming charts on the screen as follows:
(1) Line A horizontal line at the same level as the center line of road lamps.
(2) Line B vertical line that is lined up with the center line of each road lamp.
(3) Line C horizontal line 2 inches below line A.
(4) Line D horizontal line 7-1/2 inches below line A.
( 5 ) Line line B.
E vertical lines 6 inches each side of
(6) Line F horizontal line 4 inches below line A.
Turn on the road lights. Each road lamp should be adjusted to its own aiming pattern as follows:
(1) Loosen the housing mounting nut, this will allow the assembly to swivel (Fig. 1).
(2) The upper edge of the high intensity zones should fall between horizontal lines C and D.
(3) Center the high intensity zone between line
E.
The preferred position of the high intensity zone upper edge should fall at line F. After lamps are properly adjusted tighten housing mounting nut.
FRONT END LIGHTING (EXCEPT HEADLIGHTS)
General Information
placed in a plastic part wire is necessary. so that an added ground
It is important to have this wire
A good ground is mandatory for proper light securely connected to a good ground. operation. This is provided through the lamp When changing bulbs check socket for corrosion. socket to housing to the vehicle in most cases. If corrosion is present clean it off with a wire
However, in some installations the housing may be brush and coat the socket lightly with any good multi-purpose grease.
SERVICE PROCEDURES
Front Fender Turn Signal Indicator-Valiant,
Barracuda, Satellite and Fury (Fig. 1).
Removak-
(1) Disconnect lamp socket connector from har- ness connector.
(2) From under front fender remove one capnut and one clip.
(3) Remove lamp assembly from under fender.
To replace bulb, unscrew lens from socket and lift out bulb.
Installation:-
(1) Enter lamp assembly through hole from un- der fender.
(2) Position welt and cover over lamp assembly and install clip.
(3) Install attaching nut and connect lamp con- nector to harness.
Removal:
(1) Disconnect lamp socket from harness.
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e
EXTERIOR LIGHTING 5-1 5
STUD
I ;
I
FENDER PANEL
@-LENS
I
I
WGASKET
SOCKET AND CABLE
3 C T A I M E D
TAINER
EALING
WASHER
I
I
PB184
Fig. 7
-
Front Fender Turn Signal Indicator Valiant,
Barracuda, Satellite and Fury off ( 2 ) Remove screw from lamp cover and lift cover.
(3)
Lift out lens assembly.
Fig.
WELT
' 0 /
CAPNUTS PB185
2
-
Front Fender Turn Signal Indicators Fury
(4) To remove applique, bezel and welt, remove two capnuts from under fender. To replace bulb, unscrew lens from socket and lift out bulb.
COVER
LAMP CONNECTOR
Fig. 3
-
Front Fender Turn Signal Indicator Chrysler
NU641
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5-1 6 EXTERIOR LIGHTING
TURN SIGNAL
INDICATOR
LAMP ASSEMBLY
\
COVER
STUD
LENs*i
RETAINER
(2) Secure with two capnuts.
(3) Install lens assembly and position cover.
(4) Install cover screw.
Front Fender Turn Signal
(Fig. 3)
Indicators-Chrysler
WELT
I i~ from front end wiring
Removal:-
(1) Disconnect lamp lead harness.
(2) Remove one screw attaching lamp cover to fender.
(3) Lift chrome strip. r::
AND CABLE
Pull lamp and wire assembly up and out of
To replace bulb, remove one screw attaching lamp bracket to lamp cover; snapout lamp lens insert, lift out bulb and replace.
FRONT
FENDER (REFERENCE)
Fig. 4
NU601
-
Front Fender Turn Signal Indicator Chrysler
Station Wagon
Ins tollation:-
(1) Enter wire and connector through hole in fender.
(2) Position lamp attaching screw. assembly on fender and install
(3) Connect lamp lead to main harness.
Installation:-
(1) Position welt to bezel and place in position on fender. a
TURN SIGNAL INDICATOR
HOUSING AND LENS ASSEMBLY
/WELT
SOCKET
GASKET
HOUSING\
SPACER C
Fig. 5
-
Front Fender Turn Signal Indicator Imperial
NU640
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0
EXTERIOR LIGHTING 5-1 7
SOCKET AND CA
Installation:-
(1) Enter lamp lead through hole in fender and position gasket and lamp on fender.
(2) Install attaching nut and connect lead to harness.
Front Fender Turn Signal Lamps-Imperial
(Fig. 5).
Removak-
(1) Disconnect lamp lead from harness.
(2) Under front fender remove 2 nuts from indi- cator lamp cover studs.
(3) Pull lamp and lead up through fender.
To replace bulb, remove two screws attaching lens to housing, unscrew bushing from harness connector and remove bulb.
Fig. 6
-
Front Park and lurn Signal Lamps Valiant
Front Fender Turn Signal Indicator-Chrysler
Station Wagons (Fig. 4).
Removak-
(1) Disconnect lamp lead from harness connector.
(2) From under front fender remove one capnut attaching lamp to fender and lift off lamp and lead.
To replace bulb, unscrew lamp socket from lens and lift out bulb.
Installation:-
(1) Position lamp and wiring connector on fend- er and install attaching nuts to housing studs.
(2) Connect lamp lead to harness connector.
Front Park and Turn Signal Lamps-Valiant
(Fig.6)
Rem0 Val:-
(1) Remove four screws from front of lens.
(2) Lift off lens.
To replace bulb, turn and lift out.
Installation:-
(1) Position gasket and lens and install four
Fig. 7
-
Front Park and lurn Signal Lamps Barracuda
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5-1 8 EXTERIOR LIGHTING
.
SOCKET
Installation:-
(1) Install three screws to attach lamp assembly to air shield.
(2) Connect lamp lead to harness.
Front Park and Turn Signal-Satellite
Hard Top (Fig. 8).
2 Door
Removal:-
(1) Remove three screws that mount lamp as- sembly to air shield.
(2) Disconnect lamp lead from harness and lift assembly out to the rear.
To replace bulb, remove three screws from front of lens and remove lens; turn bulb and lift out.
Fig. 8
-
Front Park and Turn Signal Lamps
-
Satellite
2 Door Hardtop screws from front of lens.
Front
(Fig.
Park and Turn Signal lamps-Barracuda
7).
Removal:-
(1) Remove two screws from front of lens and remove lens and gasket.
To replace bulb, turn and lift out.
(2) Disconnect lamp lead from harness.
(3) Remove three screws mounting lamp assem- bly to air shield and lift off.
GRILLE
\
Installation:-
(1) Position assembly to air shield and install three attaching screws.
(2) Connect lamp lead to harness.
Front Park and Turn Signal lamps-Satellite
Door and Station Wagons (Fig.
9 )
4
Removal:-
(1) Disconnect ground wire and lamp lead from harness.
(2) Remove two screws that attach assembly to rear of housing and lift off.
To replace lens or bulb, remove two screws from front of lens and lift off lens. Turn bulb and lift out.
GROUND
WIRE
CAP
SCREW
I
LENS
SCiEW GASKET
Fig. 9
-
Front Park and Turn Signal Lamps Satellite 4 Door and Station Wagons
PB180
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0
EXTERIOR LIGHTING 5-1
9
Installation:-
(1) Install two mounting screws through retainer to rear of housing.
(2) Connect lamp lead to harness and ground wire to ground.
Front Park and Turn Signal
10). lamp-Fury (Fig.
Rem0 Val:-
(1) Working through panel lamp lead from harness. opening, disconnect
(2) Remove two nuts attaching lamp to panel and remove lamp.
To replace lens or bulb, remove two screws from front of lens and lift off lens, turn bulb and lift out.
Inst allation:-
(1) Position lamp on panel, install attaching nuts.
(2) Connect lamp lead to harness.
Front Bumper, Park and Turn Signal lamps-Chrysler (Fig. 11)
Removak-
(1) From under front bumper, disconnect lamp lead from harness.
(2) Remove two screws attaching lamp to bumper.
To replace lens or bulb, remove two screws from front of lens, turn bulb and lift out.
Installation:
(1) Position lamp on bumper and install two at- taching screws.
(2) Connect lamp lead to harness.
Front Bumper Park and Turn Signal lamp-Imperial (Fig. 12).
Remo Val:-
(1) Remove two screws and lamp bezel.
(2) Remove two screws and pull out lamp assembly, disconnect lamp lead from harness and remove lamp.
To replace lens or bulb, remove bezel and the two screws attaching lens to lamp housing.
Installation:-
(1) Position lamp on front bumper, connect lamp lead to harness.
VIEW IN DIRECTION OF ARROW A
Fig. 10
-
Front Park and Turn Signal Lamp Fury
PY311
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5-20
EXTERIOR LIGHTING
0
LAMP
GASKET fig. 11
- front Bumper Park and Turn Signal lamps
-
Chrysler
NU638A
Fig. 12
-
Front Bumper Park and Turn Signal Lamps
-
Imperial
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SOCKET AND CABLE
SEAL
EXTERIOR LIGHTING 5-21
Fig. 13
HOUSING
-
Front Side Marker Lamp and Reflector
Valian t
(2) Install lamp bezel and two attaching screws.
Front side Marker Lam and
Reflector-Valiant (Fig.
r3).
REMOVAL:-
(1) From under the fender press lens tabs and pull off lens, outside of fender.
(2) Disconnect lamp lead from harness.
(3) Remove two screw attaching housing to fend- er brackets and lift out lamp.
To replace lens or bulb, remove lens turn bulb and lift out. as above,
Installation:-
(1) Position lamp assembly to fender and install two attaching screws.
(2) Press in lens and connect lamp lead to harness.
Side Marker Lamps-Satellite (Fig. 14).
Note: Removal and installation ore the some for both front and rear but the parts are not interchangeable.
Removal:-
(1) Remove four capnuts from inside behind the housing.
(2) Twist lamp socket and pull down from lamp housing.
(3) Remove bezel and welt from outside of fend- er and housing from inside.
To replace bulb, turn bulb base and pull down, lift bulb out of base.
Fig. 14
-
Side Marker lamps
-
Satellite
Installation:-
(1) Position housing assembly to inside of fender and bezel to outside.
(2) Install four attaching nuts.
(3) Position and twist lamp socket into housing.
Front Fender Side Marker Lamps-Barracuda and Fury (Fig. 15).
Removak-
(1) From under front fender remove two capnuts attaching lamp and retainer to fender and bezel.
(2) Slide lamp from studs, disconnect lamp lead from harness and remove lamp assembly.
Reflector is retained to bezel by snap-in clips.
Lamp lens and bulb can be removed from lamp after lamp is removed from housing by removing the two lens attaching screws.
Installation:-
(1) Position gasket and lamp on fender and in- stall retainer and the two attaching nuts.
(2) Connect lamp lead to harness.
Front Fender Side Marker lamp and
Reflector-Chrysler (Fig. 16).
Removal:-
(1) From under fender remove two capnuts and remove bracket.
(2) Disconnect lamp lead from harness and pull lamp away from fender.
To replace lens or bulb, remove two lens atta- ching screws.
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5-22 EXTERIOR
LIGHTING
Installation:-
(1) Pull lead through fender opening and posi- tion lamp assembly.
(2) Install lamp bracket and capnuts.
(3) Connect lead to harness.
Front Fender Cornerin and Side Marker lamps Chrysler (Fig. f7).
Removal:-
(1) Remove two capnuts and remove lamp bracket.
(2) Pull lamp away from fender and disconnect lamp lead from harness and remove lamp.
To replace lens or bulb, remove two screws from lens face and remove lens.
Inst allation:-
(1) Position lamp assembly and bracket and in- stall two capnuts.
(2) Connect lamp lead to harness.
Front Fender Cornerin and Side Marker lamps Imperial (Fig.
B
8).
Removal:-
(1) Remove two nut assemblies and remove lamp bracket.
(2) Disconnect lamp lead from harness and pull lamp assembly away from fender.
To replace lens or bulb, remove two screws attaching bezel and lens to lamp and remove bezel and lens. lnst allation:-
(1) Position on fender and install lamp bracket and two attaching nuts.
(2) Connect lamp lead to harness.
0
/' RETAINER
/
-/
G A ~ K E T FENDER PANEL
(REFERENCE)
UD (2)
REFLECTOR BEZEL
Fig. 15
-
Front Fender Side Marker Lamps Barracuda and Fury
SIDE
LAMP
MARKER
ASSEMBLY
PY358A
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0
CAP
NUT(2)
EXTERIOR LIGHTING 5-23
FENDER PANEL
SIDE MARKER LAMP
AND REFLECTOR
SOCKET AND CABLE
\
\
HOUSING
I
I
BULB(1895)
GASKET
LENS
Fig. 16
-
Front Fender Side Marker lamp and Reflector
-
Chrysler
BRACKET
PY288A
AND
LAMP
CORNERING
-
LAMP BULB
Fig.
GASKET
-
Front Fender Cornering and Side Marker lamps
-
Chrysler
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5-24 EXTERIOR LIGHTING
VIEW IN DIRECTION OF ARROW A
Fig. 18
-
-
Front Fender Cornering and Side Marker Lamps
-
Imperiat
REAR END LIGHTING
HOUSING
LAM? ASSEMBLY
\
PY287A
QUARTER PANEL
Fig. 1
-
Rear Side Marker Lamp and Reflector
-
Valiant
Fig. 2
-
Quarter Panel Side Marker Lamps Barracuda
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0
QUARTER PANEL
\
CAPNUT BRACKET
\
LAMP A T L Y
\
CAPNUT hL
EXTERIOR LIGHTING 5-25
HOUSING
/
ST~JD GAS~KET SCREWr PB190
Fig. 4
-
Quarter Panel Side Marker lamps and
Reflectors
-
Chrysler
Fig. 3
-
Quarter Panel Side Marker lamps and
Reflectors
-
Fury
Rear Side Marker Lamp and
Reflector-Valiant (Fig. 1).
Rem0 vat:-
(1) Working from inside trunk remove two cap- nuts from rear of housing bracket.
(2) Disconnect lamp lead from harness and lift out lamp.
To replace lens or bulb, snap out lens and turn and remove bulb. lnst allation:-
(1) Position housing assembly on rear quarter panel after feeding lamp lead through opening and through hole in bracket.
(2) Position bracket on inside of trunk and in- stall two capnuts.
(3) Connect lamp lead to harness.
Quarter Panel Side Marker Lamps and
Reflectors (Fig. 2).
Removal:-
(1) Working from in trunk, remove two capnuts attaching bezel to retainer.
(2) Disconnect lamp lead from harness and pull away from fender.
To change bulb or lens, remove two screws from lens face and lift off lens.
Installation:-
(1) Position lamp assembly to fender.
(2) Install retainer and two capnuts.
(3) Connect lamp lead to harness.
Quarter Panel Side Marker Lamps and
Reflectors Fury (Fig. 3).
SOCKET AND CABLE
Fig. 5
GASKET PB191
-
Rear Bumper Side Marker lamps
-
Imperial
Rem0 vat:-
(1) Snap out reflector and remove two screws attaching housing to bracket inside trunk.
(2) Disconnect lamp lead from harness and re- move lamp assembly from outside quarter panel.
To replace lens or bulb, remove two screws from face of lens and lift off lens.
Installation:-
(1) Position lamp assembly to quarter panel and install bracket and two screws.
(2) Snap in reflector lens and connect lamp lead to harness.
Quarter Panel Side Marker Lamps and
Reflectors-Chrysler (Fig. 4).
Rem0 vat:-
(1) Disconnect lamp lead from harness and re- move two capnuts, working from inside trunk.
(2) Lift off lamp assembly from outside of quar- ter panel.
To replace lens or bulb, remove two screws from lens face and lift off lens.
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5-26 EXTERIOR LIGHTING
GASKET LENS
Removal:-
(1) Remove two screws attaching bezel to bumper.
(2) Disconnect lamp lead from harness and lift assembly away from bumper.
To replace lens or bulb remove two lens attach- ing screws from back of housing.
\
Installation:-
(1) Connect lamp lead to harness through open- ing in bumper.
(2) Position lamp assembly on bumper and in- stall two attaching screws.
SEAL STUD
&.
6
SCREW HOUSING REFLECTOR PB192
-
Tail, Stop, Turn Signal Lamps
-
Valiant Sedan
Tail, Stop, Turn Signal lamps-Valiant Sedan
(Fig. 6).
Removal.-
Installation:-
(1) Position lamp assembly
(1) Disconnect lamp lead from harness and re- on outside of quarter move four capnuts from housing studs, working panel and bracket inside of trunk.
(2) Install two capnuts and connect lamp lead to harness. inside trunk.
(2) Pull off housing assembly from fender.
To replace lens or bulbs, remove two screws from back of lens and lift off lens.
Rear Bumper Side Marker lamps-Imperial
(Fig. 5)
lnsf allation:-
(1) Position the housing assembly on the fender
DECK PANEL
Fig. 7
-
Tail, Stop, Turn Signal and Back-up Lamps
-
Duster
PY398
MyMopar.com
EXTERIOR LIGHTING 5-27 and install the four capnuts.
(2) Connect the lamp lead to the harness.
SCREW
BEZEL
Fig. 8
-
Tail, Stop, Turn Signal and Back-up lamps
-
Barracuda
PB193
SCREW k
Fig. 9
-
Tail, Stop, Turn Signal and Back-up lamps
-
Satellite Sedan
PB194
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5-28 EXTERIOR LIGHTING
BACK-UP BULB
TAIL, STOP, TURN SIGNAL BULB
SCREWS
LENS
GASKET
\
HOUSING
0
PB195
Fig. 10
-
Tail, Stop, Turn Signal and Back-up lamps
-
Satellite 2 Door
Tail, Stop, Turn Signal and Back-up lamps-Duster (Fig. 7).
Removal:-
(1) Working through trunk remove four capnuts and two screws and remove lamp from lamp housing.
To replace lens remove six screws attaching lens to housing.
Tail, Sto
Barracu
B
,
Turn Signal and Back-up lamps a (Fig. 8).
-
To replace lens or bulbs remove six screws atta- ching lens to housing, lift off lens turn bulbs and lift out.
Installation:-
(1) Position lamp assembly to bumper and install four attaching screws.
(2) Pass wire into trunk and position rubber to grommet in body hole. Connect lamp lead harness.
(3) Install rear bumper.
Tail, Stop, Turn lamps-Satellite
Si nal and Back-up
2
B
oor (Fig. 10).
Removak-
(1) Working from trunk compartment remove four nuts attaching bezel studs to lamp and quar- ter panel and remove bezel.
(2) Snap out lamp socket connectors, bulbs, three retainer clips and remove lamp.
(3) Install bulbs and sockets.
Removal:-
(1) Disconnect lamp lead in trunk and pass wire aft through body hole.
(2) Remove rear bumper.
(3) Remove four attaching screws from housing to bumper and drop lamp assembly out.
To change bulbs or lens remove eight screws from lens and bezel face and lift off lens.
Tail, Stop, Turn Si nal and Back-up lamps-Satellite Se
%
an (Fig.
9).
Remo Val:-
(1) Disconnect lamp lead from harness in trunk and remove gromet from body hole.
(2) Remove rear bumper.
(3) Remove four screws attaching lamp to bumper. Use care when lowering lamp assembly to insure cable passage through body hole.
Installation:-
(1) Position lamp assembly to bumper and install four attaching screws.
(2) Pass lamp lead through body panel and con- nect to harness in trunk.
(3) Install rear bumper.
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0
EXTERIOR LIGHTING
5-29
Tail, Stop, Turn Signal and Back-up lamp
Fury I and II (Fig. 11).
Removal:-
(1)
Disconnect lamp lead from harness in trunk and pass lead through body.
(2) Remove rear bumper.
(3) Remove three screws attaching lamp assem- bly to bumper and drop assembly down and out.
To replace bulbs or lens, remove six screws from face of lens and lift
off
lens.
Installation:-
(1) Position lamp assembly on bumper and in-
111 I
TAIL, STOP, TURN
SIGNAL BULB
HOUSING
Fig. 11
-
Tail, Stop, Turn Signal and Back Up lamps
-
Fury I and I1
AND CABLE
PBlW
SCREW
LENS
TAIL, STOP, TURN
SIGNAL BULBS
Fig. 12
-
Taib Stop, Turn Signal and Back-up lamps
-
Fury
GASKET
PBlW
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5-30 EXTERIOR LIGHTING
stall three attaching screws.
(2) Pass lamp lead into trunk and install grom- met in hole. Connect lead to harness.
(3) Install rear bumper.
Tail, Stop, Turn lamps-Fury (Fig,
Si nal and Back-up
Q
2).
Removal:-
(1) Remove back bumper
(2) Disconnect lamp lead from harness in trunk and pass lead aft through body.
(3) Remove four screws attaching lamp housing to bumper and remove housing down and out.
To replace lens or bulbs, remove eight screws from bezel and lens face and lift lens. off bezel and
Installation:-
(1) Position lamp housing to bumper and install four attaching screws.
(2) Pass lamp lead through body opening and install rubber grommet. Connect lamp lead to harness.
(3) Install rear bumper.
0
Tail, Stop, Turn Signal and Back-up lamps
Chrysler-(Fig, 13).
Removal:-
(1) Remove rear bumper.
(2) Disconnect lamp lead from harness.
(3) Remove four nuts and three capnuts and re- move lamp assembly.
To replace lens and bulbs, remove six screws from lens face and lift off lens.
Installation:-
(1) Position lamp on bumper and install attach- ing nuts.
(2) Connect lamp lead to harness.
(3) Install rear bumper.
Tail, Stop, Turn Signal lamps-Chrysler
(Fig. 14).
300
Rem0 Val:-
(1) Remove rear bumper.
(2) Disconnect lamp lead from harness.
(3) Remove four nuts attaching lamp housing to bumper and remove lamp.
To replace lens or bulbs, remove eight screws attaching lens to housing and lift off lens.
APPLIQUE
Fig. 13
-
Tai!. Stop, Turn Signal and Back-up Lamps
-
Chrysler
PY295
MyMopar.com
a
EXTERIOR LIGHTING 5-31
Installation:-
(1) Position lamp assembly on bumper and in- stall attaching screws.
(2) Connect lamp lead to harness.
(3) Install rear bumper.
Tail, Sto lamps-C
R
,
Turn Signal and Back-up rysler (Fig. 15).
Removak-
(1) Remove rear bumper.
(2) Disconnect lamp from harness.
(3) Remove three nuts attaching housing to bumper and remove lamp assembly.
To replace lens and bulbs, remove four screws from lens and bezel face and lift bezel. off lens and
Removal:-
(1) Disconnect lamp lead from harness and from side marker lamp.
(2) Remove six screws from bezel face and re- move bezel face and remove bezel.
(3) Remove three nuts attaching housing to bumper and remove housing.
To replace lens or bulbs, remove six screws from bezel face and two screws from lens face and lift off lens.
Installation:-
(1) Position lamp assembly to bumper and install three attaching nuts
(2) Install bezel and six attaching nuts.
(3) Connect lamp lead to harness and side mark- er lamp.
Installation:-
(1) Position lamp assembly to bumper and install three attaching screws.
(2) Connect lamp lead to harness.
(3) Install rear bumper.
Tail, Stop, Turn Signal lamps-Imperial
16).
(Fig.
Tail, Stop, Turn Signal and Side Marker lamps-Satellite Station Wagons (Fig. 17).
Removak-
(1) Remove four screws attaching lens to lamp housing.
(2) Remove two screws attaching housing to quarter panel and remove housing.
(3) Remove bumper.
GASKET
Hg. 14
-
Tail, Stop, Turn Signal Lamps Chrysler 300
UP LAMP BULB
PYB1
MyMopar.com
5-32 EXTERIOR LIGHTING
(4) Remove quarter panel extension and housing from body.
( 5 ) Disconnect lamp lead from harness and re- move extension from housing.
To replace lens or bulb, remove four screws from lens face and lift off lens.
/nstallation:-
(1) Install quarter panel extension to lamp housing.
(2) Connect lamp lead to harness and position housing to quarter panel.
(3) Install two attaching screws and four screws to lens face.
(4) Install rear bumper.
Tail, Stop, Turn Signal and Side Marker
Lamps Fury Station Wagons (Fig. 18).
Removal
-
Quarter
Panel
lamp.
(1) Remove four screws mounting bezel to quar- ter panel. These screws are three different lengths, use care not to mix them.
(2) Lift out lamp assembly and disconnect lamp lead from harness.
To change lens or bulbs, remove lamp assembly from vehicle and remove four screws that attach lens and bezel to housing.
0
Installation:-
(1) Connect lamp lead to harness.
(2) Position lamp assembly to quarter panel and install four attaching screws.
Removal
-
Tail
Gate Lamp
(1) Remove four screws from bezel face and lift off bezel and lens.
(2) Remove four screws attaching housing to tailgate and remove housing.
(3) Disconnect lamp lead from harness.
To change lens or bulb remove four screws and lift off bezel and lens.
Installation:-
(1) Connect lamp lead to harness and position housing assembly on tailgate.
(2) Install four attaching screws.
(3) Position lens and bezel and install four screws.
Tail, Sto
Lamps
P
,
Turn Signal and Side Marker hrysler Station Wagons (Fig. 19).
Removal.-
(1) Remove four screws attaching lens and bezel assembly to lamp housing.
BUMPER (REFERENCE)
SOCKET AND
CABLE
\
LSNS
GASKET
SCREW (4)
Fig. I5
-
Taib Stop, Turn Signal lamps
-
Chrysler
MyMopar.com
0
(2) Remove three screws attaching housing to quarter panel.
(3) Disconnect lamp leads from harness.
To replace lens or bulbs only step one is necessary.
Back-up lamp-Valiant (Fig. 20).
Rem0 Val:-
(1) Remove two screws from face of lamp, pull lamp away from bumper and disconnect lamp lead from harness.
To replace lens or bulb, after lamp is removed from bumper, remove four screws attaching lamp lens to housing.
Installation:-
(1) Connect lamp lead to harness.
(2) Position lamp assembly to bumper and install two attaching screws.
Back-up lamp-Satellite (Fig. 21).
Rem0 Val:-
(1) Remove two screws attaching lamp assembly to bumper.
(2) Disconnect lamp lead from harness.
To replace lens or bulb, remove two screws from
EXTERIOR LIGHTING
Rear license lamp-Valiant (Fig. 23).
5-33 lens face and lift off lens.
Ins tollation:-
(1) Connect lamp lead to harness.
(2) Position lamp assembly on bumper and in- stall two attaching screws.
Back-up lamps-Fury and Chrysler Station
Wagons (Fig. 22).
R e m 0 Val:-
(1) To replace lens or bulb, remove retainer and lens.
(2) Remove two screws attaching housing to bumper and disconnect lamp lead.
Rem0 Val:-
(1) Remove two screws and disconnect lamp lead, remove assembly.
To replace bulb or lens, remove two screws atta- ching lamp assembly to bracket.
Rear license lamp-Barracuda (Fig. 24).
Rem0 Val:-
(1) Under lower deck panel remove two lamp
LAMP
Fig. 16
-
Tail, Stop, Turn Signal lamps Imperial
MyMopar.com
5-34 EXTERIOR LIGHTING
a
SEALING WASHER
PB198
Fig. I 7
-
Tal4 Stop, Turn Signal and Side Marker
Lamps
-
Sotellite Stotion Wagons stud nuts.
(2) Pull lamp out of panel opening, disconnect lamp lead from harness.
To replace lens or bulb, remove two lens attach- ing screws from back of housing.
Installation:-
(1) Position lamp on lower panel and install two retainer nuts.
(2) Connect lamp lead to harness.
Back-up lamp-Imperial (Fig. 25).
Removal:-
(1) Remove two attaching nuts and pull assem- bly away from bumper.
(2) Disconnect lamp lead from harness.
To replace bulb or lens, remove four screws at- taching lens to housing and remove lens.
Rear license lamp-Satellite, Fury, Chrysler and Imperial (Fig. 26).
Removak-
(1) Remove two screws attaching lamp bracket to bumper.
(2) Disconnect lamp lead from harness.
To replace lens or bulb, remove assembly from bumper and remove two screws that mount assem- bly to bracket.
Fig. I 8
- h i 4 Stop, Turn Signal and Side Marker Lamps
-
Fury Station Wagons
MyMopar.com
m
EXTERIOR LIGHTING 5-35
Fig. 19
-
Tail, Stop, Turn Signal and Side Marker Lamps
-
Chrysler Station Wagons
REAR BUMPER (REFERENCE)
Fig. 20
-
Back-up Lamps
-
Valiant
PY402
MyMopar.com
0
5-36 EXTERIOR LIGHTING
SOCKET AND CABLE
/
SCREW
\
I E N <
LLI
."
\
BULB
REAR BUMPER
Fig. 21
-
Back-up lamps Satellite Station Wagon
LAMP ASSEMBLY
PB2W
Fig. 22
-
Back-up Lamps
-
Fury and Chrysler Station Wagons
Removal=-
(1)
Snap lens
off
socket to replace lens or bulb.
(2) Snap socket out of bumper and disconnect lamp lead from harness to replace complete circuit.
MyMopar.com
EXTERIOR LIGHTING 5-37
a
SCREW AND WASHER(2)
SCRFW (2)
\
LENS
I
Fig. 23
-
Rear license lamp
-
Valiant
LENS GASKET
LENS
Fig. 24
-
Rear License lamp
-
Barracuda
-L i,
PY360
MyMopar.com
5-38 EXTERIOR LIGHTING
I FNS
HOUSING
\ w
SOCKET AND
CABLE
LAMP BRACKET
REAR
BUMPER
(REFERENCE)
I
0
B E ~ E L
/
BACK-UP LAMP
Fig. 25
-
Back-Up Lamp
-
Imperial
REAR BUMPER TLlC STOP
AND TURN SIGNAL LAMP
(REFERENCE) \
PY292
Fig. 26
-
Rear License Lamp
-
Satellite
-
Fury
-
Chrysler and Imperial
NU647
MyMopar.com
(REFERENCE) e&
Fig.
VIEW IN DIRECTION OF ARROW A
27
NU585
-
Rear License Lamps
-
Fury
-
Chrysler
Station Wagons
CONCEALED HEADLAMPS
INDEX
GEAR AND LIMIT SWITCHES
Page Page
...........................
40 MOTOR AND WIRING
..........................................
40
GENERAL INFORMATION
....................................
39 SERVICE DIAGNOSIS
............................................
39
HEADLAMP DOORS
...............................................
43 SERVICE PROCEDURES
.......................................
40
TORSION BAR AND MOTOR
.............................
43
GENERAL INFORMATION
The headlamp doors (Fig. 1) are electrically operated. A single electric motor mounted behind the center of the grille is a series-wound type with two field windings. The motor has a worm gear drive and internal limit switches. A relay and cir- cuit breaker assembly is mounted to the instru- ment panel lower reinforcement, left of the steer- ing column.
To open the headlamp doors in the event of an electrical failure, disconnect the motor leads FIRST, then rotate the hand wheel located at the lower end of the motor clockwise, as indicated by the decal on the radiator yoke, until the headlamp doors are fully opened.
CAUTION: Rotating the wheel after the doors reach the end of travel will permanently dam- age the motor.
Condition
SERVICE DIAGNOSIS
Possible Cause
HEADLAMP DOORS DO NOT a) Ignition switch in wrong
OPERATE position b) Faulty Motor c) Faulty wiring t o motor d) Torsion Bar disconnected e) Crank Screws missing f) Faulty headlamp switch or relay.
Correction a) Must be in the "On", not
"Accessory" position. b) Repair or Replace per "Service
Procedure". c) Repair or Replace per "Service
Procedure". d) Reconnect. e) Replace (Tighten t o 25 t o 45 in. bs.) f) Replace
MyMopar.com
5-40 EXTERIOR LIGHTING
HEADLAMP DOORS UNEVEN -
ONE DOESN’T COMPLETELY
OPEN OR CLOSE
Torsion Bar Twisted
One crank screw missing
HEADLAMP DOORS OPERATE
WITH EXCESSIVE NOISE
NOISE IN PASSENGER
COMPARTMENT
CIRCUIT BROKEN
-
CYCLING
Motor plastic drive gear s t r i p ped
Rubber bumper(s) worn or missing
Door pivot bushings worn, missing, or dry
Door rubbing against grille
Torsion spring broken
Motor limit switch malfunction
Circuit breaker failure.
0
Replace
Replace (Tighten to
I bs.)
25 to 45 in.
Remove motor and replace gear, per ”Service Procedures“
Replace
Replace lubricate if worn or missing, if dry
Adjust
Replace
Remove motor and replace switch plate per ”Service
Procedure”.
Replace.
SERVICE PROCEDURES
MOTOR AND WIRING TESTS
(1) If headlamp doors do not operate and head- lights and ignition switch are on (not accessory connectors free of dirt and corrosion; and that the wire from the motor ground terminal is connected to a good body grounk
CAUTION: Do not operate motor with headlamp position), before starting any tests, first check for good ground continuity; terminals fully seated, and doors disconnected as operating the motor with- out load will damage motor.
If the system is still inoperative perform step (2).
(2) CAUTION: This test bypasses the limit switches so power should be applied only momen- tarily to avoid system damage.
Using jumper wires test motor operation by us- ing the car battery as a direct source of power.
Apply power to the motor terminals after limit switch (See Fig. 2) and check motor operation in both directions. If the motor draws current but does not operate in either direction, the motor has an internal short circuit or a locked armature con- dition and should be replaced. If the motor draws no current, then there is an open circuit and the motor should be replaced. If the motor operates, test the limit switches by applying power to the motor terminals before limit switch (Fig. 2). If motor operates in both directions the limit switches are functional and step 3 should be performed.
If the limit switches are not functional, perform the gear and limit switch tests as detailed in the
Service Procedures.
(3) Use jumper wires at bulkhead disconnect, to see if there is voltage at the terminal for both lights on and off. If there is no voltage for either door position, perform Step 4.
(4) Test for loose wire at the “H” terminal of headlamp switch, loose wires on headlamp motor relay, or faulty circuit breaker, as required.
GEAR AND LIMIT SWITCH TESTS
Removal
(1) Remove torsion bar and motor (see Service
Procedures).
(2) Remove the screws from the switch plate.
After checking that the indicator lugs are accu- rately lined up, and while holding the gear in place by pushing the output (drive), as shown in
Figure 2, carefully remove the switch plate.
Gear Evaluation
\
(3) Remove the gear and examine for stripped or worn teeth. If no damage is observed perform step
4 (Limit switch evaluation). If gear damage is ob- served replace the gear assembly with parts from the service kit, as detailed below: a) Position a new cam, of the same color as the original cam, in the locator slot of the new gear. b) Install the
“0”
rings, from the original gear, at each end of the shaft of the new gear. c) Remove all chipped gear particles from the gearbox and switch assembly.
Limif Switch Evaluation
(4) Position the switch cams as shown in Figure
3 and verify that the switch blade profile is as
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0
I
EXTERIOR LIGHTING 5-4
In z a b
0
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5-42 EXTERIOR LIGHTING
GROUND TERMINAL
-cjiEh
SWITCH PLATE
OUTPUT (DRIVE) \
MOTOR TERMINAL!
BEFORE LIMIT SWlTCl
MOTOR LEADS
1
TERMINALS
AFTER
LIMIT
SWITCH
\
ICATOR LUGS
IALF-WAY
'OSITION)
HAND WHEEL
Fig. 2
PY876A
-
Manually Aligning Indicator Lugs
ADJUSl
AS SHOWN
Fig. 3 w
-
Positioning Cams and Switches
PB275 a
7.
F7g. 4
-
Switches Open w
PB276
NED
TO
I
Fig. 6
- resting Swifch Operation
PB278
Fig. 5
\I
-
Switches Closed
PB277
Fig. 8
-
Removing Torsion Bar From Headlamp Door
Crank (Typical)
INDICATOR LUG
ON GEAR SHAFT
LIMIT SWITCH ACTUATING CAM'
Fig. 7
-
Gear Assembly
PB279
MyMopar.com
0 shown in Figure 4 (both switches open).
( 5 ) Inspect the switch blade contact surfaces and clean if necessary.
(6)Position the switch cams as shown in Figure
5 and verify that both switches are now closed.
(7) Test switch operation by inserting the cam side of the gear assembly into the switch plate as shown in Figure 6. Rotate the gear assembly, while pressing it against the switch plate, to open and close the limit switches and observe their operation. CAUTION: Do not over rotate since the cam can hit and damage the limit switch. Re- turn the assembly to the Figure 5 condition (both switches closed) and remove the gear assembly.
(8) If the limit switches are not operating cor- rectly replace the switch plate, using the Switch
Plate and Gasket kit as detailed below: a) Remove sealant from motor terminals
(Before and After limit switch) and unsolder the wires. b) Solder the wires on to the new switch plate and reseal with MS CC 95 or equivalent.
Installation
(9) Fill the teeth of the Armature Gear with
Lubricant per Section 0 of Service Manual.
(10) Install the gear assembly in the gearbox, taking care to position it so that the indicator lugs will line up when the switch plate is installed
.
(11) Install the switch plate (with gasket) on the gearbox, taking care not to dislodge the switch blades from their closed positions. Replace the screws.
(12) Install the torsion bar and motor (see Serv- ice Procedures).
(13) Test system operation. CAUTION: Do not operate the motor with headlamp doors discon- nected as operating the motor without load will damage the motor.
HEADLAMP DOORS
Removal
(1) Disconnect motor leads at harness connector
(Fig. 1).
(2) Rotate motor hand wheel clockwise if doors are closed; or counter clockwise if doors are open; until headlamp doors are at the halfway open pos- ition (indicator lug on motor switch plate and lug on gear near rectangular hole are in alignment.
Fig. 2)
(3) Compress torsion bar to headlamp door crank clip and slide clip from crank (Fig 1).
(4) Force the torsion bar from the crank arm slot by wiggling the door up and down with one hand while pulling the bar out from the slot with your other hand (Fig. 8).
EXTERIOR LIGHTING 5-43
( 5 ) Remove headlamp bezels (Imperial and
Chrysler 300 only), and inboard sealed beam units. CAUTION: On Imperials with the head- lamp washer option, move the washer brush by hand to the center of the outboard headlamp and remove the bezel over the arm.
(6) Remove retainer clip from crank assembly
(Fig. 1).
(7) Remove screw holding the crank assembly to the door arm at the inboard side of door.
(8) Remove crank assembly from headlamp door.
(9) Remove idler pin from outboard side of door
(Imperial and Fury only).
(10) Remove door from opening.
Installation
(1) Position door in grille opening, align crank assembly holes and insert crank.
(2) Align idler pin holes and install idler pin.
(Imperial and Fury only). Check that crank arm and idler pin bushings are in place.
(3) Install retainer on crank.
(4) Install screw on side of door, attaching the crank assembly to the door, and tighten to 25 to
45 in. lbs.
( 5 ) Position and fully seat torsion bar in slotted area of crank. (Check that the motor is in half- way open position. Fig. 2).
(6) Compress and position clip over crank and torsion bar.
(7) Install headlamp bezels (Imperial and Chrys- ler 300 only.) and headlamp sealed beam units and connect battery ground strap. CAUTION: On
Imperials with the headlamp washer option place one hand through the outboard headlamp opening of the bezel and move the washer brush to the center of the outboard headlamp; then slide the bezel over the arm and into position.
(8) Connect motor leads at harness connector
(Fig. 1).
TORSION BAR AND MOTOR
The torsion bar and motor is removed as an assembly.
Removal
(1) Disconnect battery ground strap.
(2) Disconnect motor leads including ground wire from harness.
(3) Rotate the hand wheel on the motor counter- clockwise if doors are closed; or clockwise if doors are open; until headlamp doors are at the halfway open position (Fig 2).
(4) Compress and remove clips from crank as- semblies (Fig. 1).
( 5 ) Remove torsion bar from slotted areas in cranks as described in headlamp door removal
(Fig. 8).
MyMopar.com
5-44 EXTERIOR LIGHTING
0
(6) Remove motor mounting bracket (2 bolts) from vertical lock support. (Imperial and Fury only).
(7) Remove motor (3 screws) from motor mount- ing bracket.
(8) Remove torsion bar from motor.
Installation
CAUTION: Do not bench test new motor. Oper- ating motor without load will damage motor.
(1) Insert torsion bar in motor and position clips on bar. The torsion bar and the hole in the mo- tor are rectangular and can be assembled only one way.
(2) Position motor on motor mounting bracket and install mounting screws. Verify that the motor is in the halfway open position (Fig. attaching screws to
2). Tighten
95 inch pounds, plus or minus
20 inch pounds.
(3) Position motor mounting bracket on vertical lock support and tighten attaching bolts to 220 inch pounds (Imperial and Fury only).
(4) Position and fully seat torsion bar in slotted areas of cranks. Compress clips and position over cranks and torsion bar.
( 5 ) Connect motor to harness and connect bat- tery ground strap.
(6) Test operation of doors.
HEADLAMP WASHERS
GENERAL INFORMATION
To operate the headlamp washer system the en- gine must be running and the headlamps “ON’.
Then by depressing the washer switch and holding for four to five seconds the headlamps and windshield will be washed simultaneously. If the headlamps are off the headlamp washers are inop- erative and only the windshield will be washed when the washer button is depressed.
The headlamp washer system has been designed to remove, while driving, deposits that accumulate on the headlamps. The outer lamp was selected for cleaning because it contains both a high and low beam element. The cleaning is accomplished by spraying a washer solvent and brushing with a vacuum operated brush mechanism. The spray is directly on the brush and continues through the brush arc. The brushes are spring loaded to the rest position and are operated by a vacuum actua- tor that overcomes the spring load to move the brushes over the lamp face. A special type of flasher (similar to, but not interchangable with, the hazard flasher) is used to interrupt electrical power from the switch to the vacuum solenoid and the pump motor. This causes the system to cycle even though the switch is held continuously.
WIPER SWITCH WASH SWITCH WINDSHIELD
Fig. I
-
Headlamp Washers
-
Brush at Rest
Fig. 2
-
Headlamp Washers
-
Brush in Motion
TO HEADLAMP
DOOR MOTOR
RELAY
LAMP PB262
Fig. 3
-
Headlamp Washer Wlrlng
S c h e m a t i ~ P l y m o ~ h / l m ~ r i a l
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0
PIVOT AND BRUSH
EXTERIOR LIGHTING 5-45
(LESS FENDER)
PIVOT AND BRUSH
.
- - -
. .
-
.
.
Fig. 4
-
Headlamp Washer
-
Imperial
[ SOLENOID VALVE /NUT
PB244
-..-
VIEW Z
JLESS FENDER)
ON INTAKE MANIFOLD
MAIN VIEW
CONTINUED IN
MAIN VIEW
Fig. 5
-
Headlamp Washer
-
Fury
\PIVOT AND BRUSH
ASSEMBLY
PB243
MyMopar.com
5-46 POWER WINDOWS
Condition
BRUSHES INOPERATIVE
WASHERS O.K.
-
WASHER INOPERATIVE
BRUSHES O.K.
WASHERS, LIGHT AND
BRUSHES INOPERATIVE
-
HEADLAMP WASHER AND
WINDSHIELD WASHER
INOPERATIVE
SERVICE DIAGNOSIS
Possible Cause a. Loss of vacuum b.
C. d. a.
Faulty actuator
Faulty pivot assembly
Faulty Solenoid
Faulty washer motor
Correction a. b.
C. d. a.
Check vacuum hose and solenoid operation
Replace actuator
Replace pivot assembly
Replace solenoid
Replace motor pump assembly b.
C. d. e. a.
Nozzles plugged
Broken or loose hose
Faulty pump
Faulty wiring
Faulty flasher b.
C. d. e. a.
Clean or replace
nozzles
Replace hose
Replace motor/pump assembly
Check wiring
Replace flasher b.
C. a.
Faulty headlamp washer relay
Faulty wiring
Faulty fuse b.
C. a.
Replace relay
Check wiring
Replace fuse b.
C.
Faulty switch
Faulty wiring b.
C.
Replace switch
Check wiring
0
Brush
Replacement
(1) Remove retaining nut.
(2) Remove nozzle and spring.
(3) Remove clip/pin from brush.
(4) Remove brush.
( 5 ) Replace brush and reassemble.
(6) Check operation.
Actuator Replacement
(1) Disconnect vacuum hose.
Connect vacuum
Check operation. hose.
SERVICE PROCEDURES
(2) Disconnect link from crank pin by removing pushnu t
.
(3) Remove two nuts holding actuator.
(4) Install new actuator.
Connect link to crank and install new push
Solenoid Replacement
(1) Remove all vacuum hoses.
(2) Remove electrical connector.
(3) Remove solenoid.
(4) Install new solenoid.
( 5 ) Attach electrical connector and vacuum
hoses.
(6) Check operation.
Washer Pump/Motor Assembly Replocement
(1) Disconnect electrical connector.
(2) Disconnect hose from pump nozzle.
(3) Remove mounting screws of reservoir.
(4) Remove reservoir.
( 5 ) Remove and replace motor/pump assembly.
(6) Install reservoir and pump assembly.
(7) Connect electrical connector.
(8) Connect hose.
(9) Check operation.
POWER WINDOW LIFT, POWER VENTS
INDEX
General Information
Vent Wing Motor
Vent Wing Switch
Circuit Breaker
................................................
.......................................................
Page
47
47
47
47
Electrical Tests..
Circuit Breaker
Electrical Tests
Motor Test
.....................................................
...............................................................
Motor Lubrication
.................................................
Page
47
47
48
48
48
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rn
POWER WINDOWS 5-47
GENERAL INFORMATION
Vent wing motors have two separate field windings, known as split series. Direction of rota- tion is controlled by energizing either field with the switch. The fields are grounded to body through the motor housing with the switch com- pleting the particular circuit back to ground when it is actuated.
Front, rear and quarter panel window lift motors are of the permanent magnet type. The motors are grounded through the master switch by a black lead attached to the left cowl panel.
The tailgate window lift motor for the Satellite station wagon is the permanent magnet type. It is grounded through the instrument panel switch by a black lead attached to the lower reinforcement of the instrument panel.
The tailgate window lift motor for the Fury sta- tion wagon is a wound field series type. The field has two windings, one for each direction of rotation. The fields are grounded to the body through the motor housing, with the switch com- pleting the particular circuit back to ground when it is actuated.
CIRCUIT BREAKER TEST
Connect one lead of a test light to output termi- nal of circuit breaker and other lead to a good ground. The test bulb should light, if not and wire continuity has been established, replace the circuit breaker.
VENT WING SWITCH TEST
Remove switch from trim panel for testing purposes. Carefully separate multiple terminal block from switch body. Connect lead of a test light to tan feed wire terminal of multiple termi- nal block and other lead to a good ground. If bulb does not light, inspect for broken or loose wires to circuit breaker.
If bulb does light, remove and connect a jumper wire between tan feed wire in multiple connector and “open” terminal wire. If vent operates properly, replace switch body. If vent fails to op- erate inspect for broken, loose or disconnected wires or a faulty motor. See “Bench Test”. Repeat above test on “close” terminal if first test opens vent wing. Refer to Group
23
“Body and Frame” for removal and replacement of components.
VENT WING MOTOR TEST
Connect a positive lead from a test battery, to one of the two motor terminals. Connect the neg- ative lead to the motor. The motor should actuate the output shaft approximately 120 degrees. To reverse the direction of the motor, connect the positive lead to the other motor terminal and the output shaft will actuate 120 degrees in the other direction. If the motor fails to operate in either direction, replace the motor.
ELECTRICAL TESTS
Glass may not move due to a binding condi- tion between the glass and run channels. Correct the binding condition before making electrical tests.
WINDOW LIFT SWITCH TEST
Remove switch from trim panel for testing
UP b
DOWN UP
MOTOR
I 1 h
‘.
p F : R
SECOND
/JUMPER
I \
I
FIRST
JUMPER - -., SECOND
JUMPER
I
I
‘ I
I‘ 0 0
0 0 t
”
-
1
I ,
(TAN)
BODY GROUND (BLACK)
Fig. I
I
I
-
Testing Electrical Switch
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5-48 ELECTRIC LOCKS
0
REGULATOR
WIRING CLIP
J
Fig.
C A K
GEAR AND PINION
1
2
-
Window LiH Motor Lubrication purposes. Carefully separate multiple terminal block from switch body. Connect one lead of a test light to black wire terminal and touch other lead to tan wire terminal. The test bulb should light, if not, test wires for an open circuit. Use two jumper wires to test continuity of circuits.
Connect one jumper to the tan lead and the other end to the Up or Down terminal (opposite of glass position). Connect the other jumper to a good ground and to the opposite terminal (Fig. 1).
If motor runs, install switch body on multiple connector and activate switch. Should motor fail to run, replace switch body. Each switch is tested in same manner.
The motor should run, if not, test continuity of wiring. Should continuity be established and motor still does not run, replace motor.
.To avoid injury, NEVER remove the counterba- lance spring or motor from the regulator assem- bly without locking the unit in a bench vise.
(See Body Section for proper removal).
WINDOW LIFT MOTOR TEST
Connect the positive lead from a test battery to one of the two motor terminals. Connect the neg- ative lead from the test battery to the other motor terminal. The motor should rotate in one direction to move the window up or down. Reverse the battery leads and the motor will rotate in the op- posite direction. If the motor does not operate in both directions replace the motor assembly.
GEAR AND PINION REPLACEMENT
When the gear and pinion assembly is replaced in the gear box, (Fig. 2) lubrication of the gear box, gear and pinion and seal is necessary if these parts have been disassembled. If there is no lubri- cant in the gear box, fill to the top of the gear with MoPar 2525035 Multi-Mileage Lubricant or
MoPar 1064768 Lubri-Plate or equivalent. Apply a liberal amount of lubricant to the entire inside di- ameter of the seal marked “A” and the outside diameter of the gear and pinion assembly marked
“B”, and diameter marked “C” where the seal contacts the gear and pinion.
TAILGATE MOTOR
MAGNET)
TEST (PERMANENT
Connect a positive lead from a test battery to one terminal on the motor. Connect a negative lead from the test battery to the other terminal on the motor. The motor should rotate in one direction. Reverse the battery lead and the motor will rotate in the opposite direction. If the motor does not operate in both directions replace the motor assembly.
TAILGATE MOTOR TEST (WOUND FIELD)
Connect a positive lead on test battery to one of the two motor field terminals. Connect the nega- tive lead to the motor case. The motor should ro- tate in one direction. To reverse the direction move the positive battery lead to the other motor terminal, keep the ground lead connected to the motor case. If the motor does not actuate both both ways replace motor assembly.
ELECTRIC LOCKS
INDEX
Electrical Test (Deck Lid)
Electrical Test (Doors)
Electrical Test (Tailgate)
.....................................
.......................................
Page
5 0
49
49
General Information..............
..................................
Solenoid Adjustment (Deck Lid)
Solenoid Adjustment (Doors)
Solenoid Adjustment (Tailgate)
........................
..........................
Page
48
5 0
49
50 or unlock the rear doors mechanically.
GENERAL INFORMATION
by operating either of the front door locking
The right front door can be locked or unlocked
All doors can be locked or unlocked electrically mechanically.
The left front door can be unlocked by means of buttons. The rear door locking buttons will lock the inside remote handle, but cannot be locked
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0
ELECTRIC LOCKS 5-49
MOUNTING BRACKET
I
CLIP
ELONGATED
HOLES
NN671C
Fig. I
-
Door Lock Relay mechanically from inside the car.
The tailgate door locks automatically when the ignition switch is turned on. The tailgate may be unlocked electrically with the ignition switch on, by actuating the tailgate unlock switch located on the instrument panel. Hold the switch in the en- gaged position until the tailgate has been opened.
The tailgate will lock when the spring loaded switch has been released if the ignition switch is on. When the ignition switch is off the tailgate may be unlocked by actuating the tailgate unlock switch, using the tailgate key, or the locking button. The door will lock automatically when the ignition switch is turned on.
The deck lid lock consists of a push button switch and a solenoid. The solenoid is energized only when the push button is depressed.
Fig. 2
-
Solenoid Adiustment and should be replace. If a reading of 12.4 volts is not obtained, inspect for a broken feed wire or loose connection.
To determine which solenoid is faulty, check each individual door for electrical lock and unlock or disconnect the solenoid connectors one at a time, while operating the door lock switch. When faulty solenoid is disconnected, the remaining door locks will operate. If necessary to replace solenoid, refer to Group 23 “Body and Frame”.
If the solenoid failure was caused by overheating
(sticking switch), the remaining solenoids should be checked for proper operation and replaced if necessary.
ELECTRICAL TESTS (DOORS)
The battery must be in normal condition before testing.
Make certain solenoids are correctly adjusted be- fore circuits are tested. The circuit breaker is lo- cated behind the left side cowl trim panel. The relay is located behind the right side cowl trim panel.
Connect the positive lead of a voltmeter to the buss bar on the relay assembly and the negative lead of the voltmeter to a good ground (Fig. 1).
With no load, voltage should be 12.6 volts and
9.4 volts when locks are activated. If no reading is obtained at relay, the circuit breaker should be tested next. See “Wiring Diagrams” for appropri- ate schematic wiring diagram.
Connect Voltmeter positive lead to light green terminal of circuit breaker and other lead to a good ground. If a reading of 12.4 volts is not obtained, connect the voltmeter to the battery side of the circuit breaker. If a reading of 12.4 volts is obtained, the circuit breaker is probably defective
SOLENOID ADJUSTMENT (DOORS)
(1) Loosen solenoid mounting screws and slide solenoid to full down position. (Fig. 2)
(2) Extend solenoid link until latch is in locked position.
(3) Tighten solenoid mounting screws and test operation of lock.
ELECTRICAL TEST (TAILGATE)
The battery must be in normal condition before testing. Make certain the solenoid is correctly ad- justed before circuit is tested. Remove the wiring connector at the solenoid in the tailgate. Connect a test lamp to the pink lead at the connector in the wiring harness, with the ignition switch on the test lamp should be lit.
Move the tailgate unlock switch to the unlock position and hold, the test lamp should go out.
Move the test lamp lead to the orange lead in the connector, the test lamp should be lit, release tail- gate unlock switch and test lamp should go out.
To determine if the solenoid is operating properly, connect a hot lead to the orange wire in
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5-50 POWER SEATS
A
Fig. 3
-
Tailgate Lock Solenoid Mounting the solenoid connector, the solenoid link should extend. Move the hot lead to the pink wire in the connector and the solenoid link should retreat.
SOLENOID ADJUSTMENT (TAILGATE)
(1) Loosen the solenoid attaching screws that mount the solenoid to the mounting bracket move solenoid away from the locking controls. and
(2) Grasp the solenoid link and pull it toward the locking control until the push button is in the full up position. This will move the solenoid in the direction of the locking control, but the sole- noid must be restained slightly to ensure that the internal switch is fully open.
ELECTRICAL TEST
The battery must
(DECK LID)
be in normal condition before testing. Disconnect the wire from the solenoid and connect one lead of a test lamp to the wire.
Ground the other lead of the test lamp. Actuate the deck lid lock switch. The test lamp should light. If the test lamp fails to light check the switch and wiring.
To test the solenoid, connect a hot lead to the solenoid terminal. The solenoid shaft should retract.
Failure of solenoid to retract indicates a poor ground between the solenoid and deck lid or, the solenoid is defective.
SOLENOID ADJUSTMENT (DECK LID)
If the deck lid does not latch or unlatch properly, loosen the solenoid mounting screws and move the solenoid toward or away from the latch assembly until the deck lid properly latches.
POWER SEATS
INDEX
General Information
Service Procedures
Adjuster
Installation
Removal
................................................
.......................................................................
....................................................................
Cable and Housing
..................................................
Page
50
5 1
5 1
5 1
5 1
5 2
Installation......
Removal
.........................................................
....................................................................
5 2
5 2
Electrical Tests
.........................................................
5 1
Horizontal and Vertical Transmissions
Installation
Removal
Motor
Installation
Removal
...............................................................
............................................................................
Installation
Removal
Seat Assembly and Adjuster
...............................................................
Wiring Diagrams
..............................
Page
53
5 3
5 3
52
5 2
5 2
51
5 1
5 1
......................................................
62
GENERAL INFORMATION
This power seat can be adjusted in six different directions
- up, down, forward, back, tilt forward, or tilt rearward.
The control switch is located on the lower out- board side of the seat. The front lever on the switch (Fig. 1) raises or lowers (tilts) the front of the seat, the center lever raises or lowers the complete seat by moving switch up or down. It also moves it forward or backward by moving switch forward or rearward. The rear lever raises or lowers (tilts) the back of the seat.
A three armature permanent magnet reversible
Fb. I
-
Switch Assembly
NU523
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a motor is coupled through cables to rack and pin- ion assemblies located in the seat tracks, providing the various seat movements.
POWER SEATS 5-51
The electrical circuit is protected by a 30 amp circuit breaker located on the fuse block on the inside of the cowl panel to the left of the steering column.
SERVICE PROCEDURES
ELECTRICAL TESTS
Before any testing is attempted the battery the black (BK) terminal in the center section and the open connection in the front section, if motor should be fully charged and all connections and terminals cleaned and tightened to insure proper continuity and grounds. With everything connected does not operate, reverse the jumpers in the front section. If motor still does not operate, either the harness or complete three motor assembly should and the dome light on, apply switch in direction of failure, if dome light dims the seat motion is be replaced.
(10) To check center motor connect a covered trying to work indicating mechanical jamming. If dome light does not dim then proceed with the jumper wire between the red (R) terminal of the center section (Fig. 2) and either the red with following electrical tests.
(1) Disconnect wire from instrument panel feed at fuse block side cowl circuit breaker. white tracer (R-W) tracer, or yellow with white
(Y-W) tracer connection in the center section.
Connect a second covered jumper wire between
(2) Connect test lamp C-744 in series between instrument panel feed and good ground. If test lamp lights feed-in wiring is good. the black (BK) terminal in the center section and the open connection in the center section, if motor does not operate, reverse the jumpers (RW) and
(3) Remove test lamp and connect feed to circuit breaker.
(Y-W).
If motor still does not operate, either the harness or complete three motor assembly should
(4) Disconnect wiring from other side of circuit breaker. Connect test lamp C-744 ‘in series be- be replaced.
(11) To check rear motor connect a covered tween circuit breaker and good ground, if test jumper wire between the red (R) terminal in the lamp lights circuit breaker is good. center section (Fig. 2) and either the red with
( 5 ) Remove test lamp and connect wiring dark blue (R-DBL) tracer, or yellow with dark harness. blue (Y-DBL) tracer connection in the rear
(6) Disconnect wiring harness at connector under seat. Connect test lamp C-744 between red (R) section. Connect a second covered jumper wire between the black (BK) terminal in the center and black (BK) wire in female connector on section and the open connection in the rear harness, if test lamp lights harness to seat is good.
(7) Remove test lamp and connect harness. section, if motor does not operate, reverse the jumpers in the rear section. If motor still does not
(8) Remove switch from seat harness.
(9) To check front motor connect a covered operate, either the harness or complete three mo- tor assembly should be replaced. jumper wire between the red (R) terminal in the (12) If all motors and the seat operate properly center section (Fig. 2) either the red with dark green (R-DGN) tracer, or yellow with dark green
(Y-DGN) tracer connection in the front section. this indicates that the switch is bad and should be replaced. For additional wiring diagrams see
“Wiring Diagram” section at end of this group.
Connect a second covered jumper wire between
SEAT ASSEMBLY AND ADJUSTER
Y-DGN
R-DGN
Fig. 2
-
E/edrica/ Test Area Loeofion
Removal
(1) Disconnect battery ground cable.
(2) From underneath vehicle remove mounting nuts holding seat assembly to floor pan.
(3) Tilt seat and disconnect wiring harness.
(4) Remove assembly from vehicle. lnst allation
(1) Position seat assembly in vehicle.
(2) Connect wiring harness.
(3) From underneath vehicle install and tighten mounting nuts.
(4) Connect battery ground cable and check seat operation.
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5-52 POWER SEATS
FIG. 4
-
Mounting Screw location
ADJUSTER
Fig. 3
-
Mounting Bolt location
Removal
(1) Remove seat assembly from vehicle following procedure outlined under, “Seat Assembly and
Adjuster.”
(2) Lay seat on its back on some clean object.
(3) Remove bolts attaching adjuster to seat assembly.
Installation
(1) Lay seat on its back on some clean object.
(2) Position adjuster to seat assembly and install attaching bolts.
(3) Install seat assembly following procedure out- lined under “Seat Assembly and Adjuster.”
MOTOR
Removal
CAUTION: Anytime the motor, cable and housing assemblies or vertical and horizontal transmis- sion assemblies require maintenance, the assem- blies must be synchronized to insure easy and proper operation.
(1) Remove seat assembly from vehicle following procedure outlined under “Seat Assembly and
Adjuster.”
(2) Lay seat assembly on its back on some clean object.
(3) Remove bolt which holds motor to support
(Fig. 3). Then remove mounting (Fig. 4) screws.
(4) Carefully disconnect housings and cables from motor assembly.
Installation
(1) Place motor assembly into position.
(2) Carefully connect cables and housings to mo- tor assembly.
Fig. 5
ASSEMBLY NU527
-
Removing or Installing Cable and Housing.
(3) Install mounting screws.
(4) Install bolt holding motor assembly to adjuster
.
( 5 ) Install seat assembly following procedure out- lined under, “Seat Assembly and Adjuster.”
CABLE AND HOUSING
Removal
CAUTION: Anytime the motor, cable and housing assemblies or vertical and horizontal tranrmis- sion assemblies require maintenance, the assem- blies must be synchronized to insure easy and proper operation.
It is recommended that anytime a cable is to be replaced that the motor assembly be removed also for ease of replacement.
(1) After motor has been disconnected. Remove corbin clamp from cable housing then slide cable and housing out of connector (Fig. 5).
Installation
(1) Insert cable and housing into connector and install corbin clamp.
(2) Install motor assembly.
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0
CONVERTIBLE TOP LIFT 5-53
PINION RETAINER
/
SLIDES
LOWER TRACK
’ I
AND RAIL
BELL CRANKS
RAIL
SIDE assemblies or vertical and horizontal transmis- sion assemblies require maintenance, the assem- blies must be synchronized to insure easy and proper operation.
(1) Remove seat assembly from vehicle following procedure outlined under, “Seat Assembly and
Adjuster.”
(2) Remove motor assembly following procedure outlined under, “Motor.”
(3)
Fasten a 10 inch “C” clamp from the mounting base assembly to the upper channel as- sembly just tight enough to keep it in place while removing cotter key and the front (5/16 inch) clevis pin.
(4) After clevis pin is removed slowly release the tension on the vertical spring.
(5) Remove cotter key and rear pin and upper channel assembly.
(3/8
inch) clevis
(6) Remove horizontal spring.
(7) Remove the through bolts from each end of the side rail assembly.
(8)
Remove the through bolts from the transmis- sion assemblies and separate rails and transmission assemblies (Fig. 6).
Fig.
HORIZONTAL ~RANSMISSION
6
-
Side Rail (Disassembled)
HORIZONTAL AND VERTICAL
TRANSMISSIONS
u
Removal
CAUTION: Anytime the motor, cable and housing
Installation
During assembly constant care should be exer- cized to keep both track and rail assemblies synchronized.
(1) Position transmission assemblies between side rails and install through bolts and nuts.
(2) Locate roll pin and install through bolts in each end of assembly.
(3)
Install horizontal spring.
(4) Position rail assemblies at end of torsion bars. Line up holes and upper channel and install rear
(3/8
inch) clevis pin and cotter key.
(5) Insert vertical spring and apply pressure with
“C” clamp just enough to align holes in mounting base and upper channel. Install front (5/16 inch) clevis pin and cotter key.
(6) Install motor assembly following procedure outlined under “Motor.”
(7) Install seat assembly following procedure out- lined under, “Seat Assembly and Adjuster.”
CONVERTIBLE TOP LIFT
start to lower. Repeat test with the brown wire.
TOP LIFT (CONVERTIBLE)
Electrical Tests
The top (in lowered position) should start to rise.
If top operates during these tests, but fails to op- erate when the control switch lever is moved to
Control Switch
Refer to Figure
“UP” or “DOWN” position, the switch is at fault and should be replaced. If the top fails to operate
1 and appropriate wiring dia- during these tests, inspect and test wires between gram (See “Wiring Diagrams”) and disconnect red switch and motor. wire at switch. Hold firmly against yellow wire terminal on switch. The top (if raised) should
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5-54 TAILGATE WIPER WASHER
a
SWiTCH fig.
UP
1
- wiring circuit
Q1-12R
CONNECTOR
CIRCUIT
BREAKER
T2-12R
T 3 - 1 2 Y T l
NN653A motor and connect one wire of test light to brown wire and the other to a good body ground. Posi- tion the instrument panel switch in the ‘*UP’1 position. The bulb should light. Repeat this test with the yellow wire but position the switch in the “DOWN” position. If the bulb fails to light either time and wire continuity has been established, replace the circuit breaker.
Pump Motor
Should the test bulb light on one wire but not the other, inspect wire harness for a broken wire.
If the bulb lights in both tests, place one wire of the test light to the black wire terminal (ground) on the motor and the other wire to a good body ground. Position the switch in either “UP” or
“DOWN” position. If bulb should light inspect for a poor ground connection or broken black wire. If the bulb does not light and wire harness continui- ty has been established, test black wire with a needle type connector as close to motor as possi- ble without touching motor. If bulb fails to light, replace the motor (refer to Group
Frame”).
23 “Body and
TAIL GATE WIPER WASHER SYSTEM
INDEX
General Information
Motor Pump
...............................................................
Page
5 4 Service Diagnosis
5 5 Washer Reservoir
.....................................................
Wiper Blade-Replacement
..................................
Page
5 5
5 5
5 5
GENERAL INFORMATION
The tail gate wiper washer system (Fig. 1) is a mechanically activated squeegee wiper with an electric motor driven washer pump for applying water to the tail gate glass.
Operafion-
The tailgate glass may be cleaned by:
(1) Lowering the glass by activating the tail gate switch.
(2) Activate the tail gate washer switch.
(3) Raising the glass by activating the tail gate switch. The wiped area is accomplished by using two 18 in. flexible wiper blades, end to end.
When the glass is lowered to its bottom position an actuator arm is activated which permits the spring loaded blades to move to an “on glass” position. When the glass is raised to its upper limit, the actuator arm is again activated causing the wiper blades to go to an “off glass” position.
This permits the blades to remain in the “off glass” (free) position until the glass is again lowered.
Washer fluid may be applied (as required) to the glass surface (with glass in lower position) by an electric driven pump, supplying nozzle assemblies located inside the upper part of the tail gate.
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0
TAIL GATE WIND0
TAILGATE WIPER WASHER 5-55
WIPER BLADES
Condition
INTERMITTENT OPERATION
OF WASHER.
PUMP INOPERATIVE MOTOR
RUNS.
Fig. 1
-
Tailgate Window Washer and Wiper System
SERVICE DIAGNOSIS
Possible Cause
(a) Loose wiring connection.
(b) Faulty washer push button switch.
(c) Faulty motor.
(a) Nozzle jets plugged.
NRls8C
Correction
(a) Tighten connections and repair as necessary.
(b) Replace switch.
(c) Replace motor and pump assembly.
(a) Clean nozzle jets.
PUMP ASSEMBLY
INOPERATIVE.
WIPER BLADES WILL
GO ONTO GLASS.
NOT
(b) Broken or loose hose.
(c) Faulty pump.
(a) Poor ground.
(b) Loose wiring terminals.
(c) Broken wires.
(d) Faulty switch.
(e) Faulty motor.
(a) Loose control arm.
(b) Replace hose.
(c) Replace motor and pump assembly.
(a) Clean ground wire terminal and tighten mounting screw.
(b) Tighten terminals.
(c) Repair or replace wires.
(d) Replace switch.
(e) Replace motor and pump assembly.
(a) Repair control arm.
WIPER BLADES WILL NOT
COME OFF OF GLASS.
(b) Torsion springs broken.
(a) Loose control arm.
(b) Replace springs.
(a) Repair control arm.
(b) Actuator pin loose. (b) Reinstall pin.
SERVICE PROCEDURES
Wiper Blade Replacement
-(Fig.2) tripping limit switch.
( 5 ) Position the yoke for
( I 8
(1) Lower the tail gate glass to full bottom position.
Open tail gate to horizontal position. (2)
(3)
(4)
Remove inner trim panel of tail gate.
Raise glass approximately half way, after
“off
Inch Blade) glass” condition.
(6) Remove wiper control arm assembly from glass.
(7) Disengage glass from window regulator arms and remove glass.
(8) Position the yoke for “on glass” condition.
(9) Remove and replace blades. (Locking Tab
Down)
(10)Do Not get lubricant on new wiper blades.
(11)
(12)
Position the yoke for “off glass” condition.
Install glass and assemble to window regulator.
(13) Connect wiper control arm assembly to glass.
(14) Install inner trim panel.
(15) Lower glass to full bottom position and check operation of wiper system.
Washer Reservoir and/or Motor Pump
Assembly-
Removal
(1) Lower tail gate glass to bottom position and open tail gate to horizontal position.
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0
(2) Remove tail gate inner trim panel.
(3) Raise glass sufficient to allow access to reser- voir assembly.
CAUTION: Do not exceed normal height of glass travel.
(4) Remove washer hoses from both outlets at washer pump, being careful not to break outlets; identify hoses.
( 5 ) Disconnect one wire to washer motor.
(6) Remove three mounting screws supporting reservoir and remove rubber filler hose at reservoir.
/nstallatrbn
(1) Position reservoir and install mounting screws.
(2) Connect washer hoses at washer pump, mak- ing sure hoses are routed to the correct outlets.
(3) Connect rubber filler hose at reservoir.
(4) Reconnect the wire at washer motor.
( 5 ) Install tail gate inner panel.
SPECIFICATIONS
5-57
(6) Lower tail gate glass to bottom position and recheck motor and pump operation.
Washer Nozzle Replacement
(1) Perform steps 1 through 8 under “Wiper
Blade Replacement”.
(2) Remove the screws mounting the two nozzle assemblies.
(3) Inspect and clean nozzles. Replace if nozzles are damaged.
(4) Position nozzles and install mounting screws.
( 5 ) Connect washer hose to nozzles.
CAUTION: Do not break nozzle inlets. Do not get lubricant on wiper blades.
(6) Position yoke for “off glass” condition.
(7) Install glass and attach wiper control arm.
(8) Run glass to bottom position.
(9) With tail gate closed, check operation of new nozzles.
(10) If operation is now satisfactory, install inner tail gate trim panel.
SPECIFICATIONS
BULB CHART
Valiant Barracuda
Barracuda
(Rallye)
Air Conditioner Control and
Auto-Temp
. . . . . . . . . . . . . . .
* * 1445
Ash Receiver * * 1892
Back-up Lights
. . . . . . . . . . . . . . .
. . . . . . . . . . . . .
1 156(2)
Brake System Warning Indicator
Clock
.....................
Courtesy Lamp
Dome Lamp..
.
158
. . . . . . . . . . . . .
-
. . . . . . . . . . . . . . .
1004
Door Ajar Indicator
. . . . . . . . . . .
89
-
Fender Mounted Turn Signal
Indicator
. . . . . . . . . . . . . . . . .
330( 2)
Front Park and Turn Signal
.....
1157NA(2)
““1815
**1445
1 156(2)
57
*
““1815
**1445
1 156(2)
57
*
89 89
211-1 or 1004 211-1 or 1004
1892 1892
330(2) 330(2)
1157NA(2) 1157NA(2)
Gear Selector Indicator (Column)
Gear Selector With Console
Glove Compartment
. . . . .
** 161
-
. . . . . . . . .
1891
Headlamp Switch Rheostat Value 28 OHMS
High Beam Indicator
..........
158
Instrument Cluster and
Speedometer..
Ignition Lamp
License Light
.............
. . . . . . . . . . . . . . .
1445
. . . . . . . . . . . . . . .
67
Low Fuel Indicator
Map and Courtesy Lamp
Oil Indicator
. . . . . . . . . . .
-
.......
89
................
* * 158(3)
158
** 161
* *
57
1891
15.5OHMS
57
* * 181 6(3)
1445
67
1892
89
57
* * 161
* *
57
1891
15.5 OHMS
57
* * 1893(4)
1445
67
1892
89
-
Satel I
Satellite
(Rallye)
* *
53(2)
1445
1 156(2)
158
*
-
1004
1892
* * 53(2)
**1445
1 156(2)
57
*
-
1004
1892
330(2)
1157A or
1 157NA
* * 161
* *
57
1891
15 OHMS
158
330(2)
1157A or
1 157NA
* * 161
* *
57
1891
15 OHMS
57
* * 158(4) * * 57(7)
1445 1445
67
1892
562
158
67
1892
562
-
MyMopar.com
5-58 SPECIFICATIONS
Valiant
Pocket Panel Lamp
Radio
. . . . . . . . . . . -
Radio-AM and AM with Tape..
.
-
AM/FM Stereo
. . . . . . .
""1816
Reverse 4-Speed Transmission
Indicator
Sealed Beam-Hi-Lo Beam (No.2)
Side Marker
. . . . . . . . . . . . . . . . .
Sealed Beam-Hi-Beam
Sealed Beam-Single "7"
Seat Belts Indicator
.
,
53
. . . . . . .
601 2
. . . . . . . . . . .
-
-
53
. . . . . . . . . . . . . . . . .
1895(4)
Stereo Indicator
Switch Lighting
Tachometer
. . . . . . . . . . . . .
-
. . . . . . . . . . . . .
.................
Tail, Stop and Turn Signal
*
-
. . . . .
1157(2)
Trunk and/or Under Hood Lamp. 1004
Turn Signal Indicator (Panel)
. . .
158(2)
BULB CHART (Con,.)
Barracuda
Barracuda (Rallye)
90
""1816
""1815
90
""1816
""1815
53
4001
4000
-
1892 or 53
1895(4)
1445
""1445
-
1 157(2)
1003
57(2)
*-Included in Instrument Cluster Lighting
53
400 1
4000
-
1892 or 53
1895(4) satellite
90
""1816
""1815
1445
""1445
*
11 57(2)
1003
57(2)
**-Headlamp Rheostat Dimming
(Rallye)
90
**1816
'"1815
53
4001
4000
-
1892
194(4)
Sta. Wagon
Front 194(2)
Rear 1893(2)
53
400 1
4000
-
1892
194(4)
1445 1445
**1892(3) **1892(3)
- *
1157(2)
1003
158(2)
1 157( 2)
1003
57 (2)
BULB CHART
Arm Rest Lamp
Ash Receiver
Au to-Temp
................................
..................................
....................................
Back-up Lights.
.................................
Brake System Warning Light
Clock
......................
........................................
Cornering Light
................................
Courtesy Lamp
Dome and/or
................................
"C" Pillar Light
......................
Door and Pocket Panel and/or Reading Light
. . . . . . . . . .
Fasten Belts Indicator
Fuel Indicator
Glove Compartment
High Beam Indicator
............................
Fender Mounted Turn Signal Indicator
Gear Selector Indicator (Column)
Gear Selector with Console
............................
Head Lamp Wash Indicator
Heater and/or A/C Control
. . . . . . . . . . . . . .
..................................
. . . . . . . . . . . . . . . . . .
........................
........................
........................
............................
Instrument Cluster and Speedometer Illumination
Ignition Lamp
. . . . . .
..................................
License Light
..................................
Fury
-
""1445
*
1156
57
*
1293
90
21 1-2
90
53
330(2)
57
*
* *
57
1891
1445
*
1892
**1893(3)
1445
67
Chrysler
-
* * 1892(2)
*
1156
57
*
1293
90
21 1-2
90
57
* *
330(2)
-
*
57
1891
-
*
57
* * 181 6(4)
1445
67
Imperial
1445
1156
57
*
1293
-
-
90
158
330(2)
-
*
-
1891
1445
*
158
**1816(4)
1445
67
MyMopar.com
SPECIFICATIONS
5-59
0
Low Fuel Indicator
Lock Doors Indicator
Map Lamp
Radio
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Indicator
Open Door Indicator
Panel Rheostat Value
Portable Reading Light
............................
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
............................
Park and Turn Signal (Front)
......................
..........................
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading Lamp
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealed Beam-Hi-Beam (No. 1)
....................
Sealed Beam-Hi-Low Beam (no. 2 ) .
. . . . . . . . . . . . . . . . .
Sentry Signal
Side Marker
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stereo Indicator
Switch Lighting
Tail Light (only)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tail, Stop and Turn Signal
Temperature Indicator
........................
............................
Trunk and/or Under Hood Light
....................
Turn Signal Indicator (Panel)
......................
BULB CHART (Cont.)
Fury
-
57
-
57
-
24 OHMS
1157(2)
-
*
-
4001 (2)
4000( 2)
-
1895(4)
1445
* or 1892
-
1157
-
1003
57
Chrysler
158
57
562
57
-
15.5 OHMS
1157(2)
-
*
-
4001 (2)
4000(2)
-
1895(4)
1445
*
1095
1157
57
1003
57
Imperial
-
158
562
15.5 OHMS
1 157NA(4)
89
*
90
4001 (2)
4000(2)
158
1895(2)
1445
*
1095(2)
1157
-
1003
-
"Included in Instrument Cluster Lighting.
""Headlamp Reostat Dimming.
NOTE: All of the above bulbs are brass base. Aluminum base bulbs are not approved and not to be used.
Title On Fuse Block
Accessories
Console
Dome/Stop Lamps
Emergency Flasher
Heater/Air Conditioning
Instrument Lights
M isce I laneous
Radio/Back-up Lamps
TaiVCigar Lighter
Valiant
20
-
20
20
20
3
-
20
20
FUSES
Car Model and Ampere Rating
Barracuda
20
20
20
20
20
5
20
20
Satellite
20
20
20
20
20
5
20
20
MyMopar.com
5-60 SPECIFICATIONS
Title On Fuse Block
Accessories
Cigar Lighter/Console
Console
Dome/Stop Lamp
Emergency Flasher
Heater/Air Conditioning
Instrument Lamps
M la neous
Rad io/B ack-u p Lamps
Tail Lamps
Fury
20
-
20
20
20
20
5
20
20
20
Car Model and Ampere Rating
Chrysler
20
20
20
20
20
20
5
20
20
20
Imperial
20
20
20
20
20
20
5
20
20
20
FUSES (IN-LINE)
Circuit
Automatic Temperature
Con tro I
Courtesy Lamps
(Console)
Deck Lid Solenoid
Headlamp Delay
Relay
Headlamp Dimmer
Headlamp Wash Relay (On
Imperial includes Rear
Defogger, Rear Heater and Rear Air Conditioning, if so equipped)
Heater/Air Conditioning-
Blower Motor (Tilt
Column)
Spot Light Wiring
Tail Gate Lock Solenoid
Valiant
-
-
-
20
-
-
CAR MODEL AND AMPERE RATING
Barracuda Satellite Fury Chrysler
20
-
-
20
-
-
20
-
20
20
-
20
20
20
4
-
20
Imperial
20
4
20
20
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5-62 WIRING DIAGRAMS
0
WIRING DIAGRAMS
Automatic Headlamp Beam
Changer-Chrysler-Imperial
Body Wiring-Valiant
......................................
7 0
.................................................
81
Body Wiring-Duster
.................................................
Body Wiring-Barracuda
..........................................
81
Body Wiring-Satellite (Except Station Wagon)83
Body Wiring-Satellite (Station Wagon)
............
86
Body WiringFury (Except Station Wagon)
Body WiringFury (Station Wagon)
Page
...................
INDEX
8 2
85
8 4
Body Wiring-Chrysler (Except Station Wagon187
Body Wiring-Chrysler (Station Wagon)
Body Wiring-Imperial
...............................................
74
89
Console Wiring-Fury
................................................
Console Wiring-C hrysler
........................................
71
72
Front End Lighting Wiring-Valiant
....................
66
Front End Lighting Barracuda.
............................
65
Front End Lighting WiringSatellite
..................
66
Front End Lighting WiringFury
.......................
Front End Lighting Wiring-Chrysler
Front End Lighting Wiring-Imperial
..................
...................
Overhead Console Wiring-Barracuda
Page
................
67
68
69
71
Power Seat Back Release Wiring-Fury-Chrysler and Imperial
................................................................
Power Seat Wiring-Fury
75
........................................
7 2
Power Seat Wiring-Chrysler
Power Seat Wiring-Imperial
................................
75
.................................
7 3
Power Window Wiring-Barracuda
.....................
76
Power Window Wiring-Satellite
.........................
7 7
Power Window and Door Lock Wiring-Fury.78
Power Window, Power Vents and Door Lock
Wiring-Chrysler
..........................................................
7 9
Power Window, Power Vents and Door Lock
Wiring-Imperial
..........................................................
80
Rear End Lighting Wiring-Satellite
....................
88
Fig. I
-
Bulkhead Disconnect
-
Valiant
LEGEND +
S P g y
+
B s
MALE a
FE
FEMALE
INSULATORS VIEWED
FROM TERMINAL SIDE
Code and legend
PB362
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WIRING DIAGRAMS 5-63
Fig. 3
-
Bulkhead Discon v?ecl Barracuda, Satettite
Fig. 4
-
Bulkhead Disconnut
-
Fuv, Chrysler and tmperiat
A
Fig. 5
-
Fuse Btock
-
Vatiant
P6359
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5-64 Y WIRING DIAGRAMS
a
PB361
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5-66 WIRING DIAGRAMS
HEADLAMP
MARKER LAMP
GROUND
BULKHEAD DISCONNECT rn
FENDER TURN
INDICATOR
Fig. 9
MARKER LAMP -
Front End lighting Wiring
-
V a l h t
RIGHT HOOD TURN SIGNAL
PY218
RIGHT PARK AND
TURN SIGNAL
HEADLAMP
Fig. 10
-
Front End lighting Wiring
-
Satettite
LEFT MARKER LAMP
LEFT PARK AND
TURN SIGNAL
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5-70 WIRING DIAGRAMS
PHOTO-
0
DRIVER CONTROL
(SENSITIVITY CONTROL)
BEAM
D ~ N LBL w
I
COLOR CODE
BLK BLACK
DGN DARK GREEN
GY GRAY
GY/BLK* GRAY WITH BLACK STRIPE
LBL LIGHT BLUE
LGN LIGHT GREEN
N.C. NO CONNECTION
R RED
N.C.
TO HEADLAMP-UPPER
BEAM FILAMENTS
V VIOLET OR PURPLE
V/W* VIOLET WITH WHITE STRIPE
W WHITE OR NATURAL
*
I
WITH TRACER
SEE NOTE
TO HEADLAMP LOWER
BEAM FILAMENTS
SYMBOLS c
3
PUSH-ON CONNECTOR-MALE TERMINAL f WIRES CROSSING (NO SPLICE)
-( PUSH-ON CONNECTOR-FEMALE TERMINAL
$:
PUSH-ON MULTIPLE CONNECTOR
+.;
MALE TERMINALS
2-:
PUSH-ON MULTIPLE CONNECTOR
+j FEMALE TERMINAL
-
RELAY CONTAINS DAMPENING DIODE TO PROTECT PHOTO-AMPLIFIER FROM POWER RELAY SURGES
DURING SWITCHING.
CAUTION-REPLACE POWER RELAY WITH EXACT PART NUMBER ONLY. SUBSTITUTION OF
DIFFERENT PART NUMBER WILL PROBABLY RESULT IN A RUINED PHOTO-AMPLIFIER.
N U 5 a
Fig. 14
-
Automatic Headlamp Beam Changer Wiring
-
Chrysler, Imperial
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0
TO DOME READING LAMP
WIRING DIAGRAMS 5-71
OVERHEAD
@-
G10-18Y
G7-18DBL
WIRING M3-18BK
M3-18BK 1
GROUND
TO HEADER
I
1
TO RIGHT
DOOR AJAR
SWITCH CABLE
TO LEFT
DOOR AJAR
SWITCH TO BODY
AND RIGHT
SWITCH m- m-M3-18BK
-M3-18BK
- -
Overhead Console Wiring
-
Barracuda
GROUND TO
FLOOR PAN
TO COURTESY LAMPS
1 Fkq
Y
@ = K E 2 - 1 8 3
TO GEAR SHIFT
SELECTOR LAMP
WITHOUT CIGAR LIGHTER
GROUND TO
FLOOR PAN
PANEL WIRING
INSULATOFS VIEWED
TO CONSOLE WIRING
(ON INSTRUMENT PANEL)
PY116
-TO COURTESY LAMPS X2-16BK
X2-18BK
E2-18 0
M1-18P
Em-
TO GEAR SHIFT b N D x 2 1 6 B K ~ E2-18 0 1 8 B SELECTOR LAMP
WITH CIGAR LIGHTER
L
Fig. 16
-
Console Wiring
-
Fury
TO CONSOLE WIRING
(ON INSTRUMENT PANEL)
COLOR CODE
SPLICE
+
YELLOW
PY112
MyMopar.com
a
5-72
WIRING DIAGRAMS
M2-18Y
-
M1-18P
GROUND TO
FLOOR PAN
B x2-
16BK
TO
COURTESY LAMPS
M2-18Y
M1-18P
CIGAR LIGHTER
4
To
FEED
X2-16BK.
X2-18BK
M2-18Y
M1-18P
-E2-18
M2-18Y
-
I
_1
0
@!?-
CONSOLE TO WIRING
M1-16P
(ON INSTRUMENT PANEL)
-
M2-
TO REAR DOOR
SWITCH CABLE
(FOUR D O O R HARDTOP)
M2A-
1 8Y
TO GEAR SHIFT
SELECTOR LAMP
Fig. 17
-
Console Wiring
-
Chrysler
TO
INSTRUMENT
COLOR CODE
YELLOW
P Y l l l
-Fl-l2R
TO INSTRUMENT
PANEL FEED
1 12BK
GROUND
16Y /GN
-
SEAT MOVES
+
UP IN REAR
I
-
SEAT MOVES LEFT SEAT
+
FORWARD
B HORIZONTAL
-
SEAT MOVES
+ UP IN FRONT
TO LEFT SEAT ADJUSTER SWITCH (BENCH
Fig. 18
-
POW8 v Sed Wiring
-
Fury
FEMALE
INSULATORS VlmED
FROM TERMINAL SIDE
COLOR CODE
BK BLACK
BL BLUE
GN GREEN
R RED
Y YELLOW
* WITH TRACER
NUlO5A i
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e
TO SEAT BACK RELEASE FEED
FROM INSTRUMENT PANEL
WIRING DIAGRAMS 5-75
TO DOOR
SWITCH WIRING
TO
RELAY
Bt?ll::EN*
X32-14LGN
X32-14LGN
P1-14DGN
P1-14DGN
Fig.
RIGHT SIDE SEAT
BACK RELEASE
-
TO DOOR LOCK
WIRING IF SO
EQUIPPED
I
X2-14BK b
I
21
TO RIGHT FRONT
DOOR SWITCH
X2:lbBK K
0
GROUND TO
FLOOR PAN
-
Power Seat Back Release Wiring
-
Fury, Chrysler and Imperial
SOLENOID
LEFT SIDE SEAT BACK
RELEASE SOLENOID
PB40
TO RIGHT SEAT ADJUSTER
SWITCH (RIGHT BUCKET
OR RIGHT 50-50
SPLIT SEAT ADJUSTER)
-
SEAT MOVES
+
UP IN REAR
SEAT MOVES
TO INSTRUMENT
PANEL FEED
-126KI
P
GROUND
F2-12BK
FEED FOR LEFT
OR RIGHT SIDE
-12R
-
SEAT MOVES
-t UP IN FRONT y - 1 2 R - 12BK-
TO LEFT SEAT ADJUSTER SWITCH
(BENCH SEAT OR LEFT
BUCKET SEAT OR LEFT
50-50 SPLIT SEAT ADJUSTER)
-
SEAT MOVES
+
UP IN FRONT
SEAT MOVES
FORWARD
HORIZONTAL
LEFT SEAT
ADJUSTER MOTOR
RIGHT SEAT
ADJUSTER MOTOR
-
SEAT MOVES
+
UP IN FRONT
I
INSULATORS
7-3
FEMALE
VIEWED
FROM TERMINAL SIDE
PYlW
Fig. 22
-
Power Seat Wiring
-
Chrysler
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*
WIRING DIAGRAMS 5-81
TO FADER
SWITCH ON
INSTRUMENT
PANEL
F24-18BK-a
TO REAR SPEAKER
(F25-18DGN-
REAR SPEAKER WIRING
GROUND a
CONSOLE WIRING
Fig. 28
-
Body Wiring
-
Valiant
SELECTOR LAMP
17-18BK
LEFT TAIL
-
STOP
-
TURN
PTIONAL-LBL* SIGNAL TAIL LAMP
D&18DGN
I
-17-18BK
LEFT SIDE MARKER LAMP
OPTIONAL-Y'
_ _
.
MARKER LAMP
LAMP SWITCH m p .
M l 2 1 8 B K
TO REAR SPEAKER
INSTRUMENT
TO REAR WINDOW DEFOGGER SWITCH
WIRING ON INSTRUMENT PANEL
~
LEFT SIDE MARKER
LAMP
!
~
C13-18BK k
4
~
1 3 1 4
~
B K ~ C l
~
4 -
GROUND
1 4 B K
~
~
REAR WINDOW DEFOGGER MOTOR ~ ~ 1 2 6 RESISTANCE CABLE
Fig. 29
-
Body Wiring
-
Duster
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&
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5-88
WIRING DIAGRAMS
RIGHT
RIGHT OUTBOARD
SIDE
AARKER
TAIL, STOP,
TURN
LAMP SIGNAL
LAMP
RIGHT
INBOARD
RIGHT TAIL, STOP,
TURN B$hFp
SIGNAL
LAMP
LEFT
IN BOARD
TAIL, STOP,
TURN
SIGNAL
I AMP
LEFT
BACK up
LEFT
OUTBOARD
TAIL, STOP,
TURN
SIGNAL
LAMP
0
;ROUND k.
18Gy-
I
L7-l8BK
LJl
D8B-
18DGN
B h
I
D8A- l8DGN
-D7-18BR-$=r
D8518DGN
I
TO BODY
WIRING
I
B2-18V
LEFT
LAMP
2 DOOR HARDTOP
RIGHT
TAIL, STOP,
TURN
SIGNAL
LAMP
RIGHT
BACK UP
LAMP
RIGHT
SIDE
MARKER
LAMP
,x2-,
18GY rND i
B2- v-
1 8 r
Fig. 36
SEDAN -
Rear End fighting Wiring
-
Satellite
PB128
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SIDE GLASS
IMPERIAL-CHRYSLER-PLYMOUTH-FURY
INDEX
GLASS ADJUSTMENTS-VENTWING
4-DOOR HARDTOP
..............................................
Page
6
Adjustments-With Vent Wing
.......................
6
Door Glass And Vent Wing
Replacement
Assembly
Installation
Removal
.........................................................
.............................................................
Disassembly .......................................................
..........................................................
...............................................................
6
7
7
8
GLASS ADJUSTMENTS-VENTLESS
2-DO0 R HARDTOP
Glass Rear Track
Installation
Removal
Lift Bracket
................................................
Glass Replacement
Installation
Removal
Pivot Bracket
.......................................................
Regulator Arms-Manual
...................................
Regulator Motor Replacement
......................
UpStops
.................
..............................................
..........................................................
...............................................................
...............................................................
Regulators
..........................................................
.............................................................
.................................................................
Window Lift Switch ..........................................
6
2
2
4
5
4
3
3
3
5
5
5
5
5
5
15
GLASS TAILGATE
...................................................
21
Adjustments
.........................................................
Glass Replacement
21
21
Installation
Removal
..........................................................
Glass Lift Channel
Glass R u n Channel
Installation
Removal
...............................................................
HARDTOP MODELS
...............................................
1
Adjustments
Glass Assembly
Glass Lift Brackets
Removal ...............................................................
21
22
............................................
22
..........................................................
22
Removal
Regulator Replacement
....................................
Installation
..........................................................
22
...............................................................
............................................
..........................................................
21
22
22
22
.........................................................
1 2
...................................................
Glass Replacement
Installation
............................................
2
1
15
13
13
13
Regulators
.............................................................
Regulator Motor Replacement up-stops
......................
.................................................................
Window Lift Switch
..........................................
QUARTER PANELS
.................................................
Belt Line Weatherstrip
.....................................
Garnish Mouldings
Glass Adjustment
.............................................
...............................................
Handles
...................................................................
Trim Panels
...........................................................
Watershield
QUARTER WINDOW-HARDTOP
Adjustments
.........................................................
Down Stops
Front Track
...........................................................
........................
..........................................................
...........................................................
Installation
..........................................................
Removal
...............................................................
Glass Adjustments-Sedan
...............................
Installation
Removal
..........................................................
...............................................................
Replacement
Installation
Removal
......................................................
Glass Replacement
Installation
R emova I
..........................................................
...............................................................
Glass Lower Frame
...........................................
..........................................................
...............................................................
Glass Run And Weatherstrip
Retainer
..................................................................
Installation
..........................................................
Remova I
Glass Lift Channel
Glass R u n Channel
Installation
Removal
.............................................
............................................
...............................................................
Pivot Bracket
.......................................................
Regulator
...............................................................
Regulator Motor Replacement
......................
Rear Track
............................................................
Installation
Removal
.......................................................... up-stops
...............................................................
.................................................................
Window Lift Switch
..........................................
Pane
1 2
1 2
13
1 5
15
15
15
15
1 5
15
15
16
16
1 7
17
17
17
19
2 0
20
20
20
20
20
1 8
1 8
1 8
20
20
20
21
2 0
2 0
2 0
11
12
12
1 8
18
18
1 3
9
DOOR-QU ARTER-TAILGATE
(IMPERI AL-CHRY SLER-PLY MOUTH)
GLASS ADJUSTMENTS
The circled numbers shown on the glass adjust- ment reference illustrations indicate the pariicular step number being read in the adjustment procedure
.
Prior
to
adjusting glass. all doors must be cor- rectly fitted in their opening and the weatherstrips at the
"A"
post and roof rails must be properly installed
.
Refer to the adjustment illustration
and
loosen
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6-2 IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
e
Fig. I
@
NU374
-
Glass Adjustments 2 Door Hardtop
-
Ventless
FRONT TRACK
\
Fig. 2
-
Glass Up-Stops
Parallelism o f Glass fo Primary Seal
(4) Move pivot bracket fore or aft and set glass parellel to weatherstrip locating bead at primary sealing lip.
( 5 ) Tighten pivot bracket and support screw assemblies.
(6) Set front up-stop down against bumper on glass.
(7) Tighten up-stop bracket screw on inner panel
(Fig. 2).
-'\ stop in rear frame.
(9) Tighten rear channel and bracket upper atta- chment screw.
NU300
Fig. 3
- lift Bracket the attaching screws and nuts of the various door components affecting glass adjustment.
Service procedure- for components related to the door or vent wing glass follow the glass adjust- ment procedures.
GLASS ADJUSlMENlS
-
2
DOOR HARDlOP
In-Out and Secondary Seal
(10) Move bottom of front track to create an effective glass to weatherstrip secondary seal.
(1 1) Tighten glass track to lower bracket screw.
(12) Tighten track lower bracket and retainer to inner panel nut assembly.
Fronf and Rear lrack Parrallelism
(13) Run glass approximately 2/3 down.
(14) Tighten glass run rear channel and bracket assembly lower bracket nut. Adjusfmenfs- Venfless Door (Fig.
1)
Fore and AH
(1) Raise glass completely.
(2) Move glass fore or aft to set glass to belt line weatherstrip.
(3) Tighten glass track upper bracket at belt line.
Down Sfop-Manual
(15) Lower glass until top edges of glass is even with or slightly below belt line of door outer panel. Do not allow glass to drop below weath- erstrip on door outer panel.
(16) Position stop on regulator plate against stop
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0
IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
6-3
GLASS REPAACEMENT
RETAINER NU301
Fig. 4
-
Gfass Repfacement on sector.
(17) Tighten regulator plate stop locknut. Tight- en callouts 18 through 25 securely. (Fig. 1).
Removal
(1) Remove door belt line weatherstrips.
(2) With regulator arms in the full down position, remove screws attaching lift bracket to glass (Fig. 3).
(3) Remove front track upper and lower bracket attaching screws.
(4) Raise door glass and front track assembly out of door (Fig. 4).
( 5 ) Remove front track from glass guide and guide from glass (Fig. 5).
(6) Remove fasteners and up stop from glass
(Fig. 5). tnstallation
(1) Place glass on table with outside of glass fac- ing upward.
(2) Install fasteners and up-stop in glass (Fig. 5).
(3) Position track guide over fasteners and secure with screw.
(4) Slide front track lower end flanges through guide grooves.
( 5 ) With regulator arms in the full down posi- tion insert door glass and front track assembly into door.
(6) Allow track to slide down to bottom of door panel.
(7) After up-stop bumper has cleared through glass opening, engage glass rear frame in rear channel run and lower glass to bumper of lower adjusting bracket.
FASTENER
I I l l
FRONT TRACK
Fig. 5
-
Gfass Assembfy
NU302
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6-4 IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
SECTION A-A
Fig. 6
( 8 ) brackets with screws.
NU311
-
Glass Rear Track
Secure front track upper and lower mounting
(9) Align holes in lift bracket with fasteners in glass and secure with screws.
GLASS
REAR TRACK
Removal
(1) Remove the door glass and front track assembly.
(2) Remove screw attaching track upper bracket to door lock face and nut attaching track lower bracket to lower support (Fig. 6).
(3) Remove track assembly through large access hole in door panel.
NU304
SPRING
NUT
Fig. 7
-
Glass Lift Bracket
STUD
REGULATOR ARMS
VIEW A
Fig. 8
-
Regulator Arm
NU305
0
LINK
Fig. 9
-
Regulator Assemblies
ELECTRIC
W
NU309
MyMopar.com
0
IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
6-5 slot in reinforcement.
GLASS LIFT BRACKET
The glass lift bracket (Fig. 7) is positioned over sliding blocks on the regulator arms. Screws are used to secure the lift channel to the glass fasteners. Lubricate the sliding block contact areas of the lift channel sparingly.
NU310
Fig. 10
-
Pivot Bracket
Installation
(1) Position track assembly into door through large access hole.
(2) Align track upper bracket to hole in door lock face and install screw loosely.
(3) Insert track bottom bracket adjustment stud in slot of lower support bracket and install nut loosely.
(4) Install door glass assembly and tighten rear track screw and nut after adjusting glass.
UP-STOP
The glass up-stop (Fig. 2) is attached to the door outside panel belt reinforcement with a screw and washer assembly. Engage tab on stop with
REGULA TOR ARMS-MANUAL
The manually operated regulator incorporates a replaceable type arm assembly (Fig. 8). The arm assembly is retained on the inner door panel with screws and to the regulator connector link of the regulator with a spring nut. The door glass assem- bly should be removed when replacing the arm assembly.
REGULA TORS
The manual and electric operated regulators (Fig.
9) are attached to the door inner panel with screws.
Refer to the Electrical Group for test proce- dures and wiring diagrams for electric operated regulators.
PIVOT BRACKET
The pivot bracket and support assembly (Fig. 10) is secured with screws to the electric regulator idler arm slide and to the door inner panel with the manual regulator.
REGULATOR MOTOR REPLACEMENT
When necessary to remove motor from
Q t
SECONDARY SEAL
Fig. 11
-
4 Door Hardtop
-
Glass Adiustments
SECTION A-A
BEAD
NU322A
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6-6 IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
0 stop bracket on rear channel is in full up position.
(8) Snug secure rear run channel upper attach- ment screw. tn-Out Adjustment at Top o f Glass and
Secondary Seal
(9)
Raise glass fully.
(10) Back out adjusting stud on vent wing leg until shoulder bottoms out against door panel re- inforcement and a parallelism exists between glass edge and roof rail weatherstrip.
(11) Loosen nut assembly on vent wing leg ad- justing stud.
(12) Force vent wing leg outboard until second- ary seal is accomplished between glass and roof rail weatherstrip.
(13)
Snug nut assembly and loosen screws to perform adjustment.
(14) Loosen rear channel upper bracket screw assembly.
(15) Position up-stop on rear channel down against plastic bumper on glass and snug secure screw assembly.
Fig. 12
NU336 WASHER
-
Glass Replacement regulator, it i s imperative the linkage be secure- ly clamped in a vise to lock it in place. Failure to do this allows the assist spring to drive the mounting bracket around the lift pivot.
4-DOOR HARDTOP
Division and Rear Channel Paratlelism
(16)
Loosen rear channel lower attachment nut assembly.
(17)
Run glass approximately 3/4 down.
(18) Snug secure channel lower bracket nut assembly. WIND0 W
LtFT
SWITCH
Slide a thin blade behind the switch housing
(front and back) to depress retaining clips and pull switch out from panel. Carefully separate multiple terminal block from switch body and re- move switch from panel.
ManuaJ Down Stop
(19)
Loosen stop lock nut on regulator plate.
(20) Lower glass until top of glass is even with or slightly below door outer panel belt line. Do not allow glass to drop below outer weatherstrip.
ADJUSTMENTS (WtTH VENT WtNG-FtG. I I )
(2
1) Position regulator plate stop against stop on sector, secure nut assembly.
(22)
Operate window up and down testing for
Primary Seal Adjustment
(Fore-A H-Up-Do wn) east e of operation and inspecting alignment.
CI ranking effort at the regulator handle should exceed 30 inch pounds with door closed and
(1) Lower glass fully and loosen vent wing on hinge face at belt line.
st
crew all glass in the up position.
T ighten callouts
23
through
29
securely (Fig. 1 1 )
(2) Align and set vent wing to “A” post and roof rail weatherstrip.
(3)
Snug secure vent wing screw at belt rear at- DOOR GLASS AND VENT WtNG
REPLACEMENT tachment and raise glass fully.
(4) Set top edge of glass parallel to line up bead on roof rail weatherstrip.
( 5 ) Snug secure vent wing screw on hinge at belt line.
Removal
(1)
Remove nut and washer from end of division bar adjusting rod (Fig.
12).
(2) Remove vent frame to belt spacer reinforce-
Paratletism to Belt Outer Weatherstrip
(6)
Run glass approximately 1/3 down.
(7)
Adjust rear run channel upper attachment so glass lightly touches on outer weatherstrip and up ment screw.
(3) Remove vent wing adjusting stud to upper hinge nut assembly and vent wing to belt attach- ing screw.
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0
IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
6-7
FASTENER
VIEW IN CIRCLE A
NU568
(4)
Fig. 13
-
Lift Bracket
Remove lift channel to door glass fastener screws (Fig. 13).
( 5 ) Tilt top of glass inward and remove door glass and vent wing assembly.
Disassembly
(1) Invert door glass and vent wing assembly.
(2) Remove vent wing adjusting stud at hinge reinforcement (Fig. 14).
(3) Remove lower adjusting stud and anti-rattle from division channel.
(4) Slide door glass assembly out of vent wing division channel.
( 5 ) Remove slide assembly from glass and weath- erstrip (Fig. 13) by pulling slide halves apart.
(6) Remove weatherstrip from glass.
(7) Push lift channel fasteners out of glass.
Assembly
(1) Insert lift channel fasteners into glass from concave side (Fig. 14).
(2) Position weatherstrip on glass front edge with notched end in up position.
(3) Raise edge of weatherstrip and insert slide at attachment in glass. Secure by pressing together.
(4) With glass and vent wing in inverted position
(Fig. 13) insert slides on glass assembly into vent wing division channel.
( 5 ) Insert anti-rattle into division channel adjust- ing bracket loop opposite loop joint.
(6) Insert smooth end of adjusting rod into bracket loop between anti-rattle and loop joint.
(7) Install adjusting stud to vent wing hinge loosely.
(8) Apply rubber lubricant sparingly to each side of vent wing belt weatherstrip lip for entire length.
SLIDE A
I K I r
\
FASTENER
\
WEATHERSTRIP
GLASS
VENT
WING
Q
I
Ill1 g
SEDAN-STATION WAGON HARDTOP
Fig. 14
-
Glass Assembly
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6-8 IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
Installation
(1) Insert division channel through upper lock face corner, turn as necessary and move assembly forward.
(2) Tilt glass top inward, raising the off-set front lower leg to clear spacer bracket at belt.
(3) Insert lowest point of front leg and adjusting stud and lower assembly into door, with the pivot assembly mounting plate between the spacer brack-
0 et and door outside panel reinforcement.
(4) Position adjusting stud on lower off-set leg to hole in door hinge pillar and push through to stud shoulder.
( 5 ) Fit rear edge of glass in run channel.
(6) Align vent wing lower pivot plate slot with access hole in inner panel and spacer bracket and with attaching hole in spacer bracket. Secure with screws.
(7) Position washer on division bar adjusting rod
SCREW
\
CHAN<////
CHANNEL
2 DOOR
\
SCREW
NUT
Fig. IS
-
Glass Rear Channel
4 DOOR HARDTOP
Jl
NUT
NU316
I \\I
1
\
MANUAL
REGULATOR
Fig. 16
-
Regulator Assemblies
R E G U ~ T O R
ELECTRIC
NU307
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IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
6-9
LIFT
BRACKET
I
NU303
Fig.
- lift Bracket and insert adjusting rod into lower support.
(8) Install nut assembly on adjusting rod.
(9) Position and secure vent wing at front belt attachment with a screw and adjusting stud with a nut and washer assembly.
(10) Align glass fasteners with holes in lift chan- nel and secure with screws.
&@’
LbJ
PBl77
Fig. 78
-
Vent Wing Regulator fasteners. Lubricate the sliding block contact areas of the lift channel sparingly.
REAR CHANNEL AND UP-STOP
Removal
(1) Remove up-stop at rear channel.
(2) Remove the door glass and vent wing assembly.
(3) Remove channel upper support retaining screw at door lock face, inner panel support and lower support retaining nut (Fig. 15) at door.
(4) Remove channel assembly through large ac- cess hole.
Installation
(1) Position rear channel assembly into door through large access hole.
(2) Align upper support to hole in door lock face and install screw loosely (Fig. 15).
(3) Insert channel lower stud into slot of support assembly and secure with nut.
(4)
( 5 )
Tighten upper support screw.
Install door glass.
(6) Install up-stop at rear channel.
REGULATOR MOTOR REPLACEMENT
When necessary to remove motor from regulator, it is imperative the linkage be secure- ly clamped in a vise to lock it in place. Failure to do this allows the assist spring to drive the mounting bracket around the lift pivot.
WIND0 W LIFT SWITCH
Slide a thin blade behind the switch housing
(front and back) to depress retaining clips and pull switch out from panel. Carefully separate multiple terminal block from switch body and re- move switch from panel.
VENT WING REGULA TOR
Removal
(1) With vent wing open, remove screws attach- ing regulator to door inner panel belt reinforce- ment (Fig. 18).
(2) Remove shaft to coupling screw.
(3) Move regulator off of vent wing pivot shaft.
(4) Remove regulator through large access hole in door panel.
DOOR GLASS REGULATOR
The manual and electric operated regulators (Fig.
16) are attached to the door inner panel with screws.
Refer to the Electrical Group for test proce- dures and wiring diagrams for electric operated regulators.
GLASS LIFT BRACKET
The glass lift bracket (Fig. 17) is positioned over sliding blocks on the regulator arms. Screws are used to secure the lift channel to the glass
Installation
(1) Through large access hole, position and align sleeve on regulator coupling over vent wing pivot shaft.
(2) Position and align regulator body to attach- ing slots in door inner panel belt reinforcement and install attaching screws.
(3) Install regulator coupling to vent wing pivot shaft screw.
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6-1
0
IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
FASTENER
-q
0
REAR DOORS
Q
FRONT
1
NU377
Fig. 19
-
Sedan Rear Door Glass Adjustments
Fig. 20
-
Glass Replacement
SLIDE
\*
SCREW
;-r
+*>
Fig. 2 1
-
Glass Run
PIVOT
YKET
Adjus fments-Sedan (Fig. 19)
(1) Raise window to approximately 1/8 inch be- low door frame.
(2) Adjust regulator pivot bracket so gap be- tween top of glass and door frame is constant.
Snug tighten attaching nuts.
(3) Lower glass until top edge is even with or slightly below outer panel belt weatherstrip.
(4) Position stop on regulator plate against sector stop and snug tighten nut.
( 5 ) Test operation and inspect alignment of glass.
Tighten callouts 6 and 7 securely.
NU313
Fig. 22
-
Pivot Bracket
GLASS REPLA CEMENT
Removal
(1) Remove lift channel to door glass fastener screws.
(2) Rotate front edge of glass rearward and up to disengage ends of glass from run channels.
(3) Lift glass assembly out of door.
(4) Remove lift fasteners from glass (Fig. 20).
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IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS 6-1 1
Pf VOT BRACKET
Removal
(1) Remove the rear door glass.
(2) Remove pivot support bracket to door inner panel screw assemblies (Fig. 22).
(3) Slide pivot channel off of regulator arm slide and remove pivot bracket through large access hole.
Fig. 23
-
Lift Bracket
Installation
(1) Position lift fasteners into glass from glass inner surface (Fig. 20).
(2) With bottom of glass in forward position, lower glass into door.
(3) Rotate front edge of glass forward and down, engaging glass ends into the front and rear glass runs.
(4) Align glass fasteners with holes in lift chan- nel and secure with screws.
GLASS RUN
The rear door glass run (Fig. 21) is a press fit in the door frame. Index the front notch into upper front comer of door frame and press entire front leg of run secure in channel. Position rear notch in run to upper rear corner of door frame and press entire top and rear leg securely in channel. fnsta ffation
(1) Apply lubricant to sliding contact surfaces of pivot channel.
(2) Through large access hole, position pivot channel over slide on regulator idler arm.
(3) Align pivot bracket mounting holes with holes in door inner panel and secure with screws.
(4) Install rear door glass.
GLASS LIFT BRACKET (FIG.
23)
Removal
(1) Remove rear door glass to lift bracket screws.
(2) Move lift bracket forward on front slide to disengage bracket from rear slide.
(3) Move bracket rearward to remove from front slide.
Installation
(1) Apply lubricant to channel of lift bracket.
(2) Position bracket channel to regulator arm front slide first, then move rearward to engage rear slide.
(3) Install rear door glass to lift bracket screws.
Fig. 24
-
Repufafor Assembfies
ELECTRIC NU308
MyMopar.com
6-12 IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
0 pull switch out from panel. Carefully separate multiple terminal block from switch body and re- move switch from panel.
HARDTOP MODELS
ADJUSTMENTS (FIG.
25)
Fig. 25
-
Hardtop Rear Door Glass Adjustments
REGULA TORS
The manual and electric operated regulators (Fig.
24) are attached to the door inner panel with screws.
Refer to the Electrical Group for test proce- dures and wiring diagrams for electric operated regulators.
REGULA TOR MOTOR REPLACEMENT
When necessary to remove motor from regulator, it is imperative the linkage be secure- ly clamped in a vise to lock it in place. Failure to do this allows the assist spring to drive the mounting bracket around the pivot.
WIND0 W LIFT SWITCH
Slide a thin blade behind the switch housing
(front and back) to depress retaining clips and
Parallelism and Primary Seal
(1) Raise window completely.
(2) Line up rear door glass upper front frame with upper rear edge of front door glass rear frame.
(3) Snug tighten track panel to reinforcement front screw.
(4) Set rear glass front frame parallel to rear frame of front door glass by .lifting track panel bottom edge.
( 5 ) Snug tighten rear and center floating screws in cage nuts.
In-Out and Secondary Seal
(6) Force bottom of track panel in or out for secondary seal with roof weatherstrip.
(7) Snug tighten adjusting bracket to track panel screws.
(8) Snug tighten adjusting bracket to track panel nut assembly on bottom of door panel outside surface.
(9) Tighten track panel upper attaching screws.
Parallelism to Front Glass Frame and Roof
Rail Weatherstrips
(10) Adjust pivot bracket to bring upper front comer of rear glass parallel between front and rear glass frames and between glass and roof rail weatherstrips.
SCREW
SCR
APPLICATION
CIRCLE A
IN
Fig. 26
- track Panel Upper Attachment
NU337
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0
IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS 6-13
SCREW
NU330
Fig. 28
- lift Bracket
(1
1) assemblies.
Fig. 27
-
Up-Stop Brackets
Snug tighten the pivot bracket screw up-stops
(12)
Adjust up-stops by forcing them down against plastic up-stop bumpers on glass.
(13)
Snug tighten screws on hinge and lock faces. Tighten callouts 14 through 18 securely.
GLASS REPLACEMENT
The rear door incorporates a track panel assem- bly to which the door glass is attached. When necessary to remove or install either the glass or track panel, the panel and glass must be removed or installed as an assembly.
Removal
(1) Remove track panel to door panel upper screws (Fig.
26).
(2)
Remove down-stop adjusting bracket to track panel screws.
(3) Remove up-stop adjusting brackets from door panel (Fig.
27).
(4)
Remove glass lift bracket to glass fastener screws (Fig.
28).
( 5 ) Move track panel rearward, approximately four inches, and raise door glass to the full-up position.
(6)
Raise track panel slowly until up-stop on glass (Fig.
29)
are cleared through door.
(7) Raise track panel completely and remove glass and panel assembly (Fig.
30).
(8)
Place track panel and glass assembly on a protected surface with the glass facing downward.
(9)
Remove track stabilizer guide screws (Fig.
31)
and remove guides from track panel.
(10) Remove U-nuts from outer side of track
\ scRw+sTop
FASTENER
Fig. 29
-
Door Glass Assembly panel and bumpers from top inner side (Fig.
NU319
32).
(1)
Insert U-nuts into outer side of track and bumpers into top inner side.
(2) With glass assembly inner surface positioned downward on a protected surface, place track pan- el on glass aligning fasteners in glass with chan- nels in panel.
(3)
Position stabilizer guides in track panel, align with fasteners in glass and install screws.
(4) Insert glass and track panel into door, sliding assembly rearward approximately four inches, to allow clearance for the U-nuts.
( 5 ) Slide track panel off of glass, until up-stops on glass find clearance to enter door opening.
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6-14 IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
TRACK PANEL
PANEL
-IrrJ
Fig. 30
-
Glass and Track Panel Replacement
V
NU338
-
Fig. 31
-
Track Panel Stabilizer Guides
(6) Slowly lower track panel completely to bot- tom of door, moving it forward approximately four inches, at the same time and positioning be- hind the down-stop brackets.
(7) Slowly lower the glass assembly until it is positioned on down-stop bumpers.
(8) Raise glass sufficiently to allow installing the down-stop to track panel screws.
(9) Install track panel to door panel screws, screws at panel top edge.
(10) Align holes in glass lift bracket with fasten- ers in glass and install screws.
(1 1) Install up-stop brackets on door inner panel.
WBRACKrn
NU318
Fig. 32
-
Track Panel Assembly
UP-STOPS
The rear up-stop (Fig. 27) is attached to slotted areas in the door shut face between the inner and outer panels. The front up-stop (Fig. 27) is atta- ched to slotted areas of the inside panel through the glass opening between inner and quarter panel at upper front corner.
GLASS ASSEMBL
Y
The door glass to lift channel fasteners are a press fit in glass (Fig. 29) as are the glass to track and guide fasteners. The glass up-stops are retained in the glass with screws.
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IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS 6-1 5
GLASS LIFT BRACKET
The glass lift bracket (Fig. 28) is positioned over sliding blocks on the regulator arms. Screws are used to secure the lift channel to the glass fasteners. Lubricate the sliding block contact areas of the lift channel sparingly.
REGULA TORS
The manual and electric operated regulators (Fig.
24) are attached to the door inner panel with screws.
Refer to the Electrical Group for test proce- dures and wiring diagrams for electric operated regulators.
REGULATOR MOTOR REPLACEMENT
When necessary to remove motor from regulator, it is imperative the linkage be secure- ly clamped in a vise to lock it in place. Failure to do this allows the assist spring to drive the mounting bracket around the lift pivot.
Window Lift Switch
Slide a thin blade behind the switch housing
(front and back) to depress retaining clips and pull switch out from panel. Carefully separate multiple terminal block from switch body and re- move switch from panel.
QUARTER
GARNISH MOULDINGS
The garnish mouldings should be aligned and held in position to assure satisfactory alignment.
Do not over-tighten screws, or moulding will be- come damaged at screw hole area.
PANELS
WA TERSHIEL DS
Refer to Figure 33 for sealing and application areas of the watershield.
BELT LINE WEA THERSTRIP
The belt line weatherstrip is retained on the out- er panel with spring type retainers.
TRIM PANELS
To remove quarter window trim panel it is first necessary to remove the rear seat cushion and back. Quarter window trim panels are retained with screws and clips. When installing trim panel, make certain watershield (Fig. 33) is properly ce- mented and positioned.
HANDLES
The regulator handle is attached with an allen screw.
GLASS ADJUSTMENTS
The circled numbers shown on the glass adjust- ment reference illustrations indicate the particular step number being read in the adjustment procedure.
Prior to adjusting glass, all doors must be cor- rectly fitted in their opening and the weatherstrips
1 3 9 5 2 O-O-0
W
VIEW IN CIRCLE Y
TOP OF WATERSHIELD
Fig. 33
-
Quarter Panel Wafershields
NU548
Fig. 34
-
Quarter Window Adiusfmenfs
-
Hardtop
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6-16 IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
e
AT ARROW
NU326
Fig. 35
-
Glass Replacement at the “A” post and roof rails must be properly installed.
Refer to the adjustment illustration and loosen the attaching screws and nuts of the various com- ponents affecting glass adjustment.
Fig. 36
-
Down Stops
( 1 1 )
Position stop on regulator plate against stop on sector and snug secure nut.
(12)
Position down stops against bumpers and snug secure screws.
(13)
Operate window and inspect alignment.
Tighten callouts
14
through
21
securely.
QUARTER WIND0 W (HARDTOP)
Adjustments (Fig. 34)
(1) Adjust upper rear track so rear of glass lightly touches outer panel belt weatherstrip.
(2) Raise glass fully so top of glass is seated ful- ly against roof rail weatherstrip and flushing front of glass with top of front door glass.
(3)
Adjust upper front track attachment so front of glass is aligned with rear of front door glass at belt line and snug secure nut.
(4)
Adjust lower front track attachment so front of glass is aligned with rear of front door glass at roof rail and snug secure screw.
( 5 ) Adjust pivot bracket so top of glass is fully against and parallel to adjusting bead on roof rail weatherstrip. Snug secure nuts.
(6) Loosen sleeve nut and move upper rear track attachment forward so weatherstrip and front of glass is against front door glass. Snug secure nut.
(7) Loosen pivot bracket nuts, adjust pivot bracket and snug secure nuts.
(8) Position front and rear up stops down against glass lower frame and snug secure screws.
(9) Lower glass until glass top edge is even with or slightly below belt line of outer panel.
(10)
Snug secure lower rear track adjusting screw.
GLASS REPLACEMENT
Removal
(1)
Align glass lower frame to glass attaching screws with a c e s holes in quarter inner panel
(Fig.
35).
(2) Support glass, remove lower frame to glass attaching screws and remove glass assembly from panel.
(3)
Remove spacers from openings in glass.
Installation
(1)
Position spacers in openings of glass lower frame.
(2)
Install grommets on glass retaining screws.
(3)
Align glass lower frame attaching holes with access openings in quarter inner panel.
(4) Lower glass into quarter panel, align open- ings in glass with holes in lower frame and install screw and grommet assemblies.
DOWN STOP
The down stop bracket and bumper (Fig.
36)
is attached to the outboard side of the glass lower frame assembly with screws.
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IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS 6-1 7
STOP \\\
NU328
Fig. 37
-
Pivot Bracket
NU329
Fig. 38
-
Up-Stops
GROMMET
CHANNEL
NU289
SECTION A-A
Fig. 40
-
Glass lower Frame Assembly
FRONT TRACK
Fig. 39
-
Fronf Track Assembly
PLATE
NU288
PIVOT BRACKET
The pivot bracket assembly (Fig. 37) is posi- tioned to the roller side on the regulator idler arm. The bracket weld screws are inserted through a support welded to the quarter inner panel and retained with nut assemblies.
UP-STOPS
The up-stops (Fig. 38) are attached to slotted areas on the quarter inner panel with screws. An anti-rattle type grommet is positioned over each up-stop flange.
Removal
(1) Remove nut and washer from sleeve nut at upper end of track (Fig. 39).
(2) Remove track lower plate to support screw.
(3) Push track inward and move track and roller assemblies rearward lower frame.
(4) to disengage rollers from glass
Remove track and rollers out of panel through large access hole.
( 5 ) Remove roller assemblies from track (Fig.
40). inst allation
(1) Position roller and guide assemblies on track.
(2) Insert track assembly in quarter panel.
(3) Position roller assemblies into slots of glass lower frame (Fig. 40).
(4) Insert sleeve nut on upper end of track into
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6-1 8 IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
LC
FR
0
NU286
Fig. 41
-
Rear Track hole of inner panel (Fig. 39).
( 5 ) Align track lower plate to support and se- cure with screw.
(6) Place spring washer, concave side facing out-board, on track upper sleeve nut and install retaining nut.
REAR TRACK
Removal
(1) Remove nut and washer from track upper sleeve nut (Fig. 41).
(2) Remove track lower plate to support screw.
(3) Push track inward and move track and roller assembly forward to disengage roller from slot in glass lower frame.
I."LP, u,
Fig. 42
-
Glass Lower Frame Replacement
Remove track and roller assembly out (4) panel through large access opening.
( 5 ) Remove roller assembly from track. of
Ins fallafion
(1) Position roller assembly on track and insert assembly into quarter panel through large access opening.
(2) Position roller assembly into slot lower frame. of glass
SCREW
\
MoToR\S
v
MANUAL
Fig. 43
-
Regulator Assemblies
ELECTRIC
NU306
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0
IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS 6-1
9
GLASS
FASTENER
Fig. 44
-
Quarter Window Adjustments
-
Sedan
(3)
Insert track upper sleeve into hole of inner panel.
(4) Align track lower plate on support and se- cure with screw.
( 5 ) Place spring washer, concave side facing out-board, on sleeve nut and install retaining nut.
GLASS LOWER FRAME
Removal (Fig. 42)
(1) Remove quarter glass assembly.
(2)
Remove rear track upper and lower attach- ments and move track and roller assembly forward to disengage roller assembly from glass lower frame.
'
(3)
Move lower frame assembly to disengage channel from regulator arm rear slide.
(4) Raise rear of lower frame and remove from quarter.
( 5 ) Remove roller and guide assemblies from lower frame.
LIFT BRACKET
NU331
Fig. 45
-
Quarter Window Replacement
43) are attached to the door inner panel with screws.
Refer to the Electrical Group for test proce- dures and wiring diagrams for electric operated regulators.
REGULA
1 0 R
MOTOR REPLACEMEN1
When necessary to remove motor from regulator, it i s imperative the linkage be secure- ly clamped in a vise to lock it in place. Failure to do this allows the assist spring to drive the mounting bracket around the lift pivot.
WIND0 W
LlFl
SWIlCH
Slide a thin blade behind the switch housing
(front and back) to depress retaining clips and pull switch out from panel. Carefully separate multiple terminal block from switch body and re- move switch from panel.
Installation
(1) Inspect glass lower frame to be sure grom- mets are installed at the upper outer holes (Fig.
40)-
(2)
Insert roller and guide assemblies into lower frame front upper and lower slots.
(3)
Slide front end of lower frame into panel and engage front of lift channel to slide on regu- lator front arm (Fig. 42).
(4) Turn frame to normal position and engage rear channel to regulator rear arm slide.
( 5 ) Position roller and guide assembly, on rear track, into rear slot of lower frame.
(6) Install rear track assembly on inner panel.
(7) Install glass assembly.
Regulators
The manual and electric operated regulators (Fig.
GLASS ADJUSlMENTS (SEDAN MODELS)
(1) Raise glass to approximately 1/8 inch below window opening frame.
(2)
Adjust regulator pivot bracket (Fig. 44) so gap between top of glass and window opening frame is constant. Tighten pivot bracket nuts.
(3)
Run glass approximately
2/3
way down.
(4) Allow glass to set rear run retainer for in- out position and snug tighten lower bracket screw.
( 5 ) Lower window until top of glass is even with or slightly below outer panel belt line weatherstrip.
(6) Position stop on regulator plate against stop on sector and snug tighten locknut.
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6-20 IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS
(7) Test operation and inspect alignment of glass.
Tighten Callouts 8, 9 and 10 securely.
GLASS REPLACEMENT
Removal
(1) Lower glass fully and remove lift channel to glass fasteners screws (Fig. 45).
(2) Through large access hole, rotate glass clock- wise to remove from front and rear run channels.
(3) Raise glass assembly out of panel.
(4) Remove fasteners from glass assembly (Fig.
45).
Installation
(1) Insert glass lift fasteners into glass from in- ner glass surface side.
(2) With rear edge of glass facing down, lower glass assembly into quarter panel.
(3) Through large access opening, rotate glass counterclockwise to engage front and rear edges in glass runs.
(4) Lower glass and align lift fasteners to holes in lift channel.
( 5 ) Secure glass to lift channel with screws.
(6) Test operation of quarter window.
GLASS
RUN AND WEATHERSTRIP RETAINERS
Removal
(1) Remove glass assembly.
0
(2) Remove run from front top and rear retain- ers (Fig. 46).
(3) Remove weatherstrips and screws securing weatherstrip retainers to roof rail and lock pillar.
(4) Remove weatherstrip retainers from quarter panel.
Installation
(1) The weatherstrip retainer seal is a self adhe- sive type.
(2) Insert retainer front leg in panel opening and align attaching holes with holes in body panel
(Fig. 46).
(3) Secure retainer to roof rail with screw, begin- ning with hole at radius.
(4) Secure retainer to lock pillar with screw.
( 5 ) Position upper weatherstrip to retainer and index to front corner and tab of retainer.
(6) Press weatherstrip into retainer.
(7) Position glass front run to retainer, loading bottom leg between panels at belt line.
(8) Index upper front corner, making a water tight joint and to tab at bottom of retainer.
(9) Press into retainer full length to secure.
(10) Through large access hole, position rear run to retainer, indexing to lower end of roof rail weatherstrip to create a seal.
(11) Press securely into retainer for full length.
(1 2) Install quarter window assembly.
RETAINER
VIEW AT ARROW A
WEATH ERSTRl P
SCREW
Fig. 46
-
Weatherstrip Retainer and Runs
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IMPERIAL-CHRYSLER-PLYMOUTH-SIDE GLASS 6-21
8
‘c
#. I
>NU459
Fig. 48
-
Tailgate Glass Adjustments
NUT AND WASHER
\
I
NU334
Fig. 47
-
Glass Lift Bracket
GLASS LIFT CHANNEL
The lift channel (Fig.
47)
is positioned over slides on the regulator arms and to the glass assembly with screws.
GLASS- TAIL GA TE
Adjustments
The circled numbers shown on the glass adjust- ment reference illustration (Fig. 48) indicate the particular step number being read in the adjust- ment procedure.
Prior to adjusting glass, the tailgate must be cor- rectly fitted to its opening, the inner belt weather- strip installed and all glass and related hardware component attaching screws and nuts loosened.
(1) With tailgate opened in tailgate position, push glass against belt inner weatherstrip and snug secure upper screws of lower glass run channel.
(2) With tailgate closed, from inside body, run glass up far enough to engage and align lower end of upper run channel. Snug secure bottom screw in upper run channel.
(3) Align top end of upper run channel with tailgate header run retainer and snug secure screws.
(4)
Raise glass to approximately 1/8 inch below roof rear glass run and adjust regulator so top of glass is parallel to roof glass run. Snug secure regulator attaching nuts.
( 5 ) Open tailgate to gate position and secure lower nut on glass of tailgate.
(6) Close tailgate, test for ease of operation and
3
Fig. 49
-
Regulator Assembly inspect alignment.
Tighten callouts
7,
8 and 9 securely.
GLASS REPLA CEMENT
NU296
Removal
(1) Support glass at bottom and remove glass to lift bracket screws (Fig. 48).
(2) Slide glass up and out of door.
(3) Remove lift channel fasteners from glass. lnsf allation
Utmost care must be used to prevent lubricant from touching wiper blades.
(1) Apply lubricant to surfaces of glass lift chan- nel contacting regulator sliding block.
(2) Install lift channel fasteners in glass.
(3) Lower glass into runs of lower glass channels to a position under the lift channel on each regu- lator arm.
(4) Align holes in lift channels with glass lift fasteners and secure with screws.
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6-22 SATELLITE-SIDE GLASS
0 channels.
(2) Disconnect electrical leads at regulator.
(3) Remove regulator at inner tail gate panel nut and washer assemblies.
(4) Remove regulator assembly through large ac- cess hole on right side.
NU297
Fig. 50
-
Glass Run Channel
GLASS LIFT CHANNELS
To replace the glass lift channels (Fig. 48) it is necessary to first remove the glass assembly. The channels are positioned over sliding blocks on the regulator arms.
REGULA TOR REPLA CEMENT
The electric regulator assembly is retained on the tail gate inner panel with nut and washer assem- blies (Fig. 49). Be sure wiper actuator mechanism is in OFF-GLASS position during replacement of regulator.
Removal
(1) Remove tail gate glass and glass lift
Installaiion
(1) Position regulator in tail gate through large access hole on right side.
(2) Position regulator mounting studs in holes of inner panel and install nut assemblies. It may be necessary to tilt and secure one corner of regu- lator mounting, then the opposite corner and fi- nally the remaining two nuts on units equipped with the window washer assembly.
(3) Connect electrical leads.
(4) Position glass lift channels on regulator slid- ing blocks.
( 5 ) Install tail gate glass assembly.
’
GLASS RUN CHANNEL
Removal
(1) Remove the tail gate glass assembly.
(2) Remove tail gate pillar to glass run channel screws (Fig. 50).
(3) Remove channel assembly through access holes in inner panel.
Installation
(1) Position channel assembly into tail gate and align to upper and lower holes in tail gate pillar.
(2) Secure channel to pillar with screws.
(3) Install glass assembly.
SIDE GLASS
SATELLITE
INDEX
Door Glass Regulator
.............................................
2 4
Regulator Motor Replacement
Glass Adjustments
Glass Adjustments Hardtop
I n a n d o u t
Glass Replacement
Installation
.........................
..................................................
Page
2 4
2 3
Fore and Aft
...........................................................
2 3
..............................
2 3
2 3
Parallelism
................................................................
2 3
2 3
2 3
Removal
....................................................................
Hardtop Models
2 3
2 5
Adjustments
............................................................
2 5
Glass Replacement
...............................................
2 5
Installation
Regulator
Removal
Rear Doors
Adjustments
Tailgate
Assembly
.............................................
..................................................................
........................................................................
Glass Replacement
...............................................
Page
25
2 4
2 4
2 4
2 4
2 6
Adjustments
Glass
............................................................
26
26
27
Glass Run Channels
Installation
Removal
Removal
............................................
..................................................................
Regulator Replacement
........................................
2 7
..................................................................
2 7
2 7
2 7
2 7
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FORE AND AFT
IN AND OUT
I
~
UP
SATE LUTE-S I GLASS 6-23
DOOR GLASS
\
STABiLlZER
CHANNEL
Fig. 2
-
Front Glass Attachment
PB396
IN AND OUT
Fig. I
FORE AND AFT PB394
-
Hardtop Front Door Glass Adjustments
GLASS ADJUSlMENlS
Prior to adjusting glass, all doors must be cor- rectly fitted in their opening and the weatherstrips at the ‘A’ post and roof rails must be properly installed.
Refer to the adjustment illustration and loosen the attaching screws and nuts of the various door components affecting glass adjustment.
Service procedures for components related to the door glass follow the glass adjustment procedures.
GLASS ADJUSlMENlS HARD 1 0 P
Adjustments
-
Ventless Door (Fig. 1)
Fore and Aft
(1) Raise glass completely.
(2) Move glass fore or aft to set glass to belt line weatherstrip.
(3)
Tighten glass track upper bracket at belt line.
Parallelism of Glass to Primary Seal
(4) Move pivot bracket up or down and set glass parallel to weatherstrip.
( 5 ) Tighten pivot bracket.
(6) Adjust up-stops.
In-Out and Secondary Seal
(7) Move bottom of front track to create an ef- fective glass to weatherstrip secondary seal.
(8) Tighten glass track to lower bracket screw.
(9) Tighten track lower bracket and retainer to inner panel nut assembly.
FRONT DOOR
Fig. 3
-
Front Door Regulator Assembly
PB389
Front and Rear Track Parallelism
(10) Run glass approximately
2/3
way down.
(11) Tighten glass rear run channel and bracket assembly lower bracket nut assembly.
Down Stop-Manual
(12)
Lower glass until top edge of glass is even with or slightly below belt line of door outer panel. Do not allow glass to drop below weath- erstrip on door outer panel.
(13)
Position stop on regulator plate against stop on sector.
(14) Tighten regulator plate stop locknut.
GLASS REPLACEMEN1
Removal
(1) Remove screws attaching stabilizer channel to glass (Fig. 2).
(2) Raise door glass assembly out of door.
(4) Remove fasteners.
Installation
(1) Place glass on table with outside of glass fac-
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6-24 SATELLITE-SIDE GLASS
FRONT DOOR
FORE
FR !ONT DOOR
/
/
/
PARALLEL
ADJUSTMENT
IN
AN^
OUT
FORE AND AFT
Fig. 4
OUT
ADJUSTMENT PB395
-
Sedan Front Door Glass Adjustments ing downward.
(2) Install fasteners.
(3) Install door glass assembly into door.
(4) Align holes in stabilizer channel with fasten- ers in glass and secure with screws.
DOOR GLASS REGULA
1 0 R
The manual and electric operated regulators (Fig.
3) are attached to the door inner panel with screws.
Refer to the 'Electrical Group' for test proce- dures and wiring diagrams for electric operated regulators.
Regulator Motor Replacement
When necessary to remove motor from regulator, it is imperative the linkage be recure- ly clamped in a vise to lock it in place. Fai!ure to do this allows the assist spring to drive the mounting bracket around the lift pivot.
SEDAN AND SlAllON WAGON
Adiustments (Fig. 4)
(1) Run glass all the way up.
(2) The front track upper attachment should be loosened and this will allow glass to seat in the upper door frame.
(3) The front and rear track can be adjusted in and out.
(4) The front track can be adjusted fore and aft.
( 5 ) The pivot bracket provides parrellel adjustment.
SCREW PBSV
Fig. 5
-
Sedan Glass Run and Channel
Fig. 4
PB398
-
Sedan Rear Door Glass Ad/ustmenh
Glass Run and Channel
The glass run (Fig. 5 ) is a press fit in the door frame and lower run channel. The index notch at the door upper comer should be positioned first to assure correct installation of the run. The lower run channel is positioned over the window open- ing frame from inside the door through the large access opening.
REAR DOORS
SEDAN MODELS
A diustments
(1) The glass should be in fully raised position.
(2) Loosen the pivot channel attaching screws this allows the glass to seat in the door frame.
SEDAN MODELS
Two door sedan models are equipped with a vent wing type quarter window (Fig. 7). Elongated
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SATELLITE-SIDE GLASS 6-25
FORE AND AFT
IN AND O U T
UP STOP
FORE
NR377
Fig.
GLASS
7
-
Quarter Window Vent GJass
ATTACHING NUT f
PB400
Fig. 8
-
Rear Quarter GJass Adiustments
( 5 ) Adjust pivot bracket until top of window is fully against and parallel to roof rail weatherstrip.
To raise front of window, lower front of bracket, to lower, raise bracket.
(6) Move upper track attachment forward and tighten when quarter window weatherstrip is against front door window.
(7) Tighten pivot bracket nuts.
(8) Loosen and position front and rear up stops against glass lower frame and tighten screws.
(9) Lower window until top of glass is even with or slightly below belt line outer panel.
(10) Position and tighten regulator stop against regulator sector stop.
(11) Position and tighten down stop against bumper.
Glass Replacement
AITACHINGSCREW
HARDTOP MODELS
PBW
Fig. 9
-
Hardtop Quarter Window GJass RepJacement holes in the hinge allow correct positioning of the glass assembly to the opening. The release handle assembly is attached to the glass with a grommet, washer, retainer and screw.
Adjustments
(1) With door closed, adjust quarter window track (Fig. 8) at upper attachment until rear of glass lightly touches belt line weatherstrip.
(2) Raise window seating top of glass against roof rail weatherstrip and front of window level with top of front door window.
(3) Adjust upper track until front of window is aligned with rear of front door window.
(4) Adjust lower front track until front of win- dow is aligned with rear of front door window at roof rail.
Removal
(1) Remove track upper attaching nuts from track (Fig. 9).
(2) Remove attaching screw from lower track.
(3) Work track, glass and pivot arm up and out of quarter panel.
Installation
(1) Apply lubricant to slide areas of lower glass frame and pivot slide.
(2) Simultaneously position upper track adjusting bracket slots over studs on upper bracket.
(3) Insert slide on regulator arm into pivot bracket.
(4) Install lower attaching screw and upper track attaching nuts.
Regulator Assembly
The regulator assembly (Fig. 10) is attached to the inner panel with screw and washer assemblies.
The regulator arm studs are retained in the glass
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6-26 SATELLITE-SIDE GLASS
Adjustments
(Fig. 11)
Prior to adjusting glass, the tailgate must be cor- rectly fitted to its’ opening, the inner belt weath-
0
Fig. 10
QUARTER
PANEL
PB390
-
Qwrter Window Regdotor Assembly lower frame with retainers. Lubricate the regulator tooth contact area approximately 1/2 inch wide along the entire length of the arc on the outboard side of sector and to front and rear arm roller studs. erstrip installed and all glass and related hardware component attaching screws and nuts loosened.
(1) With tailgate opened in tail gate position, push glass against belt inner weatherstrip and snug secure upper screws of lower glass run channel.
(2) The tailgate glass can be moved from side to side by adjusting the sleeve nut after loosening the jam nut. After sleeve nut has been adjusted tight- en jam nut.
(3) Raise glass to approximately 1/8 inch below roof rear glass run and adjust regulator so top of glass is parallel to roof glass run. Snug secure regulator attaching nuts.
(4) Open tailgate to gate position and secure lower nuts on glass run of tailgate.
( 5 ) Close tailgate, test for ease of operation and inspect alignment.
GLASS REPLA
CEMENT
TAILGA
TE
GLASS
Removal
(1) Support glass at bottom and remove glass to frame channel screws (Fig. 12).
(2) Slide glass up and out of tailgate.
Installation
(1) Apply lubricant to surfaces of glass regulator sliding blocks.
UP AND DOWN
FORE AND AFT
SECTION D-D
7
Fig. I ?
-
Tdlgote Gloss Adiustments
FORE AND AFT
PB401
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0
TAIL GATE
\
FRAME AND
,GASKET
SATELLITE-SIDE GLASS
6-27
GLASS RUN CHANNELS
\
1-NUT
/
\
GASKET
SLIDES
Fig.
PB392
I2
-
Taitgate Otass Attachment
(2) To install glass it will be necessary to force slides outward.
(3) Push glass in runs is aligned with pin. so that centering pin hole
(4) Install gasket, frame channel and glass atta- ching screws, gaskets and T nut.
Glass Run Channels
Fig. I 3
-
Tailgate Olass Run Channels
PB391
Removal
(1) Remove the tailgate glass assembly.
(2) Remove tailgate glass run channel screws
(Fig. 13).
(3) Remove channel assembly through access holes in inner panel.
Installation
(1) Position channel assembly into tailgate and align to upper and lower holes in tailgate pillar.
(2) Secure channel to pillar with screws.
(3) Install glass assembly.
Regulator Replacement
The regulator assembly is retained on the tailgate inner panel with four attaching screws (Fig. 14).
Removal
(1) Remove tailgate glass.
(2) Disconnect electrical leads at regulator.
(3) Remove regulator to inner tailgate panel atta-
Fig. 14
-
Tailgate Regulator Assembly ching screws.
(4) Remove regulator assembly through access hole.
Instaltation
(1) Position regulator in tailgate through access hole.
(2) Position regulator mounting screws in holes of inner panel.
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6-28 BARRACUDA-SIDE GtASS
a
SIDE GLASS BARRACUDA
INDEX
Ventless Glass Adjustment
Page
.................................
28
Adjustments
............................................................
28
28 Parallelism and Primary Seal
In-Out and Secondary Seal...............................
UpStops
....................................................................
28
Glass Assembly Ventless
......................................
28
29
Ventless Door Glass Installation
Lift Channel
............................................................
29
Glass Down Stop
Lower Front Track Support
Front Door Regulator
.......................
..................................................
..........................................
29
29
30
30
Front Door Glass Installation............
Quarter Panel Glass
...............
30
30
Quarter Window Glass Adjustment
..............
30
Belt Area Glass Adjustment
Primary Seal
............................
Quarter Window Parallelism and
Page
30
30
......................................................
31 Secondary Seal
Front UpStop
Rear U p-Stop
...........................................................
Quarter Window Installation
Pivot Bracket
Down Stop and Bumper
Front Track Adjuster
..............................
31
..........................................................
31
....................................
31
Slide and Up-Stop t o Quarter Window..
.....
32
Quarter Window Front Track
...........................................
31
31
32
32
Quarter Window Rear Run
Quarter Window Regulator
...............................
32
32
ENTLESS GLASS
SPACER
SCREW
Fig. I
-
Glass Adiustments
VENTMSS
GLASS
ADJUSTMENT
Numbers shown on glass adjustment Reference
Illustration (Fig. 1) indicate particular step number in adjustment procedure.
ADJUSTMENTS (Fig. I )
Parallelism and Primary Seal
(1) Raise window completely.
(2) Loosen screw at belt on upper end of front track.
(3) Align and set front edge of glass to "A" pil- lar and top edge to roof rail weatherstrip creating a parallelism with weatherstrip locating bead.
(4) Secure upper screw on front track previously loosened.
In-Out And Secondary Seal
( 5 ) Loosen bottom screws on front track lower
REAR
STOP
SCREW AND WA '
GUIDE tv
AND SUPPORT
NUT AND WASHER
Fig. 2
WASHER
-
Glass AssemblyVentless
PY4m support.
(6) Loosen bottom screw on rear track support.
Push front track lower support. Outboard for in- board contact at weatherstrip. Allow rear track to create it's own plane, parallel to front track.
(7) Secure previously loosened front track lower support screws.
(8) Secure rear track lower support screws.
(9) Secure front track lower support screws.
If additional alignment to "A" pillar or roof rail is necessary, adjust regulator idler arm pivot bracket up or down as required and secure.
(10) Secure regulator arm pivot guide to panel. up-stops
(1 1) Push front Up-Stops bracket down against plastic up stop on glass (Front End) and secure with screws and washers to belt reinforcement.
(12) Push rear up stop brack down against plas- tic up stop on rear stabilizer and secure with
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a
BARRACUDA-SIDE GLASS
6-29 f f
Fig. i
I I I I
3
-
Ventless Door Glass Installation
F
Fig. 4
-
1iH Channel tener in glass and secure.
(16) Assemble stop thru rear upper hole in stabi- lizer bracket, gasket and glass and secure with screw.
R O N X E S T MX)R
(17) Assemble bumper to track, brackets and
MAC
(18) Apply lubricant to guide slide surfaces of
Item 17.
(19) Assemble lubricated track and bracket as- sembly item 17 with bumper attached to guides item 14 and thread on to span glass completely.
ASSEMBLY
L S C R E W AND WASHER
Fig. 5
- lower Front Track screw and washer to rear reinforcement. support bracket belt
GLASS
ASSEMBL
Y
(VENTLESS)
(1) Position glass on bench.
(Fig.
2)
(2) Assemble gasket, door glass stabilizer guide and support assembly.
(3) Install spacer and support assembly to glass.
(4) Install guide and support assembly.
( 5 ) Position items 2, 3 and 4 to under side of glass, push weld stud and spacer thru lowest hole
(outside surface) snug secure to glass.
(6) Assemble spacer and support assembly to glass.
(7) Place washer and support assembly to glass.
(8) Install screw and washer assembly and sup- port to glass.
(9) Assemble fastener to lift channel front hole provided in glass and press to shoulder.
(10) Reposition glass by turning 180 degrees
(outside up).
(11) Assemble stop on glass front.
(12) Secure with screw.
(13) Assemble fastener to hole provided in glass and press in to shoulder.
(14) Apply lubricant to guide in screw hole and to screw.
(15) Position lubricated screw and guide to fas-
'
VENTLESS
DOOR GLASS
INSTALLA TION (Fig.
3)
To install ventless glass the following steps should be followed.
(1) Install bumper door glass down stop.
(2) Install pivot bracket front door regulator.
(3) Install regulator (Manual or electric).
(4) Install left channel to regulator arm slide.
( 5 ) Install lower support front track to front door.
(6) Secure glass guide stabilizer track, up stops, to front door.
(7) Install glass sub-assembly to door and attach lift channel.
(8) Install rear track.
(9) Install upstops front and rear to door outer rear panel belt reinforcement.
LIFT
CHANNEL (Fig.
4)
(1) Apply lubricant.
(2) Install lift channel thru major access hole in door, Dosition to slides on regulator arms and in- stall
- by sliding channel aft -movement. on slides with fore and
GLASS
DOWN
STOP
Position bumper (front elongated hole provided inner panel using major door glass down stop) to in bottom center of door access hole to locate slot and press to secure.
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6-30
BARRACUDA-SIDE GLASS
MOUNTING
SCREW AND WASHER a
FRONT DOOR-(MANUAL) fig. 6
- fmnt Door Regutator
LOWER FRONT TUACK SUPPORT (Fig. 5)
(1) Install support and retainer assembly thru major access hole in door.
(2) Position to attaching holes and snug secure with screw and washer.
FRONT DOOR REGULATOR (Fig.
6)
(1) Place operating lever arms in desired position for installation.
(2) Install assembly thru major access hole in door, insert idler arm roller in pivot bracket, posi- tion mounting plate or electric motor bracket to attaching holes in door inside panel.
(3) Secure with screw and washer to manual window regulator or electric window regulator.
FRONT DOOR GLASS INSTALLA TION
(1) Install glass rear stabilizer track slides, front fig. 7
-
P i n t Door Otass Instattation. track, up-stops and lift fastener to front door glass opening at belt, hold track from sliding while installing. (Fig. 7) off slides
(2) Lower assembly gently to bottom of door, making sure that glass is outboard of regulator arms and front track is inboard of lower support.
(3) Position front track and bracket assembly to belt reinforcement using access hole in door and snug secure with screw and washer.
(4) Position front track and bracket assembly lower end to support.
( 5 ) Secure with screw and washer.
(6) Raise glass by hand so that lift channel rear attachment slot can be inserted between screw head and washer on rear stabilizer assembly. Push lift channel rearward and secure with loosely in- stalled screw.
(7) Align front slot in lift channel with hole in glass lift fastener and secure with screw to glass front. fig. 8
-
Quarter w
Gtass
QUARTER PANEL GLASS
QUARTER WIND0 W GLASS ADJUSTMENT
Numbers shown on glass adjustment reference illustration (Fig. 8) indicates particular step num- ber in adjustment procedure.
Rear track and pivot bracket along with regula- tors have NO adjustment.
Belt Area Glass Adjustment
(1) Run glass half way up.
(2) Adjust front track upper attachment so that glass touches lightly on weatherstrip at bolt.
Loosely secure nut on upper adjusting screw.
Ad/ustment
PY833
Primary Seal
(3) Run glass full up seating top of glass fully against roof rail weatherstrip, and flush front of
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0
BARRACUDA-SIDE GLASS 6-31
-
10 i, (a
Fig. 9
-
Quarter Window Installation
PY486
Fig. 10-Pivot Bracket-Quader Window
PY488
GLASS
SCREW AND
P Y W
Fig. 11
-
Down Stop and Bumper window with top of front door glass rear edge.
(4) Secure jam nut on upper adjusting nut.
Quarter Window Parallelism and Secondary
Seal
( 5 ) Adjust lower front track attachment so front of window is aligned with rear edge of front door glass by pushing track adjusting stud fore and ,aft in support slot. To get secondary seal turn adjust- ing screw in and out as required. Secure jam nut on adjusting screw.
Down Stop (Manual)
(10) Repeat step 8 when required. Position stop on regulator plate against stop on regulator sector and secure locknut.
QUARTER WIND0
W
INSTALLA
TlON
It is recommended that the procedure shown in
(Fig. 9) be followed for quarter window installation.
(1) Apply lubricant to pivot bracket quarter window.
(2) Install regulator (Electric or Manual).
(3) Install lower support.
(4) Assemble front track, adjust studs, center slide and up-stop.
( 5 ) Install front track quarter window.
(6) Assemble slide and up-stop to quarter glass and lower frame assembly.
(7) Install quarter glass and lower frame assembly.
(8) Install rear run.
(9) Install down-stop and bumper to front track
(Electric).
(10) Install up-stop.
Front Up Stop
(6) Push front up stop bracket on front track down against slide on lower frame and secure at- taching nut.
PIVOT BRACKET QUARTER WIND0 W (Fig.
JOl
The Pivot Bracket is welded to the inside section of the Quarter Panel. Lubricant should be applied to channel slide contact surfaces using major ac- cess hole in quarter inside panel.
Rear Up Stop
(7) Push rear up stop bracket on belt reinforce- ment down against plastic up stop on glass and secure the attaching screws.
Down Stop (Electric]
( 8 ) Lower glass so top edge is even or slightly below quarter panel belt line.
(9) Push down stop bracket on lower front track upward to control lower frame slide and secure attaching screws.
DOWN STOP AND BUMPER (Fig.
11)
(Electrical]
(1) Assemble bumper to down stop.
(2) Raise glass to half open position.
(3) Install bumper and down stop assembly thru major access hole in quarter inside panel. Position to front track slots in full down position.
(4) Secure with screw and washer.
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6-32
BARRACUDA-SIDE GLASS
Fig. 12
-
Slide ond Up-Stops
WASHER STUD a
NUT AND
WASHER
Fig.
NUT
AND WASHER
L
PY484
13
-
Ouorter Window Front fmck
SCREW
PY485
Fig. 14
-
Fmnt frock Adiuster
SLIDE
(Fig.
AND
UP STOP TO QUARTER GLASS
12>
(1) Position glass and frame assembly on bench.
(2) Apply lubricant to bolt and slide track.
(3) Assemble lubricated bolt to washer and slide.
(4) Position threaded end of bolt with slide and washer assembly to taped hole in front boss of frame assembly and secure.
( 5 ) Assemble stop, (quarter glass up position) on glass, to hole provided in glass, and secure with screw.
(6) Assemble anti-rattle to quarter window glass stop.
PY483
Fig. on bench.
15
-
AND RETAINER
Reor Run Ouorter Window
(2) Assemble anti-rattle to up-stop quarter win- dow glass front.
(3) Sub-assemble up-stop and anti-rattle assembly to track assembly utilizing upper weld stud to lo- cate up-stop and snug secure in up position.
(4) Secure with nut and washer assembly.
( 5 ) Assemble washer stud upper and lower slide track.
(6) Apply lubricant to points shown in (Fig. 14).
(7) Assemble slide to lubricated center tracks and slide to bottom.
QUARTER
WINDOW
FRONT TRACK (Fig.
13)
(1) Install front track washer stud thru quarter window glass opening at belt.
(2) Position upper washer stud to elongated hole in quarter inside panel, and lower washer stud to elongated hole in lower support and snug install.
2.
(3) Use nut and washer assembly to install step
FRONT TRACK ADJUSTER (Fig.
14)
(Quarter
(1)
Panel)
Position track weld nut and stud assembly
QUARTER
WINDOW
REAR RUN (Fig.
15’
(1) Place glass in full down position.
(2) Install run and retainer assembly thru major access hole in quarter panel.
(3) Snap bottom clip on retainer to up-standing bracket on wheelhouse, position upper end to pan- el belt reinforcement, align holes and secure with screw.
QUARTER
(1)
WIND0 W
REGULA TOR (Fig.
16>
Assemble arm to glass lower frame and re- tainer and quarter window arm to glass lower frame slide.
(2) Place into hole in regulator arm, and press both together to secure.
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e
(3) Install regulator assembly (manual or electric) thru major access hole in quarter inside panel, in- sert idler arm roller slide in pivot bracket channel, position mounting plate or motor bracket to atta- ching holes in quarter inside panel and secure with screw and washer.
VALIANT-SIDE GLASS 6-33
LOWER FRAME SLIDE
&/ASSEMBLY n b.I.L..
A ND WASHER
QUARTER
WINDOW (MANUAL)
RETAINER
QUARTER WINDOW (ELECTRIC)
Fig. 16
-
Quarter Window Regulator
SIDE GLASS VALIANT
Ventless Glass
Page
...........................................................
3 3
Ventless Glass Installation
Ventless Glass Adjustments
Fore and Aft
Sedan Models
........................................................
...............................
..................
34
34
34
Adjustments-Vent Wing
.....................................
34
Door Glass Adjustments
Vent Wing Replacement
....................................
3 5
Removal
................................
Parallelism of Glass Primary Seal
.................
3 3
In-Out and Secondary Seal
Front and Rear Track Parallelism
Down Stop-Manual
...............................................
34
............................................................
....................................
....................................................................
33
33
3 3
3 5
3 5
Installation
...............................................................
3 5
Door Glass Replacement
Page
....................................
3 5
Removal
....................................................................
3 5
Installation
...............................................................
3 5
Regulator Replacement
Rear Doors
Adjustments
.......................................
..................................................................
3 5
3 5
Glass Replacement
Removal
Installation
............................................................
3 5
...............................................
...............................................................
36
3 6
Regulator Replacement
..........................................
3 6
Removal
....................................................................
36
Removal
....................................................................
36
Rear Door Stationary Glass
Installation
................................
...............................................................
36
3 6
3 6
GLASS
VENTLESS GLASS INSTALLA TION
(1) Install down stops (Fig. 1).
(2) Place pivot bracket on regulator.
(3) Install sector assembly and arms to door.
(4) Assemble gaskets to lift bracket stabilizer mounting plate.
( 5 ) Assemble spacers and stabilizer to glass.
(6) Install front track.
(7) Install lift bracket.
(8) Install up-stops front and rear.
(9) Install rear track.
(10) Install glass and lower to bottom of door.
(1 1) Install stud plate stabilizers to glass.
(12) Install adjuster-front track.
(13) (install up-stops to front and rear of glass.
(14) Install inner panel brace to door sill.
(1 5 ) Install door panel trim.
VENTLESS GLASS ADJUSTMENTS
ADJUSTMENTS- VENTLESS DOOR
Fore and Aft
(1) Raise glass completely. (Fig. 2).
(2) Move glass fore or aft line weatherstrip. to set glass to belt
(3) Tighten glass track upper bracket at belt line.
Parallelism o f Glass to Primary Seal
(4) Move pivot bracket fore or aft and set glass parallel to weatherstrip locating bead at primary sealing lip.
( 5 ) Tighten pivot bracket and support screw assemblies.
(6) Set front up-stop down against bumper on glass.
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6-34 VALIANT-SIDE GLASS
6
NU374
Fig. 2
-
Ventless Glass Adiustments d I I I I \
@ d d Q d”,,
Fig. 1
-
Ventless Glass Installation
(7) Tighten up-stop bracket screw on inner panel
(Fig. 3).
(8) Set rear channel up-stop wedge down against stop in rear frame.
(9) Tighten rear channel and bracket upper atta- chmen t screw.
In-Out and Secondary Seal
(IO) Move bottom of front track to create an effective glass to weatherstrip secondary seal.
(1 1) Tighten glass track to lower bracket screw.
(12) Tighten track lower bracket and retainer to inner panel nut assembly.
Front and Rear h c k Parallelism
(13) Run glass approximately 2/3 way down.
(14) Tighten glass run rear channel and bracket assembly lower bracket nut assembly.
Down Stop-Manual
(15) Lower glass until top edges of glass is even with or slightly below belt line of door outer panel. Do not allow glass to drop below weath-
Fig. 3
-
Glass U‘Stops entrlp on door outer panel.
(16) Position stop on regulator plate against stop on sector.
(17) Tighten regulator plate stop locknut. Tight- en callouts 18 through 25 securely.
GLASS
rearward and upward to remove looseness.
Loosen vent wing to door face screws and ad- SEDAN MODELS
Adiustments- Vent Wing justing screws at lower end of division channel.
With glass raised, move entire vent wing assembly
Fore-or-aft adjustment (Fig. 4) of the upper end up or down until glass is free in channel, not is accomplished by moving vent wing up or down. loose, and tighten screws. Insert a narrow blade
The assembly moves forward and downward to screwdriver through opening in weatherseal, just relieve a binding condition of the door glass and ahead of lower pivot, to turn adjusting screws.
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0
VALIANT-SIDE GLASS 6-35
REGULATOR
DOWN
STOP
IN AND
FORE AND AFT NP621
Fig. 4- Front Door Glass Adjustment (Sedan)
REGULATOR
DOWN
STOP
AND AFT
NP620
Fig. 5
-
Rear Door Glass Adjustment-Sedan
(6) Align window run channel.
Door Glass
Door Glass Replacement
Adius fmen fs
Lower glass and move division channel rearward to remove excessive looseness of glass without cre- ating a binding condition. Tighten adjusting screws at lower end of channel (Fig. 4).
It may be necessary to readjust the lower end of channel, to gain alignment of the channel and rear glass run.
If necessary, adjust lower end of rear run chan- nel in or out. Adjust down-stop so top edge of glass is flush with top edge of glass opening in door.
Vent Wing Replacemenf
Removal
(1) Remove nut and washer from lower vent frame stud.
(2) Remove vent frame to door screws.
(3) With glass in down position, disengage lower frame stud from door bracket, window regulator arms from lift bracket and slide glass out of run channels.
(4) Disconnect outer belt weatherstrip for a short clearance for the division distance to provide channel.
( 5 ) Tilt top of vent and up out of door. frame toward rear of door
Ins fallafion
(1) Place vent assembly into door.
(2) Move vent frame forward into position.
(3) Install attaching screws. Do not tighten.
(4) Position door glass in run channel and install regulator arms and clips.
( 5 ) Position lower run channel adjusting stud into door bracket.
Removal
(1) Loosen front run channel lower mounting screw (Fig. 4).
(2) Move run channel forward and slide glass out of channel.
(3) Remove regulator arm from lift bracket channel.
(4) Remove glass from door.
( 5 ) Push plug out of lift bracket rivet.
(6) Pinch expandable ends of rivet together and push rivet out of glass.
Ins falla
(1) Position lift bracket and gasket on glass and install rivet and plug.
Before installing glass, lubricate regulator slide channel.
(2) Position glass into door.
(3) Position regulator arm roller into lift bracket.
(4) Position glass into glass run channels and adjust door glass.
Regulafor Replacement
The regulator assemblies are attached to the door inner panels by screw and washer assemblies.
When removing a regulator, the door glass should be fully lowered. Slide regulator rearward to disen- gage from lift bracket and guide assembly. Lubri- cate tooth area of regulator when reinstalling.
REAR DOORS
Adius fmen fs
The front glass run is fixed. The division chan- nel can be adjusted fore or aft, out (Fig. 5). as well as in or
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6-36
VALIANT-SIDE GLASS
a
F&. 6
-
Rear Door Glass Replacement=Sedan
NP618
Fig. 7
-
Rear Door Stationary Glass-Sedan lnst allation
Before installing glass, lubricate all moving parts of regulator with lubriplate.
(1) Install lift bracket on glass.
(2) Position glass into door opening.
(3) Install regulator arm roller into channel glass lift bracket. of
(4) Position glass into run channels and adjust glass.
Regulator Replacement
NR377
Fig. 8
-
Quarter Window Vent Gloss
If adjustment of the division channel is necessary, loosen the upper channel attaching screw. Generally, sufficient movement of the chan- nel is possible at this point to correct any binding or looseness of the glass.
If additional channel movement is required, low- er the glass and loosen the two attachment screws at lower end of channel. movement is required
If additional in-or-out to obtain proper alignment of the glass, adjust the in-or-out adjusting screw at the lower end of the division channel.
Glass Replacement
Removal
(1) Loosen window track adjusting nuts (Fig. and remove glass from run channels.
6)
(2) Remove regulator arm from lift bracket channel.
(3) Remove glass from door.
(4) Remove lift bracket from glass.
Removal
Service procedures for the regulator are the same as for front doors.
Rear Door Stationary Glass
Removal
(1) Remove division channel attaching screws at upper and lower .ends (Fig. channel.
7) and remove
(2) Move the glass and weatherstrip assembly forward and out of window opening.
(3) Inspect the weatherstrip. lnst allation
(1) Position glass and weatherstrip assembly to window opening and move rearward into upper frame.
(2) Insert division channel run into channel.
(3) Apply a 1-1/2 inch length of sealer to joint area of division channel.
(4) With front glass in dowii position, insert di- vision channel into door and move firmly against stationary glass weatherstrip.
( 5 ) Install upper and lower attaching screws but do not tighten.
(6) Adjust the door glass.
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VALIANT-SIDE GLASS 6-37
SEDAN MODELS
holes in the hinge allow correct positioning of the glass assembly to the opening. The release handle
Two door sedan models are equipped with a assembly is attached to the glass with a grommet, vent wing type quarter window (Fig.
8).
Elongated washer, retainer and screw.
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a
STATIONARY GLASS 7-1
STATIONARY GLASS
INDEX
CONVERTIBLE
Installation
....................................................................
Installation
Removal
...............................................................
....................................................................
Page
...........................................................
3 STATION WAGON QUARTER GLASS
...............................................................
Remova I
REAR W I N D O W (WEATHERSTRIP TYPE)
STATION WAGON GLASS (NON
CEMENTED I N TYPE)
............................................
Installation
...............................................................
Removal
....................................................................
....
4 (CEMENTED IN TYPE)
3
4
Installation
Removal
....................................................................
4 WINDSHIELD (NON CEMENTED I N TYPE)
4 Installation
...............................................................
Removal
6 WINDSHIELD AND REAR WINDOW
Page
...........................................
4
...............................................................
5
4
...
2
3
....................................................................
2
7 (CEMENTED IN TYPE)
6 Installation
...........................................
...............................................................
Removal
....................................................................
1
1
1
SERVICE
WINDSHIELD AND REAR WINDOW
_ _
-
The windshield and rear window are polysulfide
PROCEDURES
lower corner of window and secure to another wooden handle.
( 5 ) With an assistant, carefully cut through ad- hesive material by pulling wire, in a sawing motion, up one side, across top, down opposite adhesive sealed (cemented-in) types. Service proce- dures for the two glass are comparable.
Short cut sealing methods should not be used.
To ensure a permanent watertight glass installation, use only the recommended adhesive sealer kit or its equivalent. side and across bottom (Fig. 1).
(6) With an assistant, remove glass from opening and if original glass is to be reinstalled, place on a protected surface.
(7) All old adhesive should be removed from glass and opening reveal using a putty knife or razor blade. DO NOT use an oil base solvent to
Removal
(1) Place protective coverings over the areas ad- jacent to the glass being replaced.
(2)
Remove window exterior mouldings using
Tool C-4009A and inner garnish mouldings.
(3) Secure one end of a two foot length of tem- pered steel wire handle.
(.028
gauge max.) to a wooden
(4) Insert other end of wire through adhesive at remove adhesive.
(8)
Using steel wool, remove loose flakes of ad- hesive and old primer from reveal. Use light air pressure to clean reveal and surrounding areas.
Installation
(1) Inspect moulding retaining clips. Remove and straighten clips bent more than 1/32 inch away from the body panel. Use self-sealing screw-on
I
Cuffing Adhesive Caulking Fig. 7 Fig. 2 Spacer Dam Insfallation
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7-2 STATIONARY GLASS
ADHESIVE CAULKING
RUBBER DAM
0
NP189A NP185
Fig. 3 Adhesive Application to Glass type clips when necessary to replace. All clips must be attached tightly.
(2) Inspect rubber spacers in window reveals when replacement of spacers is required, make certain they are positioned in the exact areas re- moved from.
(3) Install spacer dam 1/4 inch from edge and positioned so it leans toward edge on glass inner suface (Fig. 2).
(4) Attach suction cups to glass outer surface and position glass in opening.
( 5 ) Inspect relationship of glass to fence com- pletely around opening. The spacer dam should fold under and create a cushion for the glass to rest on. The glass to body fence overlap (0.30 inch minimum) should be equal across the top and sides. Use waterproof shims under spacers to obtain required overlap.
(6) Apply a piece of masking tape over each side of glass and roof extensions. Slit tape vertical- ly at edge of glass so when glass is installed, tape on glass can be aligned with tape on body.
(7) Remove glass from opening and place on a protected surface, with inside surface up.
(8) Primer solution will damage any paint or trim i t comes in contact with. Using a cheesecloth pad saturated with adhesive primer, thoroughly apply to rear window fence and reveal areas.
(9) The adhesive begins to cure immediately upon exposure to air. The working life is limited to approximately 15 minutes. Perform the fol- lowing steps as quickly a s possible.
(10) Insert adhesive tube into a standard house- hold caulking gun, install nozzle on end of tube, and puncture adhesive seal at nozzle.
(11) Apply a smooth continuous 3/8 inch bead of adhesive on glass between glass edge and spa- cer dam (Fig. 3).
(12) When positioning glass in opening, align- ment must be exact to prevent necessity of mov-
Fig. 4 Window Installation ing glass after adhesive contacts fence.
(13) With an assistant and using suction cups on glass align tape on glass with tape on body, make certain glass will set on rubber spacers and install glass in opening (Fig. 4).
(14) Press glass lightly to adhere adhesive to fence flange.
(15) Run a flat wooden or fiber tool around en- tire edge of glass to force adhesive into opening between edge of glass and reveal.
(16) Clean interior surface of glass. Hand pres- sure to clean the glass interior surface after in- stalling glass and before adhesive has set up may result in glass being pushed out of opening.
(17) Close car doors gently, do not slam and water test window. Use a cold water spray, do not run a heavy stream of water directly on freshly applied adhesive. If leaks are evident, work applied adhesive into leak point. Additional material can be applied and worked into leak point.
(1 8) Install garnish and exterior mouldings, clean glass exterior surface and remove protective covers.
(19) leave a window open and do not slam any doors for at least one hour. Sufficient pres- sure could build up in a closed car to force the window out of the opening.
WINDSHIELD
(Non-Cemented Type)
Removal
(1) Cover cowl, hood and fender area with a protective covering.
(2) Remove windshield garnish mouldings.
(3) Remove windshield outer mouldings using
To01 C-4009A
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STATIONARY GLASS 7-3
W EATH ERSTRl P
Fig. I Windshield Weatherstrip
(4) Unlock weatherstrip (Figs. 1) by prying lip of weatherstrip apart, inserting a fibre wedge, and with a slight twist to wedge, unlock weatherstrip by moving tool around weatherstrip.
( 5 ) Carefully loosen weatherstrip from glass inner and outer sides.
(6) With an assistant supporting one end of windshield, exert pressure, from inside car, to force windshield out of weatherstrip and carefully remove from opening.
(7) Whenever a glass has cracked from pressure at the fence area, remove weatherstrip and correct cause of crack. The fence should be straight, smooth, without burrs or high spots.
(8) Inspect weatherstrip for damage.
Installation
(1) Remove all old sealer and cement from origi- nal weatherstrip.
(2) Apply sealer in fence and glass groove por- tions of weatherstrip.
(3) Apply a 3/8 inch bead of sealer completely across cowl top panel lower windshield frame area
(Fig. 2).
(4) Position weatherstrip lower section to tab area, starting at corners install over tabs and work toward center.
( 5 ) Install weatherstrip on fence at sides and up- per opening. With hand pressure, seat weatherstrip fully on fence.
(6) With an assistant, slide upper edge of glass into channel of weatherstrip. Use a fibre tool to force weatherstrip lip over glass.
(7) Seat glass in weatherstrip, pounding glass with palm of hand using an upward motion.
(8) Insert a fibre tool between weatherstrip and glass, at either corner, slide tool across top, com- pletely around weatherstrip to seat glass in place. blades.
- r
Fig. 2 Windshield Installation
(9) Using a fibre tool and working across top, down sides and over bottom, force weatherstrip locking tab into locked position.
(10) Water test windshield area.
(1 1) Install exterior mouldings, wiper arms and
(12) Install garnish mouldings and remove pro- tective covering.
Convertible Models
Removal
(1) Cover cowl, hood and fender area with a protective covering.
(2) Release top locking mechanisms and push header from windshield frame to expose moulding retainer screws.
(3) Remove wiper arms and blades.
(4) Remove windshield outside mouldings.
( 5 ) Remove inner “A” post side mouldings.
(6) Remove sun visors and screws attaching header trim cap to header.
(7) Pry header moulding up slightly to clear moulding from weatherstrip, disengage from header and remove.
LOCKING TAB
NR137
Fig. 1 Windshield Installation-Conve~ible
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7-4 STATIONARY GLASS
(8)
Remove windshield in same method as other models. Installation
(1) Install windshield (Fig. 1) in same manner as described for other models.
WEATHERSTRIP TYPE
REAR WINDOW
REPLACEMENT
(2) Using a fiber wedge, unlock weatherstrip by prying weatherstrip apart and with a slight twist
(Non Cemented in Type)
Removal
(1) Place a protective covering over deck lid, quarter panel and rear window areas. Remove rear window mouldings using Tool C-4009A. move wedge around weatherstrip.
(3) With an assistant supporting glass on outside, from inside car, push against glass at one of the upper comers and remove glass from weatherstrip.
(4) Place glass on a cloth covered bench.
( 5 ) Remove weatherstrip from fence (Fig. 1)
WEATHERSTRIP
SECTIONA-A
PY345
Fig. I Weatherstrip
Installation
(1) Inspect weatherstrip fence to be certain it is clean, smooth and straight.
(2)
Flow a continuous ribbon of sealer on each lip and around entire length fo weatherstrip glass groove.
(3) Install weatherstrip making sure it is fully seated on fence.
(4) With an assistant, position rear window in weatherstrip.
( 5 ) With palm of hand, tap window glass make certain it is fully seated. to
(6) Insert a fiber tool and working around weatherstrip, force locking tab into locked position.
(7) Water test rear window area.
(8)
Install window mouldings, clean glass and remove protective covering.
STATION WAGON QUARTER GLASS (CEMENTED IN TYPE)
REPLACEMENT
(2) Remove window exterior mouldings using
Tool C-4009A and inner garnish mouldings.
Removal
(1) Place protective coverings over the areas ad- jacent to the glass being replaced.
(3) Secure one end of a two foot length of tem- pered steel wire
(.028
gauge max.) to a wooden handle.
(4)
( 5 )
Remove quarter window lower weatherstrip.
Insert other end of wire through adhesive at comer of window and secure to another wooden handle.
(6) With an assistant, carefully cut through ad- hesive across material by pulling wire, in a sawing motion, up one side, across top, down opposite side and across bottom (Fig. 1).
(7) With an assistant, remove glass from opening and if original glass is to be reinstalled, place on a protected surface.
(8) All old adhesive should be removed from glass and opening reveal using a putty knife or razor blade. DO NOT use an oil base solvent to
Fig. I Cutting Adhesive Caulking remove adhesive.
(9) Using steel wool, remove loose flakes of ad-
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STATIONARY GLASS
7-5
Fig. 2 Spacer Dam Installation
NP189A
Fig. 4 Installing Quarter Window Weatherstrip. hesive and old primer from reveal. Use light air pressure to clean reveal and surrounding areas.
(10) Remove old sealer from lower trough after marking location of spacers.
Insf cr//rr/on
(1) Inspect moulding retaining clips. Remove and straighten clips bent more than 1/32 inch away from the body panel. Use self-sealing screw-on type clips when necessary to replace. All clips must be attached tightly.
(2) Inspect rubber spacers in lower trough when replacement of spacers is required, make certain they are positioned in the areas removed from.
(3) Install spacer dam 1/4 inch from edge and positioned so it leans toward edge on glass inner surface (Fig. 2).
(4) Attach suction cups to glass outer surface and position glass in opening.
( 5 ) Inspect relationship of glass to fence com- pletely around opening. The spacer dam should fold under and create a cushion for the glass to rest on. The glass to body fence overlap (0.30 inch minimum) should be equal across the top and sides. Use waterproof shims under spacers to
Fig. 3 Adhesive Application To Glass obtain required overlap.
(6) Apply a piece of masking tape over each side of glass and roof extensions. Slit tape vertical- ly at edge of glass so when glass is installed, tape on glass can be aligned with tape on body.
(7) Remove glass from opening and place on a protected surface, with inside surface up.
(8) Primer solution will damage any paint or trim it comes in contact with. Using a cheesecloth pad saturated with adhesive primer, thoroughly apply to rear window fence and reveal areas.
(9) The adhesive' begins to cure immediately upon exposure to air. The working life is limited to approximately 15 minutes. Perform the fol- lowing steps a s quickly as possible.
(10) Insert adhesive tube into a standard house- hold caulking gun, install nozzle on end of tube, and puncture adhesive seal at nozzle.
(11) Apply a smooth continuous 3/8 inch bead of adhesive on glass between glass edge and spa- cer dam (Fig. 3).
,
(12) When positioning glass in opening, align- ment must be exact to prevent necessity of mov- ing glass after adhesive contacts fence.
(13) With an assistant and using suction cups on glass, align tape on glass with tape on body, make certain glass will set on rubber spacers and install glass in opening.
(14) Press glass lightly to adhere adhesive to fence flange.
(15) Run a flat wooden or fiber tool around en- tire edge of glass to force adhesive into opening between edge of glass and reveal.
(1 6) Install quarter window lower weatherstrip
(Fig. 4) using a small plastic roller or fiber stick.
(17) Clean interior surface of glass. Hand pres- sure to clean the glass interior surface after in- stalling glass and before adhesive has set up may result in glass being pushed out of opening.
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7-6
STATIONARY GLASS
0 w v
NU445
Fig. I Spare Zire Cover
(18) Close car doors gently, do not slam and water test window. Use a cold water spray, do not run a heavy stream of water directly on freshly applied adhesive. If leaks are evident, work applied adhesive into leak point. Additional material can be applied and worked into leak point.
(19) Install mouldings, clean glass exterior sur- face and remove protective covers.
Fig. 2 Quarter Window Garnish Mouldings
STATION WAGON
GLASS REPLACEMENT (NON-CEMENTED)
Removal
(1) Remove spare tire cover assembly (Fig. 1).
(2) Remove garnish mouldings at quarter window
(Fig.
2).
(3) Unlock weatherstrip by inserting a fiber stick
4
% INCH BAl
R Xi INCH BEAD
SEALER % INCH RAII w w
VIEW IN DIRECTION OF ARROW B
SEALER % INCH BEAD
VIEW IN DIRECTION OF ARROW C
NU443
Fig 3 Quarter Window Sealing Areas
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STATIONARY GLASS
7-7
SEALER
CEMENT
LOCKING TAB
OUTER PANEL
APPLICATION AT A-A
APPLICATION AT 6-6
NU442
Fig. 4 Weatherstrip Replacement of vehicle and weatherstrip from fence.
LOCKING TAB fnstallaiion
(1) Inspect sealing areas of quarter window to ascertain sealer is applied at areas indicated in
Figure 3.
(2) Apply a bead of sealer, starting at front and top sections of weatherstrip (Fig. 4).
(3) Apply a small bead of cement to each lip of glass groove, completely around weatherstrip.
(4) Position weatherstrip on fence with locking edges facing inboard.
( 5 ) From inside of vehicle, insert bottom of glass into weatherstrip and using a fiber stick, pull lip of weatherstrip over glass (Fig. 4).
(6) Seat glass in weatherstrip using hand
APPLICATION AT 6-6
APPLICATION AT A-A
NU441 pressure.
(7) Apply rubber lubricant to weatherstrip lock- ing tab and insert locking tab into weatherstrip groove using a fiber stick.
(8) Apply and press secure, sealer to joint of weatherstrip, body lock upper pillar and roof side rail outer front area (Fig. 5).
Fig. 5 Glass Replacement (9) Apply and press secure, sealer to joint of into locking groove of weatherstrip and forcing glass weatherstrip, outer panel weatherstrip retainer locking tab out of groove. and rear body lock pillar.
(4) Remove glass from weatherstrip from inside (10) Install garnish mouldings and spare tire cover.
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CONVERTIBLE 8-1
CONVERTIBLE
INDEX
Page
ADJUSTMENTS
Cam
............................................................................
Door And Glass Alignment
4
Control Link
.............................................................
4
Header
...............................
3
.......................................................................
4
4 Hinge Front
............................................................
Latching Mechanism
............................................
3
Major
..........................................................................
3
Minor
..........................................................................
3
Roof Side Rail Alignment
..................................
3
Shifting Top
Stack Height
............................................................
5
...........................................................
COVER TO BELT BAR
5
...........................................
9
CYLINDER HOSE ROUTING
................................
2
DOWEL BRACKET
Page
...................................................
3
ELECTRICAL TESTS
...............................................
FOLDING MECHANISM
FOLDING TOP AND WELL COVER
5
1
OPERATING THE TOP
.................
7
...........................................
1
RESERVOIR
................................................................
1
SIDE TENSION CABLE
..........................................
5
TOP DECK TO NUMBER 3 BOW
.....................
9
WEATHERSTRIPS
Header
.......................................................................
7
Roof Side Hails
......................................................
7
Seals And Sealers
WELLLINER
WEBSTRAPS
M A N U A L T O P
.................................................
..............................................................
5
............................................................
...........................................................
7
5
4
Condition
TOP AND WINDSHIELD
HEADERS NOT MEETING AT
CORRECT ANGLE
IMPROPER MEETING and aft)
(fore
OF TOP AND
WINDSHIELD HEADERS
TOP HEADER NOT ALIGNED
WITH GUIDE DOWELS
LEAKAGE AT WINDSHIELD
HEADER
SERVICE DIAGNOSIS
Possible Cause
(a) Incorrect side rail adjustment.
Correction
(a) W i t h top header locked in position, adjust front hinge.
(a) Improper power adjustment.
(a) Improper header adjustment.
(a) Header latch not properly adjusted.
(a) Adjust power link bracket in direction of movement desired.
(a) Adjust header ”fore or aft“ t o align with guide dowels.
(a) Adjust by turning hook in or out.
I
OPERATING THE TOP
SERVICE PROCEDURES
ing fluid to the reservoir in a position other than
Raise or lower top only when vehicle is standing still. its normal installed position does not allow for fluid expansion and damage to the reservoir may result.
Measure fluid level only when top is lowered.
TO LOWER TOP After filling reservoir, raise and lower top se-
Release safety catch, pull handle down and push vera1 times to expel air that may be trapped in top free of the header.
Be sure the well compartment is free of articles. system.
Insufficient fluid in the system may cause slow
Operate engine in neutral slightly above idle and raising or noise in the pump and motor. Measure hold switch control to the Down position until fluid level and if low, look for a leak due to a top is fully lowered. broken line or a loose connection. Fill reservoir
(use only AQ-ATF Suffix “A” “Dexron” type
TO RAISE 1 0 P transmission fluid) or equivalent until fluid runs
Remove boot, operate engine in neutral slightly out of filler hole. above idle and hold switch control in the Up position. As dowels seat in their sockets, pull FOLDING 1 0 P MECHANISM header down firmly and push locking handles for- ward until catches engage.
The electric-hydraulic top folding mechanisms
(Fig. 1) consists of two cylinders a pumping
RESERVOIR
DO NOT system, an electric motor, a pump and reservoir assembly, and a double-throw rotary switch. The add fluid to a reservoir until it is in- wiring and motor are protected by a separate ex- stalled in its normal position in the vehicle. Add- ternal circuit breaker.
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8-2 CONVERTIBLE
PUMP AND RESERVOIR. CLIP
CLIPS
CY Ll NDE R
\
EW
HO
APPLICATION TO BODY
AT SECTION A-A
\
L R O S E \ CLIP
\
\(D WIRE
PUMP AND CYLINDER HOSES
/
Fig. I Foldng Top Mechanism
The cylinders are serviced only as an assembly.
The reservoir end plate
“0”
ring is replaceable.
The pump cover plate is serviced as an assembly and the rotors are serviced as a package with the
”0” rings.
CYLINDER HOSE ROUTING (Fig.
2)
Removal
(1) Remove screw from clips.
VIEW IN CIRCLE B
PY792
Fig. 2 Cylinder Hose Routing
(2) Remove ground wire eyelet from support bracket.
(3) Remove cylinder hoses from rear seat back support.
(4) Lift motor pump and cylinder hoses out of wheelhouse and rear seat back clips.
FOLDING STRUCTURE a,&
0
VIEW IN DIRECTION OF ARROW W
BRACKET FOLDING TOP LOCK
VIEW IN DIRECTION OF ARROW X
Fig. 3 Folding Stmeturn And linkage
VIEW IN DIRECTION OF ARROW Z
PY700
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CONVERTIBLE
8-3
Fig. 4 Mounting Plate Assembly
VIEW IN CIRCLE
/
NP 274
Fig. 5 Cam Assembly bottom surface of the front rail and center rail directly below hinge. Little adjustment is possible at the hinge.
Installation
(1) Route existing top lift motor pump and cyl- inder hoses thru existing clip on wheelhouse panel and rear seat back.
(2) Position cylinder hose clip to rear seat back support.
(3) Position existing top lift motor gound wire eyelet between clip and support bracket.
(4) Secure clips with screw.
ADJUSTMENTS
Minor Adjustments are provided to assist in aligning the top header to the windshield header to prevent leakage into this area; to improve top frontal area appearance and assure ease of raising and lowering operation.
They are also provided to assure correct align- ment of the roof side rails with door and quarter glass to prevent leakage. Adjustments are provided to eliminate wrinkles in the top material.
MAJOR ADJUSTMENTS
Major adjustments are at the cam, control link bracket and the outer mounting. These adjust- ments are necessary to improve roof side rail alignment if minor hinge and header adjustment do not completely correct the condition.
DOOR AND GLASS ALIGNMENT
After making top adjustments, doors, door glass and quarter glass must be properly aligned. Misa- lignment in any of these areas make it impossible to obtain satisfactory results from top adjustments alone. Glass up-stop adjustments should be made after the correct roof side rail alignment to limit the upward travel of the glass and to assure effec- tive sealing between the roof side rail weatherstrip and glass.
LA TCHING MECHANISM
Good sealing at the frontal area is dependent upon proper positioning of the top header on the windshield header. The header locating dowels are cast into the latching mechanism housings and en- gage sockets in the windshield header to correctly position header.
The latch hook should be adjusted to provide proper compression of the outer weatherseal on the folding top header.
The locking and unlocking effort of the latching mechanisms are adjustable. Adjust the header catch to show five or six threads for initial setting.
ROOF SIDE RAIL ALIGNMENT
The roof side rail structure (Fig. 3) consists of separate rails, hinged together to enable the top to fold into the well. The rails must be in good alignment and parallel to top edges of door and quarter glass to provide a good weatherseal.
Alignment of the rails is controlled by the side rail structure mounting support assembly (Fig. 4), cam (Fig. 5 ) , control link and front hinge set screw.
The front hinge set screw is accessible from the
DOWEL BRACKET (Fig. 6)
Removal
(1) Raise top to clear windshield upper frame.
(2) Remove anti-rattle from dowel1 bracket.
(3) Remove dowel bracket mounting screw.
(4) Remove dowel bracket from windshield up- per frame.
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8-4 CONVERTIBLE
SCREW
UPPER
\ DOWEL BRACKET ANTI-RATTLE
0 top header.
To eliminate interference between the header and finish moulding, rotate the cams on the side rail so the cam lobes are forward. It may be neces- sary to lengthen the control links one or two serrations after the cam adiustment. If cams lobes were already in the full forward position, it may be necessary to loosen the header-to-side-rail screws and adjust header to provide proper clearance.
HEADER
APPLICATION TO BODY
, -
Fig. 6 Dowel Brackef
PIN
PY791
FRONT HINGE ADJUSTMENT
To facilitate front hinge adiustment, unfasten header latches and partially lower top, before adjusting set screws.
Leakage between the top and door or quarter glass may be caused by poor contact between roof side rail weatherstrip and glass or only a partial contact between roof rails and top edge of glass.
If inspection shows leakage is due to incorrect side rail alignment at the front hinge, adjust set screw until front and center side rails provide the proper glassline. When the rails sag, it indicates the control link is too long.
Ins f a k
(1) Position bracket to windshield outside upper frame.
(2) Secure with screw.
(3) Position and assemble anti-rattler to dowel bracket
(4)
.
Check alignment of dowel pin and dowel bracket.
MANUAL TOP
Removal, installation and adjustment for the manual operated top are similar to the Electric
Hydraulic top. The difference is a spring assist in place of a hydraulic pump to aid in manually raising or lowering the top. When assembling or disassembling the spring assist from the attach plate raise the top to a half open position to re- lieve tension on the spring.
The spring assist is mounted in the grid plate assembly like the hydraulic cylinder attach plate.
Refer to removal, installation and adjustment of the power operated top.
HEADER ADJUSTMENTS
Inspect top linkage and mouldings for sharp edges, burrs or screws that are too long which may damage the top material. Dress or file them down.
The top header is adjustable at the front roof side rails to permit fore-or-aft movement. The header is attached to the side rails by two screws on each side (Fig. 3).
Incorrect alignment between the top header and windshield finish mouldings may result in leakage or cause objectionable locking and unlocking effort. Inspect clearance for uniformity. The dow- els control the fore and aft position of the folding
CONTROL LINK ADJUSTMENT
The control links (Fig. 4) incorporate serrated adjusting links. Loosen screws just enough to per- mit moving links up or down.
Raise the side rail assembly by lifting the front end of the center rail until the folding top header is six to eight inches above the windshield header.
Loosen the control link adjusting screws and allow the control link to seek its proper position. Tight- en screws while rail assembly is held in the posi- tion described above.
CAM ADJUSTMENT
The cam assembly (Fig. 5 ) is used to change top header postion in relation to the windshield header. The cams turn inside the rear side rail and the thrust link. When rotated, it changes the relationship between the front and rear side rails by moving the thrust link forward or rearward.
The position of the cam high side determines the angle between .the center and rear side rails. When the high side i s fully forward, the angle i s at the minimum and when turned rear- ward the angle is increased. An increased angle increases the forward ''throw" of the entire top assembly.
The cam high side is indicated by a notch in the cam threaded end. Three triangular marks on the side rail indicate the amount of cam rotation when adjusting. The marks are located at the full- forward position of the high side, 45 degrees up and 90 degrees up. When adjusting, the cam high side position can be determined by referring to the
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a
CONVERTIBLE 8-5
notch and the triangular marks. Before adjusting, place top in half raised position to remove all possible strain off the cam. Make sure lock nut is loose. Tap cam threaded end with a soft-faced hammer to loosen any paint bond between cam and linkage.
(Fig. 4). Force lower portion of mounting plates to rotate fully forward while exerting pressure downward on both sides at top of side rails.
Tighten screws and inspect stack height after rais- ing and lowering top.
SlACK HElGHl
Do not move mounting plate positions until control links have been adjusted.
Stack height should be correct if the control links- have been adjusted as outlined. If control link adjustment does not correct stack height, loo- sen lower two of the three mounting plate screws
10P SHIFTS
10
ONE SIDE
If necessary to pull top to one side to engage locating dowels or top shifts to one side when raising from the windshield header, inspect posi- tion of control links. It may be necessary to ad- just the control links unevenly to achieve proper alignment of the top.
CABLE
/
FOLDING TOP HEADER
SCREW
TENSION
RAIL
‘ /
TENSION CABLE
--’
VIEW B
PY790 ng. 7 Side Tension Cable
ELEClRlCA L TESlS
Refer to the Body Electrical Unit for Tests and
Wiring Diagrams.
SIDE 1ENSION CABLE (Fig.
7)
Removal
(1) Raise Folding Top 18 inches and prop up.
(2) Remove side tension cable screw.
(3) Remove cable eye from side rail.
(4)
( 5 )
Loosen Front Cover Tension Cable Bracket.
Remove tension table bracket from side rail.
Installation
(1) Raise folding top header 18 inches and prop
U P .
(2) Position tension cable bracket to attaching hole in front side rail.
(3) Secure the cover side tension cable front bracket with screw.
(4) Route eye at rear of tension cable thru weld
NP524
Fig. 8 Web Straps clips on rear side rail.
( 5 ) Position eye of cable to attaching hole in side rail support.
(6) Secure cover side tension cable with screw.
WEB SlRAPS
Two web straps attached to the rear bow and the tacking strip are provided to keep the number
3 bow from moving forward and wrinkling the top material. They also prevent excessive tension on the backlight zipper. The straps are attached to the bow and tacking strip with 8 staples and 1 tack at each end (Fig. 8).
WELL LINER
The well liner (Fig. 9) is attached to the tacking strip in the quarter panel belt area with the use of stud snap-on type fasteners.
When installing the liner, apply a thin coat of cement to the front face of the liner lower edge approximately two inches wide at the area where liner attaches to upper face of the rear seat back support. Apply cement to the area contacting the. wheelhouse cap. Apply cement to the upper sur- face of rear seat back support approximately two inches wide.
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8-6
CONVERTIBLE
m-fTUD FASTENERS
TACKING STRIP
SEAT BACK SUPPORT
/
VIEW I N CIRCLE
\'..\ ,\"\\
CEMENT WELT
/
I
I / WY
0
Fig. 11 Top Header Wmtherstdps And W./tr Fig. 9 Well Liner Attachment
Fig. 10 Roof Rail Wmtherstrlp
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0
CONVERTIBLE
8-7
Fig. 72 Rear Bow Tacking Strip
\ t
FI
N P534
Fig. 73 Removing Staples And Tacks A t Rear Bow weatherstrip contacts windshield header outside moulding. A rubber welt is cemented to the head- er flange.
Seals and Sealers
When repairing or replacing a seal, or weather- strip at the header and pillar areas, care should be exercised to see that seals and weatherstrips are firmly seated in correct alignment and are free of twists. Clean all areas thoroughly, before installing weatherstrips and seals.
FOLDING 1 0 P AND WELL
COVER
NP533
Fig. 74 Rear Curtain Assembly
WEA 1HERSTRIPS
Roof Side Rail
After roof side rails have been aligned, inspect the side rail weatherstrip to make sure it is pro- viding a good seal at top of door and quarter glass.
If weatherstrip is not sealing properly, the retain- er can be adjusted. The retainer has elongated at- taching screw holes which permit in and out ad- justment (Fig. 10).
Raise glass until top edge of glass curls outer lip of weatherstrip inward just enough to contact in- ner lip. Adjust up-stops to limit further upward travel of glass. lop Header Weatherstrips and Welts
The entrance of water and air between the top and windshield headers is eliminated by a tube type weatherstrip (Fig. 11) secured to the under- side of the top header. The forward edge of
Removal
A visual inspection of the weatherstrips for dam- age or excessive wear should be made before re- moving the top cover. Inspect the top cover cables to make sure they are correctly connected. Inspect the top cover stay pads for excessive wear or moisture stains. Inspect web straps at rear bow.
.
(1) Place protective covers over the deck lid, deck lid upper panel, hood and cowl areas.
(2) Unsnap top boot and lay over rear seat back.
(3) Unzip the backlight and lay in well.
(4) Remove retainers from ends of tacking strip on rear bow and spread tacking strip (Fig. 12).
( 5 ) Using a sharp pointed tool remove staples and tacking strip. Use care not to damage the top material if the original cover is to be reinstalled. In some instances the staples ends may have become peened over and if excessive effort i s required to remove them, it i s advisa- ble to cut the heads off the staples and remove the pieces after the top cover has been removed, otherwise damage to the top material may result.
(6) Remove staples and tacks (one tack used on each side at binding areas and at centerline area
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a-a
CENTER BOW
VIEW IN CIRCLE A
Fig. I5 Cover Tension Cable
Fig. 16 Stay Pad Attachment
Installation
The rear curtain, backlight and ripper is serv-
Fig. 17 Cover Tacking Strip attaching top cover to rear bow (Fig. 13).
NP563 iced as an assembly.
Prior to installing cover, inspect roof bow felt pads for moisture or damage. The pads are a press fit in the bows. The cover stay pads should be inspected for damage and moisture. The stay pads are attached to the header and roof bows
(7) Prop top off of windshield header and re- move moulding from top header. The moulding with tacks (Fig. 16).
The rear window zipper top half is tacked to attaching screws are located under the the rear bow (Fig. 12) and the curtain bottom weatherstrip. portion is attached to tacking strips (Fig. 17).
(8) Raise top to the 1/2 open position and re- The circled numbers shown on the reference il- move rear roof rail weatherstrip (Fig. 10). Mark lustrations indicates the particular step number be- location of retainer screws on roof rail to aid in ing read in the installation procedure (Figs. 20 reassembling, and remove retainer.
(9) Remove top and rear curtain material from and 21).
(1) Position folding top less trim (in folded roof rail (Fig. 14).
(10) Remove sealing tape, staples, drive nails and tacks at the top header. position) to body.
(2) For attaching side flap apply even coat of adhesive approximately 2 inches wide to underside
(1 1) Mark location of top material bead on ends of top header, from latch hook outboard to under- of cover pads and loosen seals at comers.
(12) Remove front screws from front roof rail weatherstrip retainers and remove locking flaps side of front rail.
(3) Open top and adjust to body.
(4) Position center, and side to belt bar retainer from between retainer and roof rail. and tacking strip to trim.
(13) Remove cover cables at front roof rail ( 5 ) Apply even coats of adhesive to upper rear weatherstrip retainers and at rear pillars (Figs. 7 flange, header, header center welt, and header side and 15) if original cover is to be reinstalled tie a welts. Install center and side welts to header cord to one end of cables prior to removing. flange.
When cables are removed cord should be left in (6) Assemble stay pad to header using adhesive. listing.
(14) Remove cover from the folding linkage.
(15) Remove rear curtain assembly.
Install screw to header.
(7) Assemble top stay pad to Number 1, 2 and
3 bows.
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TOP DECK STAPLE SPACER
-
TOP TO QUARTER
PANEL
BELT SIDE
CONVERTIBLE
8-9
SPACER
TO DECK
SPACER STRIP TO BELT BAR STRIP
PY793
Fig. 18 Top Deck To No. 3 Bow
(8)
Assemble rear curtain to Number
3
bow, belt bar retainer and tacking strip.
(9) Assemble rear curtain stay straps to Number
3
bow, belt bar retainer, and tacking strip.
(10) Assemble side tension cable to deck and side quarter assembly pocket.
(11)
Assemble tape to rear rail top material retainer. Apply an even coat of adhesive to trim retainer and top fabric. Bond fabric to trim retainer. Assemble retainer to rear rail.
(12).
Secure side tension cable at front and rear using screws.
(13)
Position and secure top deck and side quar- ter assembly to Number
3
bow. Assemble side quarters to belt bar tacking strips (Figs.
2 1).
18
thru
(14)
Assemble top deck and side quarter assem- bly to header and rear side rail trim retainer.
(1
5) Assemble retainer weatherstrip to header.
(16)
Assemble wire on binding to Number 3 bow.
(17)
Position top to body. Adjust belt bar retain- ers as necessary to avoid wrinkles in top material.
(18)
Apply an even coat of adhesive along un- derside of front face well cover and at area where assembly connects to wheelhouse cap. Allow adhe- sive to dry onto entire area of wheelhouse cap and rear seat back support surfaces, position top well cover and press to bonded surfaces of wheel caps and rear seat back support. Fasten edges of well cover assembly by snap attaching curtain fas- teners to studs.
Top Deck To No. 3 Bow
(1) Remove header prop and lower header. Se- cure latch mechanism. Align top deck and side
Fig. 19 Cover to Belt Bar quarter assembly material to frame.
(2)
Position centerline locating hole of top deck cover assembly to centerline notch of number
3
bow.
(3)
Secure with staples to number
3
bow (staples to be installed toward front of bow).
(4)
Pull taut and align top deck cover assembly at reinforcement along number 3 bow.
( 5 ) Secure with staples. Also align side quarter binding with top material retainer attached to rear rail.
Care must be taken at this time to assure that the top deck valance is straight and without puffs or wrinkles.
(6) Pull top deck material at header to assure a wrinkle free top deck.
(7)
Remove previously installed staples when nec- essary to realign top deck cover assembly.
(8) Secure top deck to number 3 bow at rein- forcement with staples.
(9) Secure top deck cover assembly at heat seam and reinforcement joint to number 3 bow with tack.
COVER TO BELT BAR
(1)
Remove pressure adhesive protective paper from spacer strip and apply adhesive side to bar- deck opening belt center.
(2)
Remove pressure adhesive protective paper from spacer and apply adhesive side to bar-deck opening belt center.
(3) Remove pressure adhesive protective paper from spacer cover to belt bar and apply adhesive side to quarter panel belt side upper.
(4)
Apply pressure to all spacers to secure. Care must be taken to align holes in spacers with attaching holes in belt bars.
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0
VINYL ROOF 9-1
VINYL ROOF COVERING
INDEX
AIR BUBBLE REMOVAL
Page
.......................................
2 VINYL REPAIR
COVER REPLACEMENT
........................................
1
..........................................................
4
CLEAN SURFACE
..................................................
MAKING GRAINING
Page
3
TOOL
...............................
3
SERVICE PROCEDURES
CO
VER REPLACEMENT
Removal
(1) Remove windshield rear window and mould- ings on non-cemented type application. On ce- mented in type windows, remove mouldings only.
To aid in installation of mouldings, mark clip hole locations with a removable type marker.
(2) Remove roof side mouldings and pull cover off of roof panel.
(3)
Remove all sealer from drain trough, windsh- ield and rear window reveals.
Installation
Inspect old cement to make certain there are high or low areas, or areas without cement. no
(1) Mask body (Fig. 1) from edge of drain trough across upper
“A”
pillar, windshield and rear window reveal, top of deck upper and bottom or roof panel at belt line.
(2)
Locate and mark center line of roof panel and vinyl cover at front and rear ends.
(3)
Apply a thin film of cement to center four inches of roof panel and vinyl cover.
(4) When cement becomes tacky, position cover on roof aligning centerline marks.
( 5 ) Apply cement to one half of roof panel and extension and to the cover half on same side (Fig.
2).
(6) When the cement becomes tacky position
-
CE$ENT
VINYL COVER
Top/
MASKING TA
MASKING PAPER
N K983
Fig. 1 Masking The Body
2 Positioning Cover wn
IWWI
NK985A
FIG. 3 Positioning Cover In Window Reveals FIG. 4 Trimming And Sealing Cover At Windows
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9-2
VINYL ROOF
DRAIN TROUGH
FIG. 5 Positioning Cover At Sides cover on roof panel.
(7) Repeat steps 5 and 6 for the opposite side.
(8) Using a new paint roller, pressurize cover to the roof working from center area toward drain troughs.
(9) Press cover into windshield and rear window reveals using a dull pointed fiber tool (Fig. 3).
(10) Position cover to roof panel extension mak- ing certain all wrinkles are removed.
(11) Trim fabric at base of windshield reveal, halfway between upper and lower edges of pillar moulding (Fig 4).
(12) Trim fabric at base of rear window reveal.
(13) Using a dull pointed tool, press fabric into drain trough to achieve maximum contact of roof cover material to drain trough (Fig 5).
(14) Grasp outboard edge of cover and while pulling material outward and down, use upper edge of drain trough flange as a breakover for draping material onto outboard drain trough flange face (Fig. 5). Care must be taken to avoid pulling loose the cover material of drain trough. applied to base
(1 5) Press material against drain trough flange face for full length of outboard sides of roof cover.
(16) Trim excess material hanging below drain trough flange about 1/8 inch above lower edge of flange (Fig. 5).
(17) Locate and punch holes in cover at roof extension belt line.
(18) Trim cover on a line 1/4 inch below belt line moulding holes and curving upward to meet drain trough.
(19) Apply a bead of sealer to trimmed edge of cover at roof panel and smooth out to form a seal (Fig. 6).
Install sealer along entire length of outboard trimmed edges of cover material to seal exposed edge adjacent to drain trough flange.
(20) Apply a 1/4 inch ball of sealer to index
1
NN56
FIG. 6 Sealing Cover At Sides studs of pillar mouldings.
(2 1) Install side drain trough mouldings, windsh- ield and rear window mouldings.
(22) Remove masking material and inspect cover for air bubbles.
AIR BUBBLE REMOVAL
(1) Place strips of masking tape over surface bubble.
(2) Using a No. of
19 hypodermic needle and suita- ble syringe, insert 3M Vinyl Trim Adhesive No.
8064, or equivalent, into bubble area. -Extreme care must be used to avoid depositing any ad- hesive on the top surface of the vinyl cover-
The perforation must be made in center of bubble, through masking tape and vinyl material. Approxi- mately 0.5 mil of adhesive per square inch should be used.
(3) Remove needle and work adhesive to cover affected area by pressing vinyl to roof carefully.
This will also transfer some of adhesive to surface of vinyl cover.
(4) Allow cement to dry 5 minutes at room temperature.
( 5 ) Heat bubble area with relative low heat (1 50 degree- 160 degree F.) until bubble area begins to enlarge in circumference. Infra-red heat lamps pro- vide a suitable source of heat.
(6) Remove heat source and allow cover to cool.
A method of rapid cooling will be beneficial.
(7) Using a DRY No. 19 hypodermic needle, puncture cover 4 times equally around outer cir- cumference of bubble to provide an escape route for entrapped solvent and air.
(8) After bubble collapses, press cover to metal surface, starting from one side of bubble and working toward opposite side until it conforms to metal surfaces and all raised surfaces disappear.
(9) Keep vehicle from hot sunlight and other direct heat sources
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0
VINYL ROOF
9-3
FIG. I Cleaning The Material FIG. 2 Mixing Grain-On Compound
FIG. 3 Application Of Compound To Vinyl Material
(10) Examine top after a 24 hour period.
CLEAN GRAINED SURFACE OF THE VINYL
TOP REPAIR AREA
(1) Spray a little Chrysler All Purpose Cleaner or equivalent on repair area and wipe surface dry with a fine texture rubber sponge.
(2) To insure the surface is thoroughly dry, use heat from the heat gun.
(3) Put a small amount of Chrysler Vinyl Prep or equivalent on a clean lint free rag and wipe the full surface once, in one direction.
(4) Chrysler Vinyl Prep or equivalent opens the pores in the vinyl, but back and forth rubbing makes the surface tacky.
(5) Apply heat from heat gun about three sec- onds to make sure pair area. no solvent remains in the re-
FIG. 4 Application o f Second Vinyl Material
MAKING THE GRAINING TOOL:
The graining tool will duplicate any print the technician desires to make. It is made by taking an impression from the vinyl material adjacent to the repair area having the same print or grain that material under repair. as
(1) Clean the vinyl material to be used to make a print with Chrysler All Purpose Cleaner or equivalent, dry it with the heat gun.
(2) Spray a 12 in. X 12 in. surface with Chrys- ler Mold Release or equivalent (which is a painta- ble mold release) (Fig. 1). It can be washed from vinyl material with all purpose cleaner when necessary.
(3) Remove about two tablespoons of Chrysler
Grain-on material or equivalent from the container, place it on a steel or glass surface, then
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9-4 VINYL ROOF
0
FIG. 5 Removing Vinyl Pattern Die Fig. I Typical Damage
FIG. 2 Trim Damaged Area apply 10 to 12 drops of catalyst from the small bottle, quickly mix it together thoroughly and spread it evenly over the paintable mold release area using the offset pallette knife, working the
Grain-on or equivalent into the pores of the grain to eliminate air bubbles within an area of 4 inches (Fig. 2 and
3).
x 6
(4) Cut a piece of scrap vinyl material 8 x 6 inches of the same grain you wish to print and place it over the vinyl compound, canvas side to the compound mixture. Place a flat board on top of the assembly. Press down lightly by hand and put a 1/2 pound weight on the board. Keep the vinyl compound approximately
3/32
in. thick. Al- low it to dry fifteen minutes then remove it by peeling it from the paintable mold release surface
(Fig. 4).
( 5 ) Allow it to air dry five more minutes then
FIG. 3 Cleaning Area trim off the rough edges to suit (Fig. 5 ) .
(6) You now have a permanent graining tool. If it should become rigid at any time, just apply a little heat from the heat gun to restore its flexibility. The graining tool may be made large or small, but for best results it should extend two inches in every direction around the repair to produce a feathered edge effect. Once the graining tool is made it can be used over again on simular vinyl pattern repairs through out the remainder of the year.
VINYL TOP REPAIRS
(1) Trim the frayed edges (Fig’s. 1 and
2).
(2) Leave a gap between edges to be welded, for expansion, contraction, and for a good bite by the welding compound.
(3) Heat vinyl around tear to reactivate glue and
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0
VINYL ROOF
9-5
FIG. 4 Wiping Repair Area
-
FIG. 5 Application Of Welding Compound
FIRST LAYER
,
I
ROOT FILLET
FIG. 6 Curing With Heat Gun press vinyl into it. If it will not stay down use
Chrysler vinyl top to metal glue or equivalent, keeping at least one sixteenth inch away from all edges to be welded.
(4) Clean area to be refinished with Chrysler
Parts Leather Cleaner or equivalent and allow to dry (Fig. 3).
( 5 ) Wipe with Chrysler ‘Vinyl Prep or equivalent on lint free cloth in one direction only. (Do not rub back and forth.) Allow to dry (Fig. 4).
(6) The Welding Compound is not to be used as a one operation filler.
(7) The amount of heat required to cure it would be too excessive for the vinyl subject we are working with, only the surface of the weld would be cured and not the underneath portions.
(8) Excessive heat will not affect the welding compound, only the adjacent vinyl material.
FIG. 7 First layer Application
(9) Using the small pallette knife, take a little of the white welding compound on the tip and place it into the hole, working it all around the lower edges of the hole (Fig. 5).
(10) The welding compound will not air dry in the jar but always keep the jar away from heat.
(11) Be sure to remove all excess welding mate- rial from the top surface and grain of the repair area before applying the heat from the heat gun, otherwise you will cure it and cause roughness on the surface and a poorly finished repair.
(12) Using heat gun, close the shutter, move the switch to hot, holding the heat nozzle directly over the hole to be repaired and at right angles to the repair area and one inch above it. (Fig. 6).
(13) As heat is applied the air blast from the heat nozzle will tend to raise the vinyl material around the hole. To correct this, remove the heat,
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9-6
VINYL ROOF
INTERMEDIATE LAYER61
I
FINAL LAYER
LEVEL SURFACE
VINYL TOP\
AREA
R O O F A
FIG. 8 Secondary layer Application
PB88
1
I
COMPLETE FILL
FIG. 9 Final layer Application l
0
FIG. 10 Grain Patfern Die Applicafion using the thumb of your free hand to press the edges of the vinyl material down into the welding compound, the edges will now lie flat as you ap- ply heat to cure the weld. UNLESS THE WELDING
COMPOUND
APART.
I S PROPERLY CURED IT WILL FALL
(14) At first the welding compound will appear milky but as the heat cures it, it will turn trans- lucent or clear, time required varies from ten to twenty seconds according to the intensity of the applied heat. Do not be afraid to use heat.
(15) When the first weld is properly cured you will clearly see through the weld. It is best that each weld be cooled with air from the gun by opening the shutter fully with switch at cold position, before applying the next layer of welding material (Fig’s. 7 and 8).
(16) Each layer of the weld is applied and cured
FIG. I I Vinyl Color Spray in the same manner as the first. A cold water wet cloth or sponge can also be used to cool the weld.
(17) The welding compound on the fourth or last weld must be leveled off flush with the top surface using an offset pallette knife as a straight edge before applying heat (Fig. 9).
(18) When satisfied that the last weld is flush with the surface, then grain or print the repair by heating the repair until the surface material in the immediate vicinity begins to shine.
(19) Remove the heat gun in the one hand and with the other firmly press the graining tool into the hot surface, holding it there about five sec- onds (Fig. 10).
(20) When the graining tool is removed the tech- nician will find he has grained his repaired hole and blended the grain into the material around it.
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VINYL ROOF
9-7
(21)
FIG. 12 Finished Repair
After graining, the weld may not be flush with the surface, if too low, add more welding compound, cure and regrain.
(22) When the grain repair area is flush and cured, apply Chrysler Liquid Vinyl
(Fig. 11). or equivalent
BEFORE APPLYING LIQUID VINYL COATINGS BE
VERY SURE ALL RESIDUE SUCH AS DRIED
SOAPS, WAX AND ANY FORM OF FOREIGN
SUBSTANCES BE REMOVED FROM THE SURFACE
AND GRAIN OF THE VINYL MATERIAL.
SPRAYING OF COLORS
Chrysler Uticolor or its equivalent materials are not paints or dyes, but liquid vinyl. The vinyl sur- face must be properly cleaned. The first coating should be a wet one (not flooded), allowing it to dry about fifteen minutes, depending on the atmosphere. The second, a normal spray coating.
If blushing occurs, permit complete drying, then spray with a mist coat. Liquid vinyl is not a sur- face coating but is absorbed by the parent materi- al and becomes part of it. The absorption causes a wrinkling effect but when dry all wrinkles disappear. The spray color should not be cut with any form of solvent. When the procedures on vi- nyl repair are followed the finished project should be (Fig. 12).
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WOOD GRAIN
10-1
WOOD GRAIN OVERLAY
Application
Inspection
Repairs of Overlay
Page
...........................................
1 Minor scratches to clear top coat
....................................................................
Major damage to wood grain film
Major damage to clear top coat
................
3 Minor sheet metal dings in wood grain
3 applique
.....................................................................
Surface Preparation
....................
4 Temperature
Minor damage to clear top coat
....................
4 Wetting Solution
................................................
Page
.................
5
4
1
...............................................................
1
......................................................
1
SERVICE PROCEDURES
apply wetting solution to outer surface of overlay.
SURFACE PREPARATION
The body surface to which the overlay will be applied must be free of grease, oil and other for- eign material. Sand all areas to be covered with the overlay using No. 360 paper soaked in water or mineral spirits. The area to be sanded should be approximately 1/4 inch larger in all dimensions than the overlay, except when the overlay is turned at the door and other comparable areas.
All metal and/or paint nibs must be removed prior to application of overlay. Tack off all dust and dirt particles from the sanded areas.
FLAT SURFACES
Use a plastic squeegee having a cloth sleeve, or is teflon coated and pressurize all flat surfaces with firm, overlapping strokes to remove all air bubbles, water, wrinkles and to assure a good ad- hesive contact. On vertical surfaces, pressurize and level off entire top edge first with a 3 x 4 inch squeegee, then work from top to bottom.
On horizontal surfaces, start at the center and work toward the edges using a 3 x 4 inch squeegee. Do not apply pressure to edges that will be wrapped around doors, fenders, gas cap
TEMPERA TURE
The overlay is most easily handled when the air and application surface temperatures are between
70 and 90 degrees. For applications below 70 degrees, use heat lamps to warm the application surfaces. areas or to compound curve areas.
WETTING SOLUTION
Thoroughly mix two to three level teaspoons of mild powdered household detergent per gallon of clean, warm (80 to 90 degree) water in a non- rusting type container.
APPLICATION OF OVERLAY (Fig's.
7
Thru 31
It is mandatory to remove the paper backing from the overlay and not the overlay from the backing, result. as possible stretching or tearing may
Cut overlay 1/2 inch larger than area to be cov- ered and lay on a clean flat surface with the pa- per backing surface up. Hold overlay firmly and remove backing paper in a smooth 180 degree motion. Under hot, humid conditions, a slight jerking motion will aid in paper backing removal.
Thoroughly wet application surfaces of body and the adhesive surface of the overlay with the wet- ting solution and immediately apply overlay, grained side out, to the body. Adjust overlay so
1/2 inch of material shows beyond all edges and
FLANGE AREAS
(1) After being sure all metal and/or paint nibs and sanding residue have been removed, hand brush 3M Vinyl Adhesive 8064 (Quart Size Only), or equivalent, to entire flange area with a smooth, even coverage.
(2) Warm the unapplied overlay with a heat lamp.
(3) Avoid trapping air when turning the edge and wrap overlay around flange area. Press firmly into position with the fingers, making sure overlay overlaps the flange.
(4) Using a single edge razor blade, trim material extending beyond flange. off all
( 5 ) Pressurize flange area with a 2 inch rubber roller to be sure that overlay is well adhered to the painted metal surface.
CONTOURED AREAS
(1) Warm the unapplied overlay with a heat lamp, working on an area no more than 1/2 inch larger than the squeegee.
(2) Using the 3 surize and level off x 4 inch plastic squeegee, pres- the small warmed area.
(3) Repeat warming and pressurizing until entire contoured surface is completely adhered and free of air, water and wrinkles.
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10-2 WOOD GRAIN
0
SECTION F-F
SECTION E-E
L 4
SECTION D-D
4 d
SECTION A-A
U n
SECTION C-C
LL
SECTION B-B
Fig. I Wood Grain Appliccrtion Chrysler
NU632
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a
WOOD GRAIN 10-3
INSPECTION
Upon completion of an area, inspect for blisters due to trapped air or water. All blisters should be worked out with the squeegee, or punctured with a sharp needle or pin and then pressurized until the film adheres to the body surface. All edges must be adhered to the body surface.
REPAIR
OF
MAJOR DAMAGE TO VINYL
WOOD
GRAIN FILM
(1) To repair major damage, such as torn wood grain film, the entire panel must be installed.
(2) Remove the mouldings surrounding the wood grain film, (if applicable). The film is most easily handled when the temperature of the air, film, and metal surface i s between 70 degrees and
90 degrees F. Use a heat gun, heat lamp, or
SECTION A-A
/!h IPCH
SECTION C-C
E INCH
/ I
SECTION B-B
SECTION D-D
!h INCH-
/ L\
-f-
SECTION F-F
SECTION E-E
VIEW IN CIRCLE Z
CEMENT
APPLICATION
ALL FLANGES.
/
1
AREA DESIGNATED
T
OVERLAY
-k
AREA DESIGNATED
FOR SANDING
T NU284
Fig. 2 Wood Grain Application Fury
1 Ir'
SECTION F-F
SECTION A-A
1/4" MIN.
!Jd
SECTION B-B
SECTION C-C SECTION D-D
Fig. 3 Wood Grain Application Satellite
SECTION E-E
PB46
MyMopar.com
10-4 WOOD GRAIN
0 steam jet to warm film and body surfaces.
(3) Bump out sheet metal as required, utilizing approved procedures.
(4) Remove all loose pieces of wood grain film in damaged area.
(5) Sand and feather-out edges of wood grain film with No. 360 grit sandpaper.
(6) Fill imperfections with glazing putty ap- proved for service use.
(7) Remove excess putty and allow to dry.
(8) Sand the putty flush with the panel surface using No. 360 grit sandpaper.
(9) Cut off and remove portions of film that is wrapped around door edges and door openings.
(10) Sand entire panel including edges with No.
400 grit sandpaper.
(11) Wipe off surface with a clean rag dampened with a clean solvent, such as naphtha, isopropyl alcohol heptane, or equivalent.
(12) Clean with tack rags to remove all dirt and lint from sanded surfaces.
(13) Lay the film on a clean flat surface with backing up. Hold film firmly to surface and re- move backing in a smooth motion. IT I S NECES-
SARY TO REMOVE BACKING FROM FILM; NEV-
ER FILM FROM BACKING AS A POSSIBLE F I L M
STRETCHING OR BREAKING M A Y RESULT.
Fingerprints will adversely affect adhesion. To minimize this contamination, hold vinyl wood grain film in corners only.
(14) Thoroughly wet surface of body and adhe- sive surface of decorative film with a wetting solution.
The wetting solution is prepared by adding two or three level teaspoons of a mild detergent per one gallon of clean warm grees F.) water. NEVER
(80 degrees to 95 de-
USE SOAP OR HARSH
DETERGENTS.
(15) Immediately apply wetted decorative film to body. Apply wetting solution to outer surface of film to provide for easy squeegeeing.
(16) Using a squeegee, pressurize film to body with firm overlapping strokes to remove all air bubbles, water and wrinkles, and to assure good adhesive contact. Start from the center and work outward.
(17) Pressurize surface a second time and dry surface with a piece of clean cheesecloth.
(18) When wrapping film around door flanges, first raise temperature of unapplied film to ap- proximately 150 degrees F. by means of a heat source such as steam, hot air guns, or lamps.
(19) Wrap film around door hem flange area and press it firmly into position. AVOID TRAP-
PING AIR WHEN TURNING THE EDGE.
(20) Pressurize flange area with a 2-inch rubber roller to be sure film is well adhered to painted metal surface.
(21) Where film has bridged an opening, such as the gas filler tube opening, cut film diagonally so that resulting quarter sections may be pressurized to body surface.
(22) Raise temperature of unapplied film to ap- proximately 150 degrees source such as
F. by means of a heat a heat gun, lamp or steam.
(23) Fold wood grain film into opening and press firmly into position.
(24) Trim off excess material.
(25) Inspect for blisters due to trapped air or water. All blisters should be worked out with a squeegee, or punctured with a sharp needle or pin, and then pressurized until film adheres to body surface.
(26) Install mouldings.
REPAIR
OF
MAJOR DAMAGE TO THE
CLEAR TOP COAT
(1) To repair extensive surface scratches and marks in clear coating, remove mouldings sur- rounding wood grain film.
(2) Lightly sand entire panel, removing all de- fects with No. 400 grit sandpaper.
(3) Wipe off surface with a clean rag dampened with a clean solvent such as Naphtha, isopropyl alcohol, heptane or equivalent.
(4) Clean with tack rags to remove all dust and lint from sanded surfaces.
(5) Mask body to prevent overspray.
(6) Spray entire panel with Air Dry Repair
Clear Enamel Top Coat. Minimum film thickness shall be ,001 inch.
(7) Air dry at room temperature.
(8) Install mouldings.
REPAIR OF MINOR SHEET METAL DINGS
IN
THE
WOOD
GRAIN APPLIQUE
(1) Using a heat gun or lamp, raise temperature in dinged area to approximately 150 degrees F.
This should unbond wood grain film from de- pressed sheet metal. This helps to prevent film from shattering when hammered.
(2) Bump out sheet metal ding in a conventional manner.
(3) Utilizing a hypodermic needle or similar device, squirt in a repair adhesive, between wood grain and sheet metal.
(4) Utilizing a plastic squeegee, pressurize all of the repair area with firm, overlapping strokes to remove all air bubbles and wrinkles, and to assure a good adhesive bond.
REPAIR OF MINOR DAMAGE TO THE BASE
WOOD GRAIN FILM
(1) To repair small mutilations in film not larger than .04 square inches (approximately 1/8 in. x
1/4 in.) apply Air Dry Repair Touch-up Paints,
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I
0
WOOD GRAIN 10-5
using a touch-up brush only. The light colored paint should be applied first and then the dark colored paint.
(2) After all color repair is completed apply an
Air Dry Repair Clean Enamel Top Coat, using a touch-up brush. Minumum film thickness shall be
.001 inch.
(3) Air dry at room temperature.
REPAIR OF M I N O R SCRATCHES IN THE
CLEAR TOP COAT
(1)To repair light surface scratches and nicks in clear coating, lightly sand and feather-out area to be repaired with No. 400 grit sandpaper.
Caution must be taken during sanding operation.
If base printed woodgrain film is damaged dur- ing sanding, entire applique must be replaced.
(2) Wipe off surface with a clean rag dampened with a clean solvent such as Naphtha, isopropyl alcohol, heptane or equivalent.
(3) Use tack rags to remove all dirt and lint from sanded surfaces.
(4) Using a touch-up brush, apply an Air Dry
Repair Clear Enamel Top Coat, minimum film thickness shall be .001 inch.
( 5 ) Air dry at room temperature.
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SEALING 11-1
SEALING
INDEX
Page
APPLICATION
Method of Applying Sealers
.............................
BARRACUDA
Dash Panel-Cowl To Dash
..............................
Deck Lid And Front Fender
Floor Pan Area.
...........................
...................................................
Quarter Panel Area
...........................................
Quarter Panel and Sill
Roof Rail Area
.....................................
.....................................................
Dash Panel Inside Area
...................................
Pillar Area
.............................................................
Quarter Panel-Inside
.........................................
Quarter Window Area (Station Wagon)
...
Underbody Area
..................................................
Tire Well And Floor Pan (Station
Wagon)
................................................................
SATE LLl TE
Floor Pan To Dash-Rear Floor
II
......................................................
Front Fender (Station Wagon)
Front Fender (2dr. Hardtop)
......................
...........................
Inside Quarter Panel (Hardtop)
.....................
1
16
7
6
15
7
6
2
1 0
2
3
4
3
9
2
16
17
Pillar Sealing Area (Station Wagon)
Page
..........
1 4
Quarter Panel To Pillar (Hardtop)
Quarter Panel Sealing
......................................
Quarter Window (Station Wagon)
..............
8
Roof Rail Area Sealing
....................................
1 1
Rear Floor Pan (Station Wagon)
Tire Well Area
VALIANT
..................
1 1
.....................................................
12
Cowl-Dash Panel-Floor Pan
Deck Lid And Flanges
Door Frame
...............
............................
15
...........................................................
Floor Pan Area
Powder Method
....................................................
Quarter Panel-Tail Lite
GENERAL INFORMATION
Super Rubber Cement
.........................................
Windshield Rubber Seals
TESTING
......................................................................
Water Method
....................................
PURPOSE OF SEALERS
........................................
SEALERS AND COMPOUNDS
Body Seam Sealer (External)
............................
.....................................................
16
1 3
8
5
1 0
5
............................
2
Heavy Sealing Putty (Internal)
........................
...................................
........................................................
1
1
2
2
2
2
2
2
2
GENERAL INFORMA TION
The procedures for weatherstrip sealing and re- placement are incorporated with the procedures of the component unit.
The sealing illustrations used in this unit show the area sealed during manufacture of the vehicle.
These areas should be considered when testing for leaks.
For added information to sealing windnoise and air leaks, see Master Technican Service Conferance issue 70-7.
PURPOSE OF SEALERS
Sealers are used to close openings in the body metal structure to prevent water, dust, noise and fumes entering the body. In order to accomplish this purpose they must be used in the locations and manner described in (Fig. 1). Careful consid- eration has been given to all sealing problems.
The importance of sealing becomes obvious when it is realized that a vehicle in motion creates an increased pressure on body exterior and with win- dows closed establishes an interior pressure lower than atmospheric pressure. This causes air to be drawn into the body interior from all body sur- faces where openings exist.
HOLD G U N NOZZLE IN
O F
0
BY FLOW OR SPRAY
SEALER IN THIS DIRECTION
OR FLOW MATERIAL
ADJACENT T O JOINT
APPLICATION O F SEALING PUTTY
HOLD G U N NOZZLE IN DIRECTION
O F ARROW IN ORDER T O EFFECTIVELY
SEAL METAL JOINTS
D O N O T HOLD G U N NOZZLE IN DIRECTION
OF INEFFECTIVE
3 METAL THICKNESS
APPLICATION O F SEALER WHERE SEAL
2
114'
2 v
METAL THICKNESS NY1446
Fig. I Methods Of Applying Sealer
MyMopar.com
11-2 SEALING
a
TESTING
SERVICE PROCEDURES
Water Method
Normally a visual inspection of .an area will in- dicate the area for sealing. When testing with water, use a spray simulating rain or a garden hose without the nozzle and regulate the pressure to an approximate 3 inch stream. All water tests must be made starting at the bottom of the door opening or weatherstrip and slowly moving up the joint, seam or suspected area. weatherstrips, it is advisable to use trace powder and a test bulb. When the powder is sprayed at the point where a leak is suspected it will leave a trace line through the point of leakage.
In hard to reach points, such as the dog leg at the “A” post, blue carpenter’s chalk applied to the weatherstrip will transfer to the “A” post when the door is closed if a good contact exists.
SEALERS AND COMPOUNDS
fowder Method
To test the sealing between the body and the
NU366
S E ~ L E L E F
INCHES v
Fig. 2 Dash Panel Inside Area-( P-C-Y)
Super Rubber Cement
- strong bonding of rubber parts to painted or a unpainted steel surfaces is desired, attachment of weatherstrip on door and luggage compartment lid or for attachment of felt pads.
Windshield Rubber Seals
- heavy viscosity, rubber expander. Sealer can be used where rubber is confined between a glass and metal channel, such as on the windshield and rear window glass assembled in one-piece weatherstrips. Sealer will not harm paint or chrome finish and can easily be removed with a cloth before it sets.
Body Seam Sealers (For External Sealing) along welded joints, exterior roof rails, exterior
- belt lines, €3-post welds, weatherstrips and floor seams. Upon drying, the sealer forms a tough skin which can be painted with a touch-up brush.
Heavy Sealing Puffy (For Interior Sealing)
- heavy, fibrous, putty-like compound, which can be formed or rolled into pellets or long string shapes.
E SEALER PER SIDE
VIEW IN D I R E ~ I O N
OF ARROW 0 p ~ 1 5 5
Fig. 4 Front Fender (Satellite Station Wagon)
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Fig. 5 Quarter Window Area (Station Wagon) (P-C)
%
SI -4
TIRE WELL
Fig. 6 Tire Well And Floor Pan (Station Wagon P-C)
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11-4 SEALING
0
Fig. 7 Underbody Area (P-C-Y)
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SEALING 11-5
VIEW IN CIRCLE R
INSIDE FRONT DOOR PANEL
BEAD SEALER
VIEW IN DIRECTION OF ARROW V
Fig. 8 Door Frame
-
Valiant
BEAD SEALER vPY343
QUARTER PANEL
BALL SEALER
DECK OPENING
Fig. 9 Quarter Panel And Tail Lite Areas
-
Valiant
SIDE QUARTER PANEL py344
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11-6 SEALING
OUTER WINDSHIELD
SIDE FRAME
WINDSHIE~D OUTER
FRAME SIDE
VIEW IN DIRECTION OF ARROW X
(CONVERTIBLE)
R O O F SIDE
DRAIN TROUGH
VIEW IN CIRCLE W
VIEW IN DIRECTION
OF ARROW Z UPPER PILLAR
VIEW IN DIRECTION OF ARROW T FRONT LOWER PILLAR
Fia. 10 Roof Rail Area
-
Barracuda
VIEW IN DIRECTION
OF ARROW Y PY328
0
V l t W
/-
IN
Fig. 11 Floor Pan Area
-
Barracuda
CENTER FLOOR PAN
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0
BALL SEALER OKE SIDE
BEAD SEALER
FRONT FENDERSHIELD
W
VIEW IN DIRECTION OF ARROW B
FRONT FENDER AREA
SEALING 11-7
DECK LID-OUTSIDE
DECK LID-INSIDE
Fig.
DECK LID AREA
12 Deck Lid And Front Fender
VIEW IN DIRECTION
-
Barracuda
OF ARROW A PY326
SIDE SILL OUTER BEAD SEALER
VIEW IN CIRCLE Z
Fig. 73 Quarter Panel And Sill
-
Barracuda
PILLAR TO SILL
PY3n
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11-8 SEALING
a
Fig. 14 Quarter Window (Station Wagon) (Satellite)
BEAD SEALER
OUTSIDE DEC
2 DOOR COUPE
BEAD
A
BEAD
BALL SEALER
D K K LID
FILLER
VIEW IN DIRECTION OF ARROW Z
DECK LID FLANGES
QUARTER PANEL
VIEW IN DIRECTION OF CIRCLE A
Fig.
OUTSIDE REAR WINDOW AREA
15 Deck Lid And Flanges
-
Valiant
UPPER DECK OPENING p y w
MyMopar.com
0
SEALING 11-9
>?&m
VIEW I N DIRECTION
OF ARROW Y
I
1/4" DIA. BEAD
SEALER
N
>OR
.
PANEL
JON
QUARTER PANEL
EXTENSION
3F ARROW \
C
3 1 8 DIA. 'BEAD SEALER
3/8" DI'A. BEAD
SEALER
QUARTER PANEL
FXTENSION
VIEW I N DIRECTION
OF ARROW W
Fig. 16 Floor Pan To Dash-Rear Floor Pan-Cowl And Sill Area (Satellite)
PB149
MyMopar.com
11-10 SEALING
VIEW IN DIRECTION OF
ARROW B
FRONT FLOOR PAN
VIEW IN DIRECTION OF
ARROW A VIEW IN DIRECTION
OF ARROW Y
0
QUARTER PANEL
EXTENSION
FLOOR PAN
Fig. 17 Floor Pan Area
-
Valiant
NU128
Fig. 18 Pillar Area (P-C-Y)
MyMopar.com
0
TROUGH-ROOF SIDE DRAIN FRONT
I
IC U U l C K I
SEALING 11-1 1
ROOF
1/2" DIA. BALL
\ROOF RAIL
SIDE SUPPORT
7 \ 1 / 8 " SEALER
BODY LOCK PILLAR
1 / 8 DIA. BEAD
SEALER
VIEW IN DIRECTION
OF CIRCLE Y
112" DIA. BALL SEALER
3/16" DIA. BEAD
VIEW IN DIRECTION
OF ARROW K
BODY FRONT PILLAR-LOWER
3 / 8 ' DIA. BEAD
WHEELHOUSE
VIEW IN DIRECTION
OF CIRCLE Z
FRONT PILLAR
Fig. 19 Roof Rail Area Sealing (Saielliie)
3/4" DIA. BALL REAR FLOOR
3/16" DiA. BEAD
SEALER
PBlsO
REAR FLOOR
PAN SILL
QUARTER
TAILGATE PILLAR
REAR FLOOR PAN
Fig. 20 Rear Floor Pan (Siaiion Wagon) (Saiellite)
PANEL
LEFT
VIEW IN DIRECTION
OF ARROW Z
PB156
MyMopar.com
G
11-12 SEALING
OUTSIDE
.
QUARTER rnriu
3
3/4" DIA. BALL SEALER
LOWER SPARE
TIRE HOUSING
1" DIA. B A t SEALER
SPARE TIRE HOUSING
0
I
WHEELHOUSE
ASSEMBLY
VIEW I N DIRECTION
OF ARROW Z
Fig. 21 fire Well Area (Satellite)
PB158
SILL TO PANEL 'INNER SIDE SILL PB152
Fig. 22 Inside Quarter Panel (Hadtop) (Satellite)
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0
SEALING 11-15
FRONT
SIDE
INSIDE QUARTER
BEAD SEALER
NTER FLOOR PAN
Fig, 25 Quarter Panel Area
-
Barracuda
COWL SIDE PANEL
COW1 TOP
INSIDE-QUARTER PANEL
(HARDTOP -COUPE)
PY331
Fig. 26 Cowl-Dash Panel-Floor Pan Area
-
Valiant
MyMopar.com
1 1-1
6
SEALING
COWL
SIDE
U PANEL
PY329 a
%
OPENING
FLANGE HOOD
CENTER
MEMBER
YOKE
I
UPPER GRILLE
314" DIA. BALL
SEALER
Flg. 28 Front Fender (Satellite 2dr. Hardtop)
SIDE SILL OUTER
Fig. 29 Quarter Panel To Pillar (Hadtop) (Satellite)
0
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over MoPrep dust.
(1 6) Apply Chrysler Engineer Approved MOPAR
Acrylic Lacquer Colors. (Four to six double coats)
Refinishing in field must be done with acrylic lacquer. Acrylic lacquer can be polished to match original finish gloss. Care must be exercised when selecting paint for refinishing Acrylic Metallics, to select the proper paint code.
(17) When colors have dried hard, compound and polish.
Application o f Color Coats
Metallic color can appear to vary in richness.
Variation can be described as:
A closed pattern that appears lighter with fine metallic dispersion.
An open pattern that appears richer with metal- lic flakes less noticeable.
A closed pattern is best matched by reducing
MOPAR Acrylic Lacquer Color 150% with MO-
PAR Deluxe Acrylic Lacquer Thinner equivalent.
G35, or
An open pattern is achieved by lowering air pressure to 20-30 lbs. at gun, reducing MOPAR
Acrylic Lacquer Color 100% with a blend of
MOPAR Deluxe Acrylic Lacquer Thinner G35 and MOPAR all Purpose Retarder equivalent.
G36, or
SPOT REPAIRS
The procedures for making spot repairs with acrylic lacquer are the same as for complete panel refinishing with the following exceptions:
Sealer Coats
The use of a sealer is not practical where a spot repair is demanded, as it is difficult to spray seal- er without leaving an edge. If care is taken in preparation of surface, a satisfactory repair is pos- sible by sanding the original finish about 2 or 3 inches beyond area where acrylic lacquer will be applied. Apply lacquer directly on sanded original finish, being careful not to overlap color on un- sanded enamel.
Compounding Color Coats
Compound sanded area that extends around re- finish lacquer and then compound lacquer, blend- ing it into enamel. Hard surface of acrylic ena- me1 will permit compounding without leaving scratches.
PAINT BAKE OVEN TREATMENT (WITH
TEXTURED GRILLES)
To avoid warpage, all models with textured grilles and headlamp bezels should be covered with paper or other material to shield grille as- sembly from heat before car enters paint bake ovens, or be completely removed from cars.
PAINT CHARTS
EXTERIOR COLORS
USED ON:
PA1 NT
CODE
A4
A8
A9
B2
B5
B 7
B9 c7
C8
E5
V= Valiant
B= Barracuda
COLOR NAME
Winchester Gray Poly
Slate Gray Poly
Charcoal Poly
Glacial Blue Poly
True Blue Poly
Evening Blue Poly
Midnight Blue Poly
I n-Violet Poly
Mood Indigo Poly
Rallye Red
R= Satellite
P= Fury
CHRYSLER
CODE
NUMBER
AY2GA4
AY2GA8
AY2EA9
AY2GB2
AY2GB5
AY2GB7
AY2GB9
AY2FC7
AY2GC8
AY 1 FE5
C= Chrysler
Y= Imperial
DI TZLER
CODE
2314
2315
* 2017
2304
23 06
2302
2303
* 2210
2305
2136
REMARKS
MyMopar.com
12-4 REFINISHING
E7
F3
F7
F9
J4
J6
K6
L1
L5
L6
M8
Q5
T 2
T8 v 2 w 1 w 3 x 9
Y1
Y3
Y 4
Y5
Y8
Y9
Burnished Red Poly
Amber Sherwood Poly
Sherwood Green Poly
Avocado Poly
April Green Poly
Sassy-Grass Green
Autumn Bronze Poly
Sandalwood Beige
Bahama Yellow
Azyec Gold Poly
Sparkling Burgundy Poly
Coral Turquoise Poly
Tunisian Tan Poly
Tahitian Walnut Poly
Tor-Red
Spinnaker White
Sno-W hite
Formal Black
Lemon Twist
Curious Yellow
Light Gold
Crystal Dawn
Gold Leaf Poly
Tawny Gold Poly
AY2GE7
AY2GF3
AY2GF7
AY2GF9
AY 2GJ4
AY 1
AY2GK6
A Y l B L 1
A Y l E L 5
AY64FL6
AY2GM8
AY2FQ5
AY2GT2
AY 2GT8
AY2EV2
A Y l E W l
AYlGW3
AY 1TX9
A Y l F Y l
AYlGY3
AYlGY4
AY2GY5
AY2GY8
AY2GY9
2321
2316
2317
2318
2319
* 2259
2312
* 22542
2325
* 2261
2322
2301
2313
2309
21 86
* 2033
2300
* 9300
* 2211
2320
2310
2308
2307
231 1
* Carryover Colors
EXTERIOR STRIPING COLORS
(or equivalent)
-
CHRYSLER-IMPERIAL
CHRYSLER
CODE
DITZLER
CODE COLOR NAME
White
Black
Light Brite Blue
Light Brite Green
Brite Red
Light Gold
ASlEWl
TASl X9
ASlGB4
ASlGG5
BAS1 R5
ASlGY4
(or equivalent)
EXTERIOR STRIPING COLORS
-
PLYMOUTH
2033
9000
14016
44229
7 1 498
8 1 806
COLOR NAME
White
Black
Medium Dark Blue
Medium Dark Gold
Medium Dark Green
Light Gold
CHRYSLER
CODE
ASlEW1
TAS 1 X9
ASlGB7
ASlGY9
ASlGG8
ASlGY4
(or equivalent)
DITZLER
CODE
2033
9000
14013
23362
44216
81 806 a
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a
REFINISHING 12-5
CORPORATE IDENTITY COLORS
Corporate White
Corporate Blue
Single Tone
Two-Tone x 9 - x 9 x9-w 1
The first two digits are accent or roof color.
Second two digits are basic body color.
For special colors (coded 999) furnish Special Order (SO) number and selling dealer with Serial number of car.
Argent Silver DX-8555
Medium Textured Argent Silver DNA-8575
Painted Grilles are painted in Exterior Colors.
INTERIOR LOW GLOSS FINISH COLORS
-
IMPERIAL
8367
12785
COLOR NAME
Rear View Mirron Arm
Backlite Inner Garnish Moulding
Rear Window Defogger Bezol
"C" Pillar Trim Surface and Upper Inner Garnish Moulding
Instrument Panel and Ash Receiver
Radio Speaker Grill and Stereo Grill
Gear Selector and Steering Column
Windshield Garnish Moulding
Roof Rails
Seat Side Shield
Backlite Moulding Cap
CHRYSLER
CODE NO.
DI TZLE R
White
Black
Medium Blue Poly
Dark Blue Poly
Light Blue Poly
Medium Gold Poly
Medium Dark Saddle
Light Gold Poly
Light Tan
Medium Blue Gray Poly
Dark Green Poly
Burgundy
Medium Russet
AB61 EW 1
AB61 DX9
AB62GB 7
AB62GB9
AB62GB2
AB62GY6
AB61GT6
AB62GY 5
AB62GT1
AB62GA6
AB62G F 7
AB61 GM9
AB61GE9
8849
9388
14090
14098
14120
23426
23428
23468
23490
32877
44290
50860
60613
(or equivalent)
REMARKS
MyMopar.com
12-6 REFINISHING
INTERIOR LOW GLOSS FINISH COLORS
-
CHRYSLER
USED ON: Tailgate Frame 3rd. Seat Well (Exterior Paint All Codes)
Rear View Mirror Arm
Backlite Inner Garnish Moulding
Rear Window Defogger Bezel
"C" Pillar Trim Surface and Upper Inner Garnish Moulding
Instrument Panel and Ash Receiver
Radio Speaker Grille and Stereo Speaker Grille
Automatic Gear Selector Quadrant Steering Column
Windshield Garnish Moulding
Upper and Lower Backlite Moulding
Backlite Moulding Caps
The following are Suburban parts: Rear Deck and Seat Panel
Assembly Floor, Wheelhouse and Tire Cover Moulding, Grille
Assembly Wheelhouse Cover, Quarter Window and Upper Tailgate
Moulding, Head Lining Retainer Moulding, Accessory Unit
Cargo Area.
COLOR NAME
White
Black
Medium Blue Poly
Light Blue Poly
Medium God Poly
Beige
Medium Dark Saddle
Light Gold Poly
Medium Blue Gray Poly
Dark Green Poly
Medium Russet
CHRYSLER
CODE NO.
AB61 EW 1
AB61 DX9
AB62GB7
AB62GB2
AB62GY6
AB61EL1
AB61 GT6
AB62GY5
AB62GA6
DITZLER
CODE-DIA
8849
9388
14090
14120
23426
23427
23428
23468
32877
REMARKS
0
EXTERIOR GLOSS FINISH COLORS
-
CHRYSLER
Used On: Tailgate Frame 3rd. Seat well (Exterior Paint all Codes)
COLOR NAME
Black
Medium Blue Poly
Medium Tan Poly
Medium Gold
Medium Dark Green Poly
CHRYSLER
CODE NO.
AB 1TX9
AB2GB7
AB2GT8
ABlGY4
AB2G F7
DI TZLE R
CODE-DIA
9000
2302
2309
2310
2317
(or equivalent)
REMARKS
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0
SEMI-GLOSS FINISH COLORS
-
CHRYSLER
Used On: Accessorv Unit Retainers
Ivory AB3VW2 8355
LOW GLOSS FINISH COLORS
-
CHRYSLER
REFINISHING 12-7
COLOR NAME
White
Black
Medium Blue Poly
Light Blue Poly
Medium Gold Poly
Medium Dark Saddle
Light Gold Poly
Medium Blue Gray Poly
Dark Green Poly
Medium Russet
Instrument Panel and Ash Receiver
Glove Box Door and Radio Speaker Grille
Automatic Gear Selector Quadrant and Steering Column Collar
Stereo Speaker Grille
Steering Column
Windshield Garnish Moulding (coach)
Roof R a i Is (Coachman)
"C" Pillar Upper
Backlite Upper and Lower Moulding
Windshield Upper Header Garnish
Backlite Cap
Rear Shelf Defogger Bezel
"C" Pillar Moulding
Rear Deck and Seat Panel Assembly (Floor)
Wheelhouse and Tire Cover Mouldings Grille Assembly
Wheelhouse Cover
Quarter Windows and Upper Tailgate Mouldings
Headlining Moulding Retainer
Rear Shelf Fasteners, Luggage Compartment all Codes
Convertible Top Folding Assembly, all Codes
CHRYSLER
CODE NO.
AB61 EW 1
AB61 DX9
AB62GB7
AB62GB2
AB62GY6
AB61GT6
AB62GY5
AB62GA6
AB62GF7
AB61GE9
DITZLER
COD E-DI A
8849
9288
14090
14120
23426
23428
23468
32877
44290
606 13
(or equivalent)
REMARKS
MyMopar.com
12-8 REFINISHING
EXTERIOR GLOSS FINISH COLORS
-
FURY
Used On: Tailgate Frame 3rd. Seat Well (Exterior Paint all Codes)
COLOR NAME
Black
Medium Blue Poly
Medium Tan Poly
Medium Gold
Medium Dark Green Poly
CHRYSLER
CODE NO.
AB 1TX9
AB2GB7
AB2GT8
ABlGY4
AB2GF7
DI TZLE R
CODE-DIA
9000
2302
2309
2310
2317
(or equivalent)
SEMI-GLOSS FINISH COLOR
-
FURY
Used On:
Ivory AB3VW2 8355
LOW GLOSS FINISH COLORS
-
FURY
Used On: (a) Instrument Panel and Ash Receiver
(b) Glove Box Door and Radio Speaker Grille
(c) Automatic Gear Selector Quadrant and Steering Column Collar
(d) Stereo Speaker Grille
(e) Steering Column
( f ) Windshield Garnish Moulding (coach)
(9) Roof Rails (Coachman)
(h) "C" Pillar Upper
(i) Windshield Upper Header Garnish
(j) Windshield Upper Header Garnish
(k) Backlite Cap
( I ) Rear Shelf Defogger Bezel
(m) "C" Pillar Moulding
(n) Rear Deck and Seat Panel Assembly (Floor)
( 0 ) Wheelhouse and Tire Cover Mouldings Grille Assembly
Wheelhouse Cover
(p) Quarter Windows and Upper Tailgate Mouldings
(4) Headlining Moulding Retainer
(r) Rear Shelf Fasteners, Luggage Compartment all Codes
Convertible Top Folding Assembly, all Codes
COLOR NAME
White
Black
Medium Blue Poly
Light Blue Poly
Medium Gold Poly
Medium Dark Saddle
CHRYSLER
CODE NO.
AB61 EW 1
AB61 DX9
AB62GB7
AB62GB2
AB62GY6
AB61 GT6
DIT2 L E R
CODE-DIA
8849
9388
14090
14120
23426
23428
REMARKS
REMARKS
MyMopar.com
a
Light Gold Poly
Medium Blue Gray Poly
Dark Green Poly
Medium Russet
AB62GY 5
AB62GA6
AB62G F7
AB61GE9
(or equivalent)
EXTERIOR GLOSS FINISH COLORS
-
SATELLITE
REFINISHING 12-9
Used On: Inner Tailgate Integral and Sill (Exterior Paint)
"B" Pillar Cover.
COLOR NAME
CHRYSLER
CODE NO.
DI TZLE R
CODE-D
I
A
Black
Medium Blue Poly
Medium Tan Poly
Medium Gold
Medium Dark Green Poly
ABlTX9
AB2GB7
AB2GT8
ABlGY4
AB2G F7
9000
2302
2309
2310
2317
(or equivalent)
LOW GLOSS FINISH COLORS
-
SATELLITE
Instrument Panel End Cap Glove Box
Instrument Panel Defroster Outlets
Lower Rear Window Garnish Moulding
Windshield Upper Inner Garnish Moulding
"C" Pillar Garnish Moulding
Rear Shelf Bezel Degoffer Outlet
Roof Rail Garnish Moulding
"C" Pillar Lower Coachman
Steering Column and Gear Selector Housing
Hinge Arm Split Back Cover Front Seat Back
Bucket Seat Outer and Inner Hinge Covers
Rear Window Side Upper Corners Garnish Mouldings
Steering Column
Spacer Can and Cover
Upper Tailaate Garnish Moulding Coachman
Quarter Window Belt Moulding
Quarter Window Roof R a i l Moulding
Floor Pans Panels Hinaes Fillers and Moulding Assembly
"C" Pillar Moulding
Roof Rail and Rear Door Headliner Retainer
"D" Rillar Speaker Grille
COLOR NAME
White
Black
Medium Blue Poly
Brite Blue Poly
Medium Gold Poly
CHRYSLER
CODE NO.
AB61EW1
AB61DX9
AB62G B 7
AB62GB5
AB62GY6
DITZLER
COD E-D
I
A
8849
9388
14090
14096
23426
REMARKS
REMARKS
MyMopar.com
12-10 REFINISHING
Medium Dark Saddle
Light Gold
Medium Blue Gray Poly
Dark Green Poly
AB61GT6
AB61GY4
AB62GA6
AB62GF7
LOW GLOSS FINISH COLORS
-
BARRACUDA
COLOR NAME
White
Black
Medium Blue Poly
Brite Blue Poly
Medium Gold Poly
Medium Dark Saddle
Light Gold
Dark Green Poly
Instrument Panel
Glove Box Door Inner and Outer Check Arm
Ash Receiver Face and Handle
Stereo Speaker Grilles
Steering Column
Housing Assembly
Collapsible Can
"A" Pillar Cap and Outboard Moulding Header
Inner Windshield Moulding
Upper Windshield Header Moulding
Backlite
Roof Rail
Forward Edge "C" Pillar Garnish
Bench and Bucket Outer Hinge Cover
Bucket Only Inner Hinge Cover
Rear Shelf Defogger
CHRYSLER
CODE NO.
AB61 EW1
AB61 DX9
DITZLER
CODE-DI A REMARKS
0
EXTERIOR GLOSS FINISH COLORS
-
VALIANT
Upper and Lower Integral Door Garnish
Upper and Lower Integral Quarter Panel Garnish
Integral "B" Pillars
Upper Lock Pillar
Quarter Garnish Extension
"C" Pillar Cover
Door and Quarter Tirm Retainer
"B" Pillar Cap
Roof Rail
Backlite and Center Joint Cap
Upper Quarter Panel Moulding
MyMopar.com
a
CHRYSLER
CODE NO.
DI TZLE R
COD E -D I A
COLOR NAME
Black
Medium Blue Poly
Medium Tan Poly
Medium Gold
Medium Dark Green Poly
A B l T X 9
AB2GB7
AB2GT8
ABlGY4
AB2GF7
LOW GLOSS FINISH COLORS
(or equivalent) -
VALIANT
REFINISHING 12-1 1
REMARKS
Used On: (a)
(b)
( C)
(d)
(e)
(f)
(9)
(h)
Instrument Panel
Glove Box Door and Outer Inner Check Arm
Ash Receiver Face and Lighter Plug Cover
Steering Column
Automatic Gear Selector Quadrant
Bucket Seat Outer and Inner Hinge Covers
Rear Shelf Defogger. Bezel
Rear Shelf Fasteners
COLOR NAME
White
Black
Medium Blue Poly
Medium Gold Poly
Medium Dark Saddle
Light Gold
Dark Green Poly
CHRYSLER
CODE NO.
AB61 EW1
AB61 DX9
AB62GB7
AB62GB7
AB61GT6
AB61GY4
AB62GF7
DITZLER
CODE-DIA
8849
(or equivalent) f
REMARKS
MyMopar.com
0
BODY AND FRAME ALIGNMENT 13-1
BODY A N D FRAME ALIGNMENT
INDEX
Body to Frame Alignment
....................................
Body Alignment Dimensions
Page
1 Frame Dimensions
...............................
2 Replacement
Page
................................................
1
............................................................
2
SERVICE PROCEDURES
FRAME D I M E N S I O N S
The various frame dimensions (Figs. 1,
2
and
3)
may be used as a guide in measuring frame alignment. Diagonal measurements should be taken
BODY TO
FRAME ALIGNMENT
The body to frame alignment measurement when straightening frame. should be performed whenever the stub frame has
Minor frame alignment can usually be corrected been removed, replaced or repaired. by straightening bent frame parts. A badly distort- Use shims from original frame, when replacing ed frame can in most cases be replaced more eco- frame, as a guide in accomplishing body to frame nomically than by attempting repairs. alignment.
Fig. I
-
Frame Dimensions (Fury 6 Cylinder) Fig. 2
-
Frame Dimensions
MyMopar.com
13-2 BODY AND FRAME ALIGNMENT
0
Follow equipment manufacturers recommenda- tions and procedures.
BODY ALIGNMENT DIMENSIONS
Body alignment may be accurately measured by the following method. Elevate vehicle to a level position over a clean and smooth floor.
Refer to (Figs. 4 through 9) and place the line of a plumb-bob on point “A” with the plumb-bob just contacting the floor. Mark the plumb-bob contact point of floor. Repeat process at points B,
C, D, E and F on both sides of body. Snap a chalk line between points as illustrated. Care should be taken that all diagonals compared
I
L l r u represent the corresponding measuring points.
Compare the dimensions with the specifications.
All matching point to point dimensions should agree within 1/4 inch.
In making any body opening measurements, ways compare the matching measurements al- of both sides of the vehicle. All dimensions must be meas- ured at the welded joints of the body to insure
-73*3aw
Fig. 3
-
Frame Dimensions (Imperial)
Align front suspension and aim headlights after
FRAME REPLACEMENT (FIG.
10)
The forestructure isolated (stub-frame), engine, body to frdme alignment has been completed. For transmission, steering and suspension can be re- body to frame alignment dimensions refer to moved as an assembly for further disassembly out
“Body Alignment Dimensions” (Figs. 4 through 9). of the vehicle.
I
A
\
”K” MEMBER ATTACHING BOLT
BOTTOM VIEW
1 “
F
I-,
44.85
I _ t pypopA
Fig. 4
SIDE VIEW
-
Body Alignment Dimensions (Valiant)
MyMopar.com
0
BODY AND FRAME ALIGNMENT 13-3
Remove hood and bumper, then remove fenders, wheel house panels, grille and radiator as an assembly, support vehicle at sill area and remove frame assembly.
(1) Remove battery and air cleaner, drain cool- ing system, remove radiator and shroud, discon- nect heater hoses from engine, and disconnect bat- tery tray from frame.
(2)
Discharge air-conditioning system, (refer to
“Group 24 Air-conditioning” in the Chassis Serv- ice Manual for discharging and charging the system), disconnect air-conditioning lines at firewall, discharge line at muffler and suction line at evaporator. Seal open ends of air-conditioning fittings and connectors.
( 3 ) Disconnect throttle and speed control cables at carburetor, vacuum hose controlling accessories at engine manifold, remove or disconnect electrical wiring including engine to cowl ground strap.
(4) Remove roll pin from steering gear coupling, disconnect shift linkage, steering column floor pan and steering column from support bracket and move column up approximately 3 inches.
( 5 ) Raise vehicle on twin post hoist, remove drive shaft, exhaust pipes, shift rod or clutch link- age at torque shaft, rear seat heater or air-condi- tioning clamps at side rail, wheel house bolts at frame side rails, radiator support brace, bumper assembly and hood lock vertical lower support.
(6) Disconnect speedometer cable, electrical leads at starter, gas line at frame connection and plug line, emergency brake cable at rear cable attaching bracket and remove from rear frame crossmember.
(7) Support vehicle securely on stable floor stands (4,000 lbs. capacity) at rear of rear spring shackle boxes. At the front of vehicle place stands under body at rear of stub-frame at the side sill area, place a 4 x 4 inch x 7 foot wood beam across stands for extra strength and 2 x 4 x 6 inch pieces of wood on top of main support beam and to lower flat surface of the side sills. Then lower rear axle to lowest position to assist in bal- ancing body weight when frame assembly is removed.
(8) Position a hydraulic transmission jack under the frame rear crossmember.
It is recommended that the following service procedure be used when removing isolated stub frames. After the above steps 1 through 8 have been performed.
The body isolators (Fig. 10) which are located at three positions: the radiator yoke, the dash foot, and the frame rear, will transfer normal loads to the body. IF, HOWEVER, AN IMPROPER TIGHT-
ENING OR LOOSENING SEQUENCE OF THE ISO-
LATOR SYSTEM OCCURS, EXCESSIVE LOADS
A
I
I
Fig. 5
-
SIDE VIEW
/ I I I
POINT D OR E
I
Body Alignment Dimensions (Barracuda)
F
SECTION H-H
VERTICAL
“0” LINE
PY913A
MyMopar.com
13-4 BODY AND FRAME ALIGNMENT
0
MAY BE TRANSFERRED TO THE FRONT END
SHEET METAL. THIS CAN RESULT IN BUCKLING
OF THE FRONT FENDERS.
The front end sheet metal alone should never support the stub frame as this will cause the fend- ers to buckle. The front end sheet metal is atta- ched to the stub frame through the radiator yoke, isolators and through bumper-to-sheet metal attachment. Removal of the stub frame may be started by removing the bottom nuts at the radia- tor yoke locations. This must be done before the bolts are removed from the dash foot, or the frame rear locations. Total separation of the frame and body may be completed by lowering the frame after all three locations are disconnected.
(9) Remove the frame assembly from the vehicle by lowering the front post and transmission jack slowly at the same speed.
(10) If a twin post hoist is not available the ve- hicle can be supported on short stands about 36 inches high and using the same wood blocking with the use of floor jacks to support the trans- mission and suspension the stub-frame assembly removal can be accomplished.
(11) If frame is to be replaced transfer servicea- ble parts to new frame. fnsf ollatbn
When a frame is being reinstalled on a body, spacers should be used on each side. Tightening of the isolators must always follow this order: dash foot, (2)
(1) the the frame rear are fully tightened prior to installing the bottom cup washer and nut at the radiator yoke.
(1) With frame assembly raised into position guide frame rear crossmember into channel and studs and the front top edge of frame into slots in lower flange of the radiator support.
(2) Install body to frame bolts, nuts, washers and/or insulators.
(3) On Station Wagon and Convertible models torque to 75 foot-pounds.
On Sedan-Hard Top models tighten to specified torque in (Fig. 10).
(4) Install nuts and washers on studs at radiator support lower flanges.
( 5 ) Remove transmission jack and body support stands.
(6) Connect emergency brake cable, starter leads, gas line and speedometer cable.
(7) Install drive shaft, exhaust pipes, shift rod or clutch linkage at torque shaft, rear seat heater or air-conditioning piping clamps at side rails, wheel house and battery tray bolts at frame, radiator support brace, hood lock vertical lower support and- bumper assembly.
(8) Lower vehicle, install and adjust steering h . . I .
Fig. 6
-
Body Alignment Dimensions (Satellite)
PY9 '1 OA
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0 column, accelerator and speed control cables.
(9) Install radiator and shroud, connect coolant lines, radiator and heater hoses, electrical wiring, vacuum and air conditioning lines.
(10) Install battery and air cleaner, fill cooling system and charge air-conditioning system.
Individual Insolafor Changes (Fig. 10)
If a single isolator change is made using a twin post suspension hoist, the following steps are to be followed:
(1) All front end sheet metal pencil struts (front structure reinforcement), and the wheel house in- ner panels must be installed and the bolts tight.
(2) Remove bumper to hood latch support bracket.
(3) Remove bumper rod assembly.
(4) Remove bumper rubber pad.
( 5 ) The lower nut at the radiator yoke position, should be removed on both sides.
(6) Do not loosen bolts at the dash foot position and at the frame rear position at this time.
(7) By supporting the body adequately on the sills but not on any portion at the front end sheet metal, and lowering the hoist slightly, suffi- cient body to frame separation can be obtained by
BODY AND FRAME ALIGNMENT 13-5
loosening the bolts at the dash foot position and frame rear position to change body isolator at any location.
If a single isolator change is made using a frame contact hoist the steps 1 through 5 are to be followed then procede as follows:
(8) All mounts on the side of the car where the mount is being changed should be loose. At the frame rear, the isolators will still carry a load even though the nut is loosened. (Do not remove nut unless that mount is being changed). At the radiator yoke, both sides right and left are to be loose at all times during the change.
(9) The dash foot position, isolators should never all be loose at the same time. Both isolators on one side, either right or left, may be loosened or changed at one time but the other side is to be tight while this is being done.
(10) Jacking or prying or any other technique used to separate the body and frame at any time be especially on a frame contact hoist (so that isolators can be changed) must be performed with extreme care since this is the way load can be transferred to the front end sheet metal, the radia- tor yoke studs should be loose at all times. h k 2 1 . 3 5 4
53.33
52.41 STATION WAGON
I _ 57.98
4 -
'
60.90 STATION WAGON
5.22 STATION WAGON
Fig. 7
-
Body Alignment Dimensions (Fury)
ATION
WAGON
NK1166B
MyMopar.com
13-6 BODY AND FRAME ALIGNMENT
21.3
~
54.34
52.41 STATION WAGON
4
60.90
~
-
4
_ _
5.22 STATION WAGON
Fig. 8
-
Body Alignment Dimensions (Chrysler) t
1.02 STATION
WAGON
NK1168B
0 h
--
-Y
7/32 .225 4.72
Fig. 9
-
Body Alignment Dimensions (Imperial)
1
.oo
NP665
MyMopar.com
0
UPPORT YOKE
ISOLATOR-INSERT
BODY AND FRAME ALIGNMENT 13-7
CROSS MEMB
Fig. 10
-
Isolated Stub Frome
SCREW
@
P Y W A
IMPERIAL RUBBER ISOLATED FRONT CROSSMEMBER
Removal
Should it become necessary to remove the rubber isolated
Suspension, Group 2 in the Chassis Service
Manual.)
(8) Remove ball joint studs from steering
“K” frame (Fig. 11) from the Imperial, knuckles. (See Front Suspension, Group 2 in proceed as follows: Chassis Service Manual.)
(1) Raise vehicle on hoist and support stub (9) Remove wheel house splash shields. frame on jackstands. (10) Remove upper shock absorber attaching
(2) Raise and support engine assembly, using en- nuts, then slide shock absorbers and dust shields gine support Fixture C-3487. Disconnect engine out of well in frame. front motor mounts from
“K”
frame assembly. (11) Remove upper control arm and bracket as-
(3) Remove steering gear assembly, as described semblies from “K” frame. (See Front Suspension, in Group 19, Steering, of Chassis Service Manual. Group 2 in the Chassis Service Manual.)
(4) Remove front wheels and tires. (12) Remove lower control arm and pivot shaft
( 5 ) Remove steering linkage tie rods and idler assemblies. (See Front Suspension, Group 2 in arm. (See Front Suspension, Group 2) in Chassis Chassis Service Manual.)
Service Manual. Remove lower bolts from shock absorbers.
(13) calipers.
Disconnect brake hose at disc brake
(6) Remove lower control arm struts and sway bar assembly. (See Front Suspension, Group 2 in
Chassis Service Manual.
(14) Remove ground strap, connecting insulated
“K’ frame to stub frame.
(15) Remove “K’ frame bracket and insulator
(7) Remove tension on torsion bars by turning assemblies and lower “K” frame to shop floor, adjusting bolts counterclockwise. Remove snap using transmission jack. rings and slide torsion bars toward the rear, far enough to clear lower control arms. Be careful /nstu/lut;on not to damage balloon type seals. (See Front When installing isolated
“K”
frame, the follow-
MyMopar.com
13-8 BODY AND FRAME ALIGNMENT
e ing information is very important: All front sus- pension points that contain rubber, should be tightened only while the suspension of the vehi- cle is at the specified height (see
Specifications-Front Suspension Group 2 in the
Chassis Service Manual) with full weight of ve- hicle on its wheels.
(1) Center “K” frame in position under vehicle and raise into position with transmission jack. In- stall attaching bolts and tighten securely.
(2) Install ground strap and secure with attach- ing bolts.
(3) Reconnect brake hose at disc brake calipers.
(4) Install lower control arm and pivot shaft as- semblies (See Front Suspension, Group
Chassis Service Manual.)
2 in the
( 5 ) Install upper control arm and bracket assemblies. (See Front Suspension, Group 2 in
Chassis Service Manual.)
(6) Install shock absorbers and dust shields by sliding up into well. Install retaining insulators, covers and nuts. Tighten securely.
(7) Install wheel house splash shields.
(8) Install ball joint studs in steering knuckles.
(See Front Suspension, Group 2 in Chassis Service
Manual.)
(9) Slide torsion bars forward, engaging lower control arms. Install retaining snap rings. Be care- ful not to damage balloon type seals. Increase ten- sion on bars by turning adjusting bolts clockwise.
BRACKET AND SLEEVE ASSEMBLY
\
(See Front Suspension, Group 2 in the Chassis
Service Manual.)
(10) Install lower control arm struts and sway bar assembly. (See Front Suspension, Group 2 in the Chassis Service Manual.)
(11) Install idler arm and steering linkage tie rods. (See Front Suspension, Group 2 in the
Chassis Service Manual.) Install lower attaching bolts on shock absorbers.
(12) Install front wheels and tires. Adjust front wheel bearings as described in Group 22, Wheels
Bearings and Tires found in Chassis Service
Manual.
(13) Install steering gear assembly as described in Steering, Group 19 in the Chassis Service
Manual.
(14) Lower engine assembly and install front mo- tor mounts to “K” frame. Tighten attaching bolts securely. Remove Engine Support Fixture (2-3487.
(15) Remove jackstands from under stub frame and lower vehicle to shop floor.
(16) Check and adjust front suspension height.
(See Front Suspension, Group 2 in the Chassis
Service Manual.)
(17) Bleed the hydraulic brake system, using a pressure bleeder.
(18) Tighten all front suspension points that con- tain rubber to specified torques. (See Front
Suspension, Group 2 in the Chassis Service
Manual.)
SCREW & WASHER (4)
SCREW & WASHER (4)
-REAR ANCHOR CROSSMEMBER
BRACKET AND S
SCREW & WASHE! (12) \-
&-SCREW & WASHER (2)
ISOLATOR ASSEMBLY (4)
BRACKET AND SLEEVE ASSEMBLY
BRACKET AND SLEEVE ASSEMBLY
Fig. 11
-
Isolated “K** Frame
NP314B
MyMopar.com
0
ALPHABETICAL INDEX 14-1
1971 BODY SERVICE MANUAL
ALPHABETICAL INDEX
BODY AND FRAME ALIGNMENT
Page
....................
13-1
Body Alignment Dimensions
Body t o Frame Alignment
Frame Dimensions
Frame Replacement
CONVERTIBLE
............................
.................................
................................................
13-1
..............................................
1 3-2
13-1
13-2
...........................................................
8-1
Adjustments
............................................................
8-3
Cam Adjustment
...................................................
8-4
Control Link Adjustment
Cylinder Hose Routing
Dowel Bracket
Electrical Tests
...................................
8-4
........................................
8-2
........................................................
8-3
.......................................................
8-5
Folding Top and Well Cover
Folding Top Mechanism
............................
8-7
.....................................
8-1
Front Hinge Adjustment
....................................
8-4
Header Adjustment
Index
..............................................
8-4
...........................................................................
8-1
Manual Top
.............................................................
8-4
Operating t h e Top
................................................
8-1
Reservoir
...................................................................
Stack Height
8-1
8-5
Seals and Sealers
.................................................
8-7
Side Tension Cable
...............................................
8-5
Service Diagnosis
..................................................
8-1
Weatherstrips
.........................................................
8-7
Web Straps
..............................................................
8-5
Well Liner
.................................................................
8-5
ELECTRICAL
Bulb Charts
..............................................................
5-1
............................................................
5-57
Concealed Headlamps
Convertible Top Lift
........................................
5-39
............................................
5-53
........................................................
5-48 Electric Locks
Front End Lighting (Except Headlights)
Fuse Charts
......
............................................................
5-59
Headlamps (Adjustment and Aiming)
Headlamp Washers
Power Seats
.............................................
Power Window Lifts
Rear End Lighting
..........
...........................................................
5-43
...........................................
5-46
................................................
5-4
5-50
5-24
Specifications
.........................................................
5-57
Tailgate Washers
Wiring Diagrams
.................................................
5-54
5-62
INTERIOR TRIM
Console
.......................................................
.....................................................................
Cover Material Installation
4-1
4-1 8
Floor Covering
Front Seat Back Latch
Garnish Mouldings
Glove Box
.................................................................
Glove Box Lock
Headlining
Lining Section
Power Seats
Replacement
Safety Belts
.........................................................
4-6
4-1 8
Seats
Shelf Trim Panel
..............................
4-18
........................................................
................................................
......................................................
................................................................
. Seats & Covers
.............................................................
4-1
......................................
4-1 4
4-1
4-2
4-2
4-4
4-1 7
4-7
.........................................................................
4-1 2
...................................................
4-7
Six Way Manual Seat
.......................................
4-1 6
INTRODUCTION
.......................................................
Capacity Conversion Table
Foreward
Manual Description
Models
Specifications Chart
...............................
...................................................................
..............................................
.......................................................................
Quick Reference Index
.............................................
Torque Reference
..................................................
Vehicle and Engine Numbers
LUBRICATION
Page
1
Body Maintenance
Deck Lid Hinges
Deck Lid Latch
....................................................
.......................................................
2- 1
2-5
2-5
Door Hinges
.............................................................
Door Lock Ratchet and Striker Bolt.
............
2-2
2-3
Door Locks and Locking Control Linkage.. 2-4
Door Remote Control Link
Hood Hinges
Safety Catch
Lock Cylinders
Tailgate-Door Lubrication
Drain Holes
General Information
Index
................................
Fuel Tank Access Door Hinge
License Plate Bracket Hinge
.........................
............................................................
Hood Locks, Release Mechanism and
............................
........................................................
Tailgate-Window Wiper Linkage
.....................
Window Regulator, Glass Lower Frame.
MAINTENANCE AND CARE
Appearance
..............................................................
..............................................................
.....
;
................................
............................................................
2-4
2-6
2-2
2-2
2-6
2-3
2-5
2-6
.....
2-4
1-1
1-1
1-4
1-1
1-1
Interior Trim
Lubrication
Tires
............................................................................
Vinyl Roof Covering
REFINISHING PROCEDURES
Acrylic Finish
Refinishing
Index
......................................................
...............................................................
.............................................
...........................................................................
Purpose of Sealers
.............................
12-1
Definitions of Technical Terms
Index
.......................
...........................................................................
Paint Bake Oven Treatment
Paint Charts
............................................................
Paint Repair on Galvanized Metals
...............................................................
Spot Re pairs
SEALING
......................................................................
General Information
..............................................
1-1
1-4
1-4
1-1
12-1
12-1
12-1
12-3
12-3
12-2
12-2
12-3
11-1
11-1
11-1
11-1
Sealers and Compounds
Service Procedures
BARRACUDA
Bumpers
....................................
..............................................
1 1-2
1 1-2
SHEET METAL
.........................................................
3-1
.........................................................
3-47
................................................................
3-52
Cowl Seal t o Cowl Panel
..............................
3-49
Cowl Side Trim Panel
Deck Lid
.....................................
................................................................
3-49
3-60
Deck Lid Weatherstrip
....................................
3-61
Doors
......................................................................
3-55
1
5
6
2
4
1
2
1
2- 1
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14-2 ALPHABETICAL INDEX
0
Door and Latch Adjustment
Door Latch Striker Adjustment
Door Lock Cylinder Linkage
Door Trim Panel Installation
Fenders
.........................
.........................
Page
3. 5 5
...................
3.55
3-56
........................
3-57
..................................................................
3.5 1
Folding Top Pocket Airshield
Grille
Hood
Latch Link
Lock Cylinder
Quarter Panel Airshield
Quarter Panel Trim
..........................................
Quarter Trim Panel Moulding
Radiator Yoke Support
Rear Bumper
Sub-Assem bly
Rear Bumper to Car
Scuff Plate
.
.......................
Front Door Latch Locking Control
...................................
3.58
3.57
.......................................................................
3-54
............................................................
..................................
3-58
3.60
3-52
......................................................
3-53
........................................
3-49
3-56
3-56
Outside Air Vents
Outside Handle
.............................................
3-48
...................................................
3-57
3-57
3-54
Remote Control
..................................................
3-56
Cowl Top Panel Seal
Electric Door Locks
Fenders
Grille
...........................................................
3.48
Shelf Trim Panel
...............................................
Torsion Bar Replacement
IMPERIAL
.
CHRYSLER
.
Air Shield and Cross Bar
Arm Rest
Bumpers
Hinge Replacement
...............................
................................
...............................................................
........................................
..........................................
3.1 8
...................................................................
.........
3-1
............................................
3-48
3-60
3-7
-3-1
-3-1
3-1
3-4
3-7
3-3
........................................................................
3-3 Hood
Inside Handles
Latch and Striker
Lock
.
Hood
T r i m Panel
Vent Door
....................................................
..........................................................
Outside Air Vent
Outside Handle
................................................
Radiator Yoke Support
....................................
3-6
Side Cowl Trim Panel
......................................
3-1
........................................................
3-1
3.1 6
3-1
3-23
.....
3-3
3-1
3-3
Water Shield
Wheelhouse
G ri le
Hood
.......................................................
Weatherstrips and Windcords
SATELLITE
Air Shield
..........................................................
Latch and Striker
Outside Air Vents
Outside Handles
..............................................
3-27
..................................................
3-39
Radiator Yoke Support
3-1 6
3-25
3-27
3-35
Bumpers
................................................................
3-35
Carburetor Air System
Doors
......................................................................
Fenders
..............................................................
....................................
3-30
.......................................................................
3-3 5
.......................................................................
....................................... ......,
3-4
3-35
3-30
3-29
3-35
Tail Gate
Weatherstrip Roof Rail
Weatherstrip Tail Gate
....................................
3-35
....................................
3-41
3-40
....................................
3-43
VALIANT
..................................................................
3-62
Bumpers
Deck Lid
Doors
Fenders
Grille
Hood
Radiator Yoke Support
SIDE GLASS
BARRACUDA
Glass Assembly Ventless
Quarter Window
Quarter Panel Glass
Ventless Door Glass Adjustment
Ventless Door Glass Installation
IMPERIAL
Glass Adjustment
Glass Adjustment
Glass Adjustment
Glass Lift Bracket
Glass Replacement
Hardtop Models
Index
......................................................................
........................................................................
.......................................................................
. CHRYSLER
Glass Rear Track
Glass Adjustment
Glass Adjustment
.
.
Glass Replacement
Regulators
Rear Doors
Tail Gate Glass
VALIANT
I
nsta
.
.
I
.
................................ la tion
.........................................
............................................
...........................................................
........................
Page
..67
3-72
-3-68
3.65
3.68
3-63
3.67
6-29
6-31
..................
..............................
Door Hardtop
.
Door Hardtop
..............................................
........................................................................
Quarter Panels
Quarter Windows
Regiiiator Arm
Rear Doors
...........................................................
Water Shields
SATELLITE
.........................
..............................................................
.........................................................
................................................................
Rear Doors
.....................................................
Rear Door Stationary Glass
Regulator Replacement
.................................
6-35
Sedan Models
Ventless Glass
...................................................
6-34
I
................................................................
..............................................................
................................................
...................................................
..........
6-2
..........
...................................................
.
Hardtop
.
Manual
.........................
.............................
.........................................................
..................................................
STAT1 ON ARY GLASS
.....................................
Station Wagon Glass Replacement
6-10
6-18
6-12
6-15
6-16
6-10
6-15
6-22
6.23
6.24
6-23
6-24
6-24
6-26
6-33
6-35
6-36
......
...........
6-1
6-28
6-30
6-28
6-1
6-6
6-5
6-6
6-1
6-5
6-33
7-1
7-1
-.7-6
Station Wagon Quarter Glass
.....................
Weatherstrip Type Replacement
,.7-4
...................
7-2
Windshield and Rear Window
VINYL ROOF COVERING
Cleaning Grain Surface
Cover Replacement
...................................
7-1
9-1
9-3
.............................................
9-1 lndes
.........................................................................
9-1
Making Graining Tool
Spraying of Colors
........................................
..............................................
Vinyl Top Repair
WOOD GRAIN OVERLAY
9-3
9-7
9 4
Application of Overlay
Index
Inspection
Repair of Minor Damage
................................
10-1
...................................
............................................................
.1 0.1
.......................................................................
10-1
.1
.1 0.4
...........................
-1
0.3
Repair of Minor Scratches
Repair of Sheet Metal Dings
0-5
.......................
10-4
Service Proccedures
Temperature
.........................................
10-1
........................................................
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