Chrysler Valiant (1969) Workshop Manual

A

(4)

Slide door glass assembly out of vent wing divi-

sion channel.

(5)

Remove slide assembly from glass and weather-

strip (Fig.

(6) (7)

36)

by pulling slide halves apart. Remove weatherstrip from glass. Push lift channel fasteners out of glass.

Assembly

(1)

Insert lift channel fasteners into glass from con-

cave side (Fig.

(2)

Position weatherstrip on glass front edge with

37).

notched end in up position.

(3)

Raise edge

of

weatherstrip and insert slide at

attaching in glass. Secure by pressing together.

(4)

With glass and vent wing in inverted position

(Fig.

36)

insert slides on glass assembly into vent wing

division channel.

(5)

Insert anti-rattle into division channel adjusting

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.

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 bracket

BODY AND FRAME

23-75

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 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 channel

and secure with screws.

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 sup-

38)

port retaining nut (Fig.

(4)

Remove channel assembly through large access

at door.

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.

38).

2

DOOR

Fig.

38-Glass

Rear

CHANNEL

Channel

4

DOOR HARDTOP

NUT

NU316

23-76

(3)

BODY AND FRAME

Insert channel lower stud into slot of support

assembly and secure with nut.

(4)

Tighten upper support screw.

(5)

Install door glass.

(6)

Install up-stop at rear channel.

DOOR GLASS REGULATOR

The manual and electric operated regulators (Fig.

39)

are attached to the door inner panel

Refer to the Electrical Group for test procedures

and wiring diagrams for electric operated regulators.

Glass Lift Bracket

The glass lift bracket (Fig.

40)

sliding blocks on the regulator arms. Screws are used to secure the lift channel to the glass fasteners. Lubri-

cate the sliding block contact areas of the lift channel sparingly.

Regulator Motor Replacement

When necessary to remove motor from regulator,

it

is

imperative the linkage vise to lock it in place. Failure to do this allows the assist spring to drive the mounting bracket around

the lift pivot.

be

securely clamped in

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 arid remove switch from panel.

with

screws.

is

positioned over

NU303

\----

Fig.

40--Lift

Brocket

VENT WING REGULATOR

Removal

(1)

With vent wing open, remove screws attaching

regulator to door inner panel belt reinforcement (Fig.

41).

(2)

Remove shaft to coupling screw.

(3)

Move regulator

(4)

Remove regulator through large access hole in

door panel.

a

lnstallation

(1)

Through large access hole, position and

sleeve on regulator coupling over vent wing pivot

shaft.

(2)

Position and align regulator

slots in door inner panel

stall attaching screws.

(3)

Install regulator coupling to vent wing pivot

shaft screw.

off

of vent wing pivot shaft.

body

to attaching

belt

reinforcement and in-

A

align

MANUAL

MOTOR

REGULATOR REGULATOR

Fig. 39-Regulator Assemblies

ELECTRIC

I

NU307

A

PIVOT

SHAFT

BODY AND FRAME

23-77

/

d

\

MANUAL

Fig. 4 1

4

DOOR SEDAN

Adjustments

(1)

Run

glass approximately

(2)

Tighten vent wing lower adjusting rod to inner

panel screw assembly.

(3)

Lower glass until top

slightly below top of door at outer panel.

(4)

Position stop on regulator plate against stop on

sector and snug tighten locknut.

(5)

Test operation and inspect alignment of glass.

Tighten callouts 6 and 7 securely.

DOOR

GLASS AND VENT WING

REPLACEMENT

(Fig.

and

STATION WAGON

42)

2/3

edge is even with

way down.

d’

-Vent Wing Regulator

(3)

Move glass assembly rearward into glass run.

(4)

Position washer on division channel lower adjusting rod and insert adjusting rod into opening in support bracket.

(5)

Position vent wing frame to door upper frame,

aligning notch in lower pivot to hole in spacer bracket.

or

(6)

Install retaining screw at spacer bracket.

(7)

Starting at bottom attaching hole, secure vent

wing frame to door frame with screws.

(8)

Install lower adjusting rod nut and washer.

(9)

Install lift channel to door glass fastener screw.

(10)

Position loosen 4 inches

and fully seat in channel.

ELECTRIC

NU325

of

upper run channel

Removal

(1)

Remove forward four inches

of

glass run at

upper corner.

(2)

Remove division bar adjusting rod nut and

washer (Fig.

(3)

Remove screw assembly attaching vent wing

43).

frame to outside belt reinforcement.

(4)

Remove vent wing frame to door frame screws.

(5)

Remove lift channel to door glass fastener

screws.

(6)

Lift vent wing and door glass out of panel.

lnstallation

(1)

Inspect seal on vent wing upper surface.

(2)

With regulator arms in the down position, lower

vent wing and door glass assembly fully into door.

Fig.

424

Door Sedan and Station Wagon

Glass Adiustments

VIEW A

NU373

23-78

BODY

AND FRAME

A

GLASS.

RUN

Fig.

43-Glass

a

'

'WASHER

Replacement

LIFT

SECTION

BRACKET

NU335

A-A

GLASS RUN

The

glass run

frame. Position run

leg between inner and outer door panels. Index

molded corner to upper rear corner of frame and

press firmly into place. Press run into upper door frame leaving forward four inches out facilitate vent wing installation.

(Fig.

io

44)

is

a press fit

door frame

by

in the door

inserting lower

of

retainer to

and back) to depress retaining clips and pull switch out from panel. Carefully separate multiple terminal block from switch body and remove switch from panel.

VEN'T WING REGULATOR

Removal

(1)

With vent wing open, remove screws attaching

regulator to door inner panel belt reinforcement (Fig.

41).

(2)

Remove shaft to coupling screw.

(3)

Move regulator

(4)

Remove regulator through large access hole in

door panel.

lnstallat ion

(1)

Through large access hole, position and align

sleeve on regulator coupling over vent wing pivot

shaft.

(2)

Position and align regulator body to attaching

slots in door inner panel belt reinforcement and in-

stall attaching screws.

(3)

Install regulator coupling to vent wing pivot

shaft screw.

off

of vent wing pivot shaft.

REAR DOORS

Adjustments-Sedan

(1)

Raise window door frame.

(2)

Adjust regulator pivot bracket top of glass and door frame attaching nuts.

(Fig.

to

approximately

is

45)

1/8

inch below

so

gap between

constant. Snug tighten

Glass

sliding blocks on the regulator arms. Screws are used

to secure the

cate the sliding block contact areas of the lift channel sparingly.

Lift

Bracket

The glass lift bracket (Fig.

lift

channel to the glass fasteners. Lubri-

40)

is

positioned over

DOOR GLASS REGULATOR

The manual and electric operated regulators (Fig.

39)

are attached to the

Refer to the Electrical Group for test procedures

and wiring diagrams for electric operated regulators.

Regulator Motor Replacement

When necessary to remove motor from regulator,

is

imperative the linkage

it vise to assist spring to drive the mounting bracket around the lift pivot.

Window

lock

it in place. Failure to do

Lift

Switch

Slide a thin blade behind

door

inner panel with screws.

be

securely clamped in

this

the

switch housing (front

allows the

RUN

a

i

Fig.

44-Glass

dU320

Run

A

BODY

AND

FRAME

23-79

NU377

Fig.

45-Sedan Rear

(3)

Lower glass until top edge

Door

Gluss Adjustments

is

even with

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.

GLASS REPLACEMENT

FASTENER

-T

or

Fig.

46-Gfuss Replacement

(2)

Remove pivot support bracket to

panel screw assemblies (Fig.

(3)

Slide pivot channel

and remove pivot bracket through large access hole.

off

48).

of

regulator

door

arm

I

inner

slide

Removal

door

(1)

Remove

lift

channel to

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. 46).

Installation

(1)

Position lift fasteners into glass from glass inner

surface (Fig.

(2)

With bottom of glass in forward position, lower

46).

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 channel

and secure with screws.

Glass

the

Run

The rear door glass run (Fig.

door

frame. Index the front notch into upper front

47)

is

a press

fit

in

corner of door frame and press entire front leg of run secure. Position rear notch in run to upper rear corner of door frame and press entire top and

rear

leg

securely in channel.

lnstallation

(1)

Apply lubricant to sliding contact surfaces

pivot channel.

(2)

Through large access hole, position pivot chan-

nel over slide on regulator idler arm.

G2

FRONT

-

of

Pivot Bracket

Removal

(1)

Remove the rear

door

glass.

Fig.

47-410s~ Run

23-80

(3)

in door inner panel and secure

(4)

Glass

BODY AND FRAME

SLIDE

\

Fig.

48-Pivot

Align pivot bracket mounting holes

Install rear door glass.

Lift

Bracket

(Fig.

Brueket

49)

with

screws.

Removal

(1)

Remove rear door glass to lift bracket screws.

(2)

Move

lift

bracket forward on front slide to dis-

engage bracket from rear slide.

(3)

Move bracket rearward to remove from front

slide.

lnstallation

(1)

Apply lubricant to channel of lift bracket.

with

'.

,CREW

).

3T

KET

holes

A

LIFT

Fig.

49-lift

(2)

Position bracket channel to regulator arm front

Brueket

slide first, then move rearward to engage rear slide.

(3)

Install rear door glass to lift bracket screws.

Regulators

The manual and electric operated regulators

50)

are attached to the door inner panel with screws.

Refer

to

the Electrical Group for test procedures

and

wiring

diagrams

for

electric operated regulators.

(Fig.

Regulator Motor Replucement

When necessary to remove motor from regulator,

it

is imperative the linkage vise to lock assist spring to drive the the pivot.

Window

it

in

Lift

place. Failure

Switch

be

securely clamped

to

do

this allows the

mounting

bracket around

in

a

Slide a thin blade behind the switch housing (front and back) to depress retaining clips and pull switch out from panel. Carefully separate multiple terminal block from switch body and remove switch from panel.

-

SCREW

MANUAL

SCREW-

\\

ELECTRIC NU308

Fig. 50-Regulator Assemblies

A

Fig.

5 1-Hardtop Rear Door

Glass

Adjustments

HARDTOP MODELS

Adjustments (Fig. 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

door

of front

(5)

Snug tighten

glass by lifting track panel bottom edge.

cage nuts.

In-Out and Secondary Seal

(6)

Force bottom of track panel in

ondary seal with roof weatherstrip.

(7)

Snug tighten adjusting bracket to track panel

screws.

5

rear

1)

and

center

floating

or

out for sec-

BODY AND FRAME

(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 F rame and Roof Rail Weatherstrips

(10)

Adjust pivot bracket to bring upper front corner of rear glass parallel between front and rear glass frames and between glass and roof rail weatherstrips.

(11)

Snug tighten the pivot bracket screw assemblies.

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 assembly

to which the door glass

or

to remove

install either the glass the panel and glass must be removed an assembly.

Removal

(1)

Remove track panel to door panel upper screws

(Fig.

in

52).

(2)

Remove down-stop adjusting bracket to track

panel screws.

(3)

Remove up-stop adjusting brackets from door

panel (Fig.

(4)

screws (Fig.

(5)

53).

Remove glass lift bracket to glass fastener

54).

Move track panel rearward, approximately four

is

attached. When necessary

or

track panel,

or

23-81

installed as

APPLICATION

CIRCLE

A

IN

Fig.

52-Track Panel Upper Attachment

SCREW

NU337

23-82

SCREW

BODY AND FRAME

STOP

'1

SCREW

ill

---a

Fig. 53-Up-Stop Brackets

inches, and raise door glass to the full-up position.

(6)

Raise track panel slowly until up-stop on glass

55)

(Fig.

(7)

and panel assembly (Fig.

(8)

tected surface with the glass facing downward.

(9)

and remove guides from track panel.

(10)

and bumpers from top inner side (Fig.

installation

(1)

bumpers into top inner side.

(2)

downward on a protected surface, place track panel on glass aligning fasteners in glass with channels in panel.

are cleared through door.

Raise track panel completely and remove glass

56).

Place track panel and glass assembly on a pro-

Remove track stabilizer guide screws (Fig.

Remove U-nuts from outer side of track panel

58).

Insert U-nuts into outer side of track and

With glass assembly inner surface positioned

NU317

57)

(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

(5)

Slide track panel glass find clearance to enter door opening.

(6)

Slowly lower track panel completely to bottom

of

door,

at the same time and positioning behind the down-stop brackets.

(7)

Slowly lower the glass assembly until it tioned 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 fasteners

in glass and install screws.

(11)

Install up-stop brackets on door inner panel.

U

P-STOPS

The rear up-stop (Fig. areas in the door shut face between the inner and outer panels. The front up-stop (Fig. slotted areas of the inside panel through the glass opening between inner and quarter panel at upper front corner.

GLASS ASSEMBLY

The door glass to

fit in glass (Fig.

for

moving

the U-nuts.

off

of

glass, until upstops

it

forward approximately four inches,

is

53)

is

attached to slotted

53)

is attached to

lift

channel fasteners are a press

55)

as are the glass to track and guide

on

posi-

d?

Fig. 54-Lift Bracket

NU330

\

FASTENER

Fig. 55-Door Glass

NU319

Assembly

A

PANEL

BODY

AND FRAME

23-83

Fig.

56-Glass and

Track

fasteners. The glass up-stops are retained in the glass with screws.

Glass

sliding blocks on the regulator arms. Screws are

Lift

Bracket

The glass lift bracket (Fig.

54)

is

positioned over

used

to secure the lift channel to the glass fasteners. Lubricate the sliding block contact areas of the lift channel sparingly.

Regulators

The

manual and electric operated regulators (Fig.

50)

are attached to the door inner panel with screws.

Refer to the Electrical Group for test procedures

and wiring diagrams for electric operated regulators.

’/

Panel Replacement

Regulator

When necessary to remove motor from regulator, is

imperative the linkage be securely clamped in

it vise to lock it assist spring to drive the mounting bracket around

the lift pivot.

Window

Slide

I

--

- - -

Mot

or Replacement

in

place. Failure to do this

Lift

Switch

2

thin blade behind the switch housing (front

-

..

NU338

allows

the

and back) to depress retaining clips and pull switch

out from panel. Carefully separate multiple terminal

block from switch body and remove switch from panel.

QUARTER PANELS

GARNISH MOULDINGS

The garnish mouldings should be aligned and held

Do

in position to assure satisfactory alignment.

or

over-tighten screws,

moulding will become dam-

not

aged at screw hole area.

TRIM PANELS

a

Fig.

57-Track

Panel Stabilizer Guides

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.

59)

is properly cemented and posi-

tioned.

HANDLES

The regulator handle is attached with an allen

screw.

23-84

BODY AND FRAME

A

BRACKET

NU318

Fig.

SI-Track

Panel Assembly

WATERSH I ELDS

Refer

to

Figure

of the watershield.

BELT LINE W EATH ERSTRl

The

belt line weatherstrip

panel with spring type retainers.

GLASS

The circled numbers shown on the reference illustrations indicate the particular step number being read in the adjustment procedure.

Prior to adjusting glass, all doors must be correctly fitted in their opening and

“A”

ADJUSTMENTS

post and roof rails must

59

for sealing and application areas

P

is

retained on

glass

the

weatherstrips at the

be

properly installed.

the

adjustment

outer

Refer to the adjustment illustration and loosen

the

attaching screws and nuts of the various components affecting glass adjustment.

QUARTER WINDOW (HARDTOPCONVERTIBLE)

Adjustments (Fig.

(1)

Adjust upper rear track

touches outer panel belt weatherstrip.

(2)

Raise glass fully against roof rail weatherstrip and flushing front of glass with top of front door glass.

(3)

Adjust upper front track attachment

is

of glass

aligned with rear of front door glass

belt line and snug secure nut.

(4)

Adjust lower front track attachment of glass

is

aligned with rear of front door glass at roof

rail and snug secure screw.

(5)

Adjust pivot bracket against and parallel to adjusting bead on roof rail weatherstrip. Snug secure nuts.

(6)

Loosen sleeve nut and move upper rear track attachment forward

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

or

slightly below belt line of outer panel.

(10)

Snug secure lower rear track adjusting screw.

60)

so

rear of glass lightly

so

top of glass

is

seated fully

so

top

of

glass

is

so

weatherstrip and front of glass

is

even

front

at

front

fully

with

VIEW

TOP

OF

IN

CIRCLE

Y

Fig. 59-Quarter Panel Watershields

WATERSHIELD

NU548

Fig.

60-Quarter

Hardtom-Convertible

Window Adjustmen?s-

A

(11)

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. Tight-

en callouts

G

LASS REPLACEMENT

14

through

21

securely.

Removal

(1)

Align glass lower frame to glass attaching

screws with access holes in quarter inner panel (Fig.

61).

(2)

Support glass, remove lower frame to glass at-

taching screws and remove glass assembly from panel.

(3)

Remove spacers from openings in glass.

lnsta

Ila

ti0

n

(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 openings In glass with holes in lower frame and install screw and grommet assemblies.

DOWN STOP

The down stop bracket and bumper (Fig.

of

attached to the outboard side

the glass lower frame

assembly with screws.

62)

is

BODY AND FRAME

Fig.

62-Down

Stops

23-85

PIVOT BRACKET

The pivot bracket assembly (Fig. to the roller slide 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.

U

P-STO PS

The up-stops (Fig.

64)

are attached to slotted areas

63)

is

positioned

./ NU326

Fig.

61-Glass

Replacement

Fig.

63-Pivot

NU329

Bracket

23-86

BODY

AND FRAME

A

/

P

GROMMET

P

\,

\

-

Fig.

64-Up-StOp

on the quarter inner panel with screws. An anti-rattle

is

type grommet

FRONT TRACK

Removal

(1)

Remove nut and washer from sleeve nut at up

per end of track (Fig.

(2)

Remove track lower plate to support screw.

(3)

Push track inward and move track and roller assemblies rearward lower frame.

(4)

Remove track and rollers out of panel through large access hole.

(5)

Remove roller assemblies from track (Fig.

positioned over each up-stop flange.

65).

to

disengage rollers from glass

NU328

66).

Fig.

66-Glass

\

ROLLER AND

Lower

Frame

GUIDE

NU289

Assembly

Installation

(1)

Position roller and guide assemblies on track.

(2)

Insert track assembly in quarter panel.

(3)

Position roller assemblies into slots

lower frame (Fig.

(4)

Insert sleeve nut on upper end of track into hole

of

inner panel (Fig.

(5)

Align track lower plate to support and secure

with

screw.

(6)

Place spring washer, concave side facing outboard, on track upper sleeve nut and install retaining nut.

66).

65).

of

glass

REAR TRACK

(1)

Remove nut and washer from track upper sleeve nut (Fig.

(2)

(3)

assembly forward to disengage roller from slot in glass lower frame.

(4)

through large access opening.

(5)

67).

Remove track lower plate to support screw.

Push track inward and move track and roller

Remove track and roller assembly out of panel

Remove roller assembly from track.

SECTION A-A

CHANNEL

Fig.

65-Front

Track

Assembly

SCREW

Flg.

67-Rear

NU286

Truck

A

BODY AND FRAME

(5)

Place spring washer, concave side facing out-

board, on sleeve nut and install retaining nut.

GLASS LOWER FRAME

23-87

\

37

Fig. 68-Glass Lower Frame Replacement

Installation

(1)

Position roller assembly on track and insert

assembly into quarter panel through large access

opening.

(2)

Position roller assembly into slot of glass lower

frame.

(3)

Insert track upper sleeve into hole of inner

panel.

(4)

Align track lower plate on support and secure

with screw.

~~

Removal (Fig.

(1)

Remove quarter glass assembly.

(2)

Remove rear track upper and lower attachments

68)

and move track and roller assembly forward to disengage roller assembly from glass lower frame.

(3)

Move lower frame assembly to disengage chan-

nel from regulator arm rear slide.

(4)

Raise rear of lower frame and remove from

quarter

(5)

Remove roller and guide assemblies from lower

frame.

lnstallation

(1)

Inspect glass lower frame to

are installed at the upper outer holes (Fig.

(2)

Insert roller and guide assemblies into lower

be

sure grommets

66).

frame front upper and lower slots.

(3)

Slide front end of lower frame into panel and

engage front of lift channel to slide on regulator front

arm (Fig.

(4)

68).

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.

69)

are attached to the door inner panel with screws.

Fig. 69-Regulotor Assemblies

ELECTRIC

NU306

23-88

Refer to the Electrical Group for test procedures

and wiring diagrams for electric operated regulators.

Regulator Motor Replacement

When necessary to remove motor from regulator,

it

is

vise to lock it in place. Failure to do this allows the assist spring to drive the mounting bracket around the lift pivot.

BODY AND FRAME

imperative the linkage

be

securely clamped in a

'v1

A

FASTENER

Window

Slide a thin blade behind the switch housing (front and back) to depress retaining clips and pull switch out from panel. Carefully separate multiple terminal block from switch body and remove switch from panel.

Lift

Switch

GLASS ADJUSTMENTS (SEDAN MODELS)

(1)

Raise glass to approximately

window opening frame.

(2) Adjust regulator pivot bracket (Fig. 70) between top of glass and window opening frame constant. Tighten pivot bracket nuts.

(3)

Run glass approximately

(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

slightly below outer panel belt line weatherstrip.

(6)

Position stop on regulator plate against stop on

sector and snug tighten locknut.

(7)

Test operation and inspect alignment of glass.

8,

9

Tighten Callouts

and 10 securely.

2/3

1/8

inch below

way down.

is

even with

so

gap

is

or

GLASS REPLACEMENT

Removal

(1)

Lower glass fully and remove lift channel to

glass fasteners screws (Fig. 71).

(2) Through large access hole, rotate glass clock-

I!

LIFT BRACKET

@-SCREW

Fig.

7

I

-Quarter Window Replacement

wise to remove from front and rear run channels.

(3)

Raise glass assembly out of panel.

(4)

Remove fasteners from glass assembly (Fig. 71).

lnstallation

(1)

Insert glass lift fasteners into glass from inner

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 glass 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.

NU331

B

NU376

Fig. 70-Quarter Window Adjust ments-Sedan

GLASS RUN AND WEATHERSTRIP

R

ETA1 N E RS

Removal

(1)

Remove glass assembly.

(2) Remove run from front top and rear retainers

(Fig. 72).

(3)

Remove weatherstrips and screws securing

weatherstrip retainers to roof rail and lock pillar.

(4)

Remove weatherstrip retainers from quarter

panel.

lnstallation

(1)

The weatherstrip retainer seal

type.

is

a

self

adhesive

A

BODY AND FRAME

23-89

Fig. 72-Weatherstrip Retainer and Runs

(2)

Insert retainer front leg in panel opening and

align attaching holes with holes in body panel (Fig.

72).

(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 and bend tab

over.

(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.

(12)

Install quarter window assembly.

GLASS LIFT CHANNEL

The lift channel (Fig. the regulator arms and to the glass assembly with screws.

STAT1 0 N

WAG0

N

73)

is

position over slides on

GLASS REPLACEMENT

Removal

(1)

Remove

spare

tire

cover assembly (Fig.

74).

(2)

Remove garnish mouldings at quarter window

(Fig.

75).

(3)

Unlock weatherstrip by inserting a fiber stick into locking groove of weatherstrip and forcing locking tab out

(4)

vehicle and weatherstrip from fence.

of

groove.

Remove glass from weatherstrip from inside of

J

4

NU334

Fig.

73-Glass

lift

Bracket

,

23-90

BODY AND FRAME

A

NU445

Fig. 74-Spare Tire

Cover

lnstallcrtion

(1)

Inspect sealing areas of quarter window to as-

is

certain sealer

76.

(2)

Apply a bead of sealer, starting at front and

top sections of weatherstrip (Fig.

(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.

applied at areas indicated in Figure

77).

T

SEALER

%

INCH

BEAD<

mW

into weatherstrip and using a weatherstrip over glass (Fig.

tab and insert locking tab into weatherstrip groove using a fiber stick.

erstrip, body lock upper pillar and front area (Fig.

I

IN DIRECTION

Fig. 75-Quurter Window

(5)

From inside of vehicle, insert bottom

Gurnish

fiber

stick, pull

Mouldings

78).

(6)

Seat glass in weatherstrip using hand pressure.

(7)

Apply rubber lubricant to weatherstrip locking

(8)

Apply and press secure, sealer to joint

roof

79).

OF

ARROW D

SEALER

?4

INCH BALL-

VIEW

Lw

IN

DIRECTION

of

side rail outer

OF

ARROW

of

glass

lip

weath-

of

B

SEALER

VIEW IN DIRECTION

?4

INC”

nA’’

OF

ARROW A

Fig.

76-Quarter

Window

SEALER % INCH

VIEW IN DIRECTION

Swling

Arwr

OF

ARROW

C

NU443

A

BODY AND FRAME

SEALER

23-91

Fig. 77-Weatherstrip Replacement

(9)

Apply and press secure, sealer to joint of glass weatherstrip, outer panel weatherstrip retainer and rear body lock pillar.

(10)

Install garnish mouldings and spare

tire

cover.

QUARTER PANEL EXTENSIONS

Refer to Figures

tions of the quarter panel extensions.

80

and

81

for attachment applica-

PANEL SIDE REFLECTOR

The quarter panel assembly (Fig. within the luggage compartments.

Gl

82)

side

marker reflector and bezel

is

attached with sealer nuts from

SEA~ER

LOCKING

CEMENT

TAB^

7

OU~ER PANEL

APPLICATION AT A-A

APPLICATION

Station Wagon

way” tail gate that can be opened as a swingout type door or in the conventional tail gate manner. The sequence of adjusting the linkage should be followed, as outlined in this service manual, to ascertain correct locking and releasing operations.

ALIGNMENT

Vertical adjustment and in and out adjustments are

made at the hinge plate. In and out alignment

top of the tail gate in or out to permit ease of entry of the tail gate glass

into the upper run channel. Lateral adjustment to

center the tail gate in the body opening at the hinge (Fig.

AT

B-B

TAIL GATE

Models

is

83).

are equipped with a “two-

adjusted by moving the striker

NU442

of

is

controlled

the

APPLICATION AT

Fig. 78-Glass Replacement

LOCKING TAB

B-B

APPLICATION AT A-A

NU441

WINDOW WASHER SYSTEM

Refer to the Accessory Group for Service Proce-

dures, Tests and Wiring Diagrams.

VIEW

IN

CIRCLE

Fig.

79-Sealing Weatherstrip

A

NU440

23-92

BODY

AND FRAME

““SEWS

NU21 1

Fig. 80-Quarter Panel Extension-Station Wagon

REPLACEMENT

Removal

Remove trim panel and disconnect terminals at control switch. Disconnect wiper and washer electrical leads.

(1)

Remove check arm and torsion bar guide from

pillar guide plates.

(2)

Support tail gate on jacks

(3)

Loosen hinge pivot pin locking screws (Fig.

(4)

Use a pencil and outline hinge plate position on

pillar post for future assembly.

(5)

Remove hinge plate attaching bolts from pillar

post.

(6)

Slide hinge plate and torsion bar in through

guide toward center of tail gate.

(7)

Lower tail gate down and out of body opening.

lnstallation

(1)

With torsion bar and hinge plates pushed in

NUT

AND

or

stands.

SEAL

83).

toward center of lower opening

(2)

Attach hinge plate attaching bolts into pillar

of

tail

gate, engage hinge plates into

body.

posts and locate hinge plates in relation to previous marked positions.

(3)

Tighten attaching bolts firmly enough to hold

position and inspect alignment.

(4)

Close 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.

TRIM PANEL

The tail gate trim panel is attached with metal

screws. Clean all foreign material from the seating

of

area

the trim panel before installing.

LOCK

To

replace the lock assembly (Fig. panel glass and glass runs. The lock assembly tained on tail gate by screws accessible at end

83)

remove trim

of

is

re-

tail

gate.

LOCK CYLINDER

The tail gate lock cylinder assembly is retained on

the outer panel with a horseshoe type retainer (Fig.

83).

LOCK LINKAGE

lnstallation

The lower right to upper right latch link and upper right lock to release regulator mechanism arm link can only 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

NUT

/

and

Adjustment

be

adjusted to three total turns from nominal

(Fig.

84)

it

contacts upper

Fig.

8

1-Quarter

Panel Extension--Except

Stdon Wagon

RET

At

NER

Fig.

824aneI

&&

Side

9

Rdlecior

NU186

A

BODY

AND

FRAME

23-93

Fig.

83--Tail

(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 control

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

re-

lease regulator mechanism arm and adjust link threaded end to this point.

(9)

Install link into upper right lock remote lever

and test operation of tail gate and door assembly.

GLASS

Adjustments

The circled numbers shown on the glass adjustment

85)

reference illustration (Fig step number being read in the adjustment procedure.

indicate the particular

Prior to adjusting glass, the tail gate must be correctly fitted to its’ opening, the inner belt weatherstrip installed and all glass and related hardware component attaching screws and nuts loosened.

(1)

With tail

gate

opened in tail gate position, push

Gate

Assembly

glass against belt inner weatherstrip and snug secure upper screws of lower glass run channel.

(2)

With tail gate 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

gate header run retainer and snug secure screws.

(4)

Raise glass to approximately roof rear glass run and adjust regulator

is

parallel to roof glass run. Snug secure regulator

1/8

inch below

so

top of glass

attaching nuts.

(5)

Open tail gate to gate position and secure lower

nut

on

glass run of tail

(6)

Close tail gate, test for ease of operation and

gate.

inspect alignment.

Tighten callouts

7,

8

and 9 securely.

GLASS REPLACEMENT

Removal

(1)

Support glass at bottom and remove glass to

lift bracket screws (Fig.

(2)

Slide glass up and out of door.

(3)

Remove lift channel fasteners from glass (Fig.

81).

86).

tail

23-94

BODY

AND

FRAME

A

lnstallation

Utmost care must

touching wiper blades.

(1)

Apply lubricant

contacting regulator sliding block.

(2)

Install

(3)

Lower glass into runs of lower glass channels

to

a position under the

arm.

(4)

Align holes in

ers

and secure with screws.

lift

be

used to prevent lubricant from

to

surfaces of glass lift channel

channel fasteners in glass.

lift

channel on each regulator

lift

channels

x

Q

Fig.

84-Lock

with

glass lift fasten-

Linkuge

Adjustments

Glass

necessary to channels are positioned over sliding blocks on regulator arms.

Regulator Replacement

tail

(Fig.

GLASS

Removal

Lie

Channels

To

replace the glass lift channels (Fig.

first

remove

The electric regulator assembly

gate inner panel with nut and washer assemblies

87).

Be sure wiper actuator mechanism

position during replacement of regulator.

(1)

Remove

(2)

Disconnect electrical leads at regulator.

tail

gate glass and glass

the

glass assembly.

is

86)

retained on

is

in

lift

channels.

it

is

The

the

OFF=

...-

Fig.

85--Tuil

Gcrte

Gloss

=/NU459

Adjustments

.I

Fig.

86-GIurr

Replucement

A

Fig. 87-Regulator

(3)

Remove regulator at inner tail gate panel nut

Assembly

and washer assemblies.

(4)

Remove regulator assembly through large ac-

cess hole on right side.

NU296

BODY AND FRAME

(2)

Remove tail gate pillar to glass run channel

screws (Fig.

(3)

Remove channel assembly through access holes

88).

in inner panel.

lnstallation

(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.

TORSION BAR

Removal

(1)

Remove trim panel from tail gate.

(2)

Remove screws attaching torsion bar clamp to

83)

tail gate pillar (Fig.

(3)

Remove torsion bar bearing retainer and bear-

ing.

(4)

Remove screws attaching torsion bar and hinge

to tail gate.

(5)

Remove torsion bar from hinge.

and remove clamp.

23-95

lnstallation

(1)

Position regulator in tail gate through

large ac-

cess hole on right side.

(2)

Position regulator mounting studs in

inner panel and install nut assemblies:

necessary to tilt and secure one corner

mounting, then the opposite corner and finally the remaining two nuts on units equipped with the win-

dow washer assembly.

(3)

Connect electrical leads.

(4)

Position glass lift channels on regulator sliding

holes of

It

of

regulator

may

be

blocks.

(5)

Install tail gate glass assembly.

Glass

Run

Channel

Removal

(1)

Remove the tail gate glass assembly.

lnstallation

(1)

Lubricate torsion bar at right hinge area and at

torsion bar bearing area.

(2)

Install hinge on torsion bar and insert torsion

bar into tail gate.

(3)

Position hinge to tail gate and install mounting screws. Tighten screws.

(4)

Install bearing and bearing retainer on torsion

83).

bar (Fig.

(5)

Position clamp over end of torsion bar and from outside end

(6)

Install tail gate trim panel.

Tighten retainer nut.

of

tail gate install attaching screws.

Rear Header Weatherstrip

The roof rear header weatherstrip

is

a press fit in

Fig. 88-Glass Run Channel

NU297

SECTION

Fig. 89-Rear Header Weatherstrip

A-A

NU298

23-96

the retainer (Fig. a seal

Rear Header Weatherstrip Retainer

The roof rear header weatherstrip retainer tached to the header with “pop” rivets (Fig. seal has adhesive applied to one it to the retainer.

Pillar Weatherstrip-Retainer and Seal

The tail gate upper pillar, retainer, seal with weatherstrip The seal has adhesive applied to one side which attaches clip assembly weatherstrip clips. Index top edge of outer weatherstrip flush with top edge of inner weatherstrip.

BODY AND FRAME

Fig. 90-Rear Header Weatherstrip Retainer

89).

Position the ends

with

the

quarter pillar runs.

side

the

retainer. Trim the ends of the seal flush

is

retainer on the pillar with screws (Fig.

it

to the retainer. The outer weatherstrip and

is

held in position in the retainer by the

first

to

90).

which attaches

form

is

at-

The

with

91).

Se-

AIR DEFLECTOR

4

NUT

...

.\2’

Fig. 92-Roof

cure weatherstrip notches in retainer.

RWr

Air

Ddktor

by

pressing weatherstrip clips

ROOF REAR AIR DEFLECTOR

The

rear

air

deflector (Fig.

is

wagon models deflector studs through holes drilled in securing with sealing type nuts from the car interior. Tighten the nuts

mounted on

75-115

inch-pounds.

the

92)

roof

used

by

the

DECK LID

NU372

into

on station

inserting the

panel and

Fig. 9 1

RET AI

SUB

-Pillar Wedherstrip-Retainer and

NER

ASSEMBLY

NU294

Sed

ALlG

N

The deck

.

\

-r

M

ENT

lid

hinge (Fig.

Fig. 93-Deck Lid Hinge and

93)

to lid attaching holes

NU68

Latch

A

-

~~

are slightly oversize, allowing slight to and fro, and, in and out adjustment.

REPLACEMENT

The deck lid screws. An assistant’s aid placing lid to prevent aging paint, also to aid holes when installing.

is

attached to each hinge by two

is

recommended when

it

sliding rearward and dam-

in

aligning

of

hinge screw

re-

BODY AND FRAME

23-97

LOCK REPLACEMENT

The deck lid lock (Fig.

lid by two screws. Scribe location of lock mounting flanges to aid in installation. On vacuum actuated units, disconnect vacuum hose.

Adjustment

Vertical adjustment

ing screws and side adjustment is made at the striker

attaching bolt.

Cylinder Replacement

The lock cylinder is retained by a spring steel

shaped clip (Fig.

94).

of

94)

lock

is

attached to the deck

is

made at the attach-

“U”

VACUUM ACTUATED DECK LID LOCKS

The vacuum actuated deck lid lock release system

(Fig.

Fig. 94-Deck Lid Lock Cylinder

95)

consists

of

a vacuum tank mounted over the

RETAINER

A

NU192

right front wheel housing, a push button control switch and a vacuum actuated diaphragm assembly connected to the lock. Vacuum

is

supplied to system from intake manifold. Rubber hoses are used to connect component units.

If failure

of

the system is accompanied with a rough engine idle, remove hose from manifold fitting 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

GROMMET

VIEW

IN

CIRCLE

WITH AUTOMATIC

TEMPERATURE CONTROL

X

Fig. 95-Vacuum

Aducrted

VIEW

IN

CIRCLE

Deck Lid Lock

Y

23-98

button in glove box while a helper observes gauge. If

no reading can be obtained, inspect for a pinched

hose. A reading of less than leak in the system.

BODY

AND FRAME

Fig. 96-Deck Lid

Torsion

16

Bar

inches will indicate a

HINGE

Removal

(1)

Remove deck lid assembly and disengage torsion

bar from hinge (Fig.

(2)

Remove hinge to hinge bracket spring nut and

remove hinge.

/nstallation

(1)

Position hinge on bracket pin and install a new

spring nut.

(2)

Install deck lid, connect torsion bar and inspect

alignment.

TORSION

Removal

Use care when removing torsion bar as it a load. Release load from torsion bar slowly and remove from support bracket.

BAR

96)

being removed.

is

under weatherstrip contact surface of deck lid opening

WEATHERSTRIP

VIEW

IN

CIRCLE

VIEW

IN

CIRCLE

X

Fig. 97-Deck Lid Weatherstrip

(1)

Remove torsion bar (Fig.

slot.

(2)

Push bar out of roller in hinge arm and remove

from hinge support.

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 adjusting

slot.

(4)

Place lid in various open positions and test

tension.

(5)

Adjust bars until deck lid stays in open position.

WEATH ERSTR

Apply an even continuous coat of cement to entire

(Fig.

97).

Install weatherstrip, make sure weatherstrip

molded corners are correctly positioned.

I

PS

96)

from adjustment

Y

NP114

A

INTERIOR

Floor Covers

Scuff Plates

Garnish Mouldings

Glove Box

Head

Hardboard

Scuff Plates

Trim

Package Shelf and Silencer

SAFETY

SEATS

Adjustment

TRIM

................................

...............................

..........................

..................................

I

in i ng-Fa br i c

...........................

................................

Moulding and Retainer

.................................

Pa nels-l nstrument Panel

BELTS

...............................

.................................

INTERIOR TRIM

Page

..................

................

INDEX

99 99 99

102

99 101 101

99

104

111

105

AND

Cover Replacement Front Seat

Rear Seats

SEATS

..........................

Back Latch Reclining Mechanism-Bucket Type

4

Door Models

Replacement

Replacement-Back

Cushion

Station Wagon-2nd Back

Cushion

3rd

3rd Cushion

...............................

..........................

..............................

........................

................................

..............................

Back

..............................

Back and Panel

...................

..........................

Page

.........

................

111

106

107

108 108

110 109 109

109

109 109 110

A

SERVICE PROCEDURES

BODY

AND FRAME

23-99

INTERIOR TRIM

GARNISH MOULDINGS

When removing a garnish moulding that 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.

not to draw screws down too much or the moulding

will be damaged by metal stretching at the screw

holes.

Removal and installation procedures for the garnish

mouldings are covered with the related component.

is

over-

Use care

INSTRUMENT PANEL TRIM PAD

The instrument panel trim pads are attached with

1

and

2)

stud type retainers and nuts (Figs.

on

Satellite and Fury Models. On Valiant-Barracuda

Models, screws are also used at the lower end (Fig.

3).

When installing a trim panel, do not tighten nuts until trim panel has been aligned.

CONSOLE

The consoles (Fig.

ets 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. ing screws are accessible from within the console.

4)

are attached to welded brack-

All

other attach-

FLOOR COVERING

Scuff Plates

The scuff plates and extensions are retained to the

floor sills, quarter inner panels and support brackets

with metal screws. When replacement of a sill scuff plate is required, a continuous

1/4

inch bead of sealer

should be applied at the ends and outer edge.

Floor Covering

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. remove the rear floor covering it

is

necessary to re-

To

move the front seat assembly and the rear seat cushion.

Center Floor Panel (Fastback)

The center floor pan panel carpet

is

attached to a foundation with cement. The foundation is also cemented to the panel. The moulding at the forward end of panel

is

attached with screws at the front side

of moulding.

H EADLl

Removal-Fabric Type (Satellite-Fury Models)

(1)

Nl

NG

Remove rear seat cushion, dome light, bezel 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.

5,

6

and

7)

by gently forcing material up and off of retainers and while maintaining pressure on fabric, pull down and out. Work only small areas at a time.

(5)

Remove headlining at the windshield header

and from fasteners at rear window area (Figs.

(6)

Remove listing

wires

from side rail retainers

and support wire from rear listing wire (Figs.

(7)

Remove all foreign material and cement from

5

8

and

7).

9).

windshield header area and rear window opening areas.

(8)

Remove listing wires from headlining and insert

in comparable listing of new liner.

LOWER

LEFT

Fig. I --Instrument Panel Trim Pads-Satellite

NR344

installation

(1)

Trim excess listing material even with edges

headlining.

(2)

Locate centerline of lining at front and rear

ends, cut a small notch as an aid

in

maintaining head-

lining alignment during installation.

(3)

Locate and mark the centerline points of wind-

shield and rear window openings.

(4)

Center headlining at rear window and insert

rear listing wire to retainer clips on roof

sions.

rail

of

exten-

23-100

BODY

AND

FRAME

A

Fig. 2-lnstrument Panel Trim Pads4

(5)

Hook rear listing wire to wire supports (Fig.

9)

and stretch material sufficiently to remove all

wrinkles while maintaining front to rear alignment.

The

same amount of material should hang down at

both sides.

(6)

Insert remaining listing

rail retainers following same cautions as in step

(7)

Apply cement to windshield header area and

when cement becomes tacky, start at centerline area

wires

into roof side

5.

of

windshield and position headlining on cemented area.

(8)

Using a dull putty knife, secure liner on

at header area,

shield posts,

fabric seam

(9)

Locate sun visor mounting bracket screw holes

do not install material at top

making sure there are no wrinkles and

is

straight.

of

barbs

wind-

in header and cut holes in headlining slightly larger than attaching screws.

(10)

Install sun visors and tuck in corners of head-

lining at top of windshield posts.

(11)

Locate rear

visor

mirror bracket screw holes, cut holes in fabric slightly larger than screws and install mirror.

(12)

When installing headlining at

ers,

work only a small section at one time

certain seams

are

straight and material

side

rail retain-

is

to

make

free of

wrinkles.

(13)

Using a dull putty knife and working alter-

ury

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

the

outward and down

(15)

Install rear seat cushion and coat hooks.

SECTION

Fig. 3-Instrument Panel Trim Pads-Valiant-

A-A

sides.

SECTION

Bcrrracuda

B-B

NUT

NR345

A

SECTION-DD

BODY

(USED

AND FRAME

VIEW

A

WITHUMN

23-101

SHIFT)

SECTION-CC

Fig.

4-Console

(16) Locate dome light opening and cut out

suffi-

cient material for correct lighting. Install dome lamp bezel and lens.

Valiant-Barracuda Models

The headlining is attached to the windshield header,

roof

side rails and quarter panel areas with cement

only (Fig.

10).

Listing wire retainers are installed in slots in the

roof side rail and quarter panel areas (Fig.

HARD

BOARD

LINING

11).

Retainer Moulding Replacement

The individual hard board headlining sections are

held in position with semi-flexible type plastic mould-

ings (Figs.

12

and 13) forced over the retainer sections

of the roof bows. Starting at either outer end, remove

end cap and pry the moulding

off

retainer. When

SECTION-EE

NN408A

Adaptation

installing moulding make certain

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

tions, remove the windshield

mouldings and the one bow moulding at the panel inner edge.

Removal

(1)

Remove plastic mouldings (Figs.

edges of section being removed.

(2)

Using a fibre tool force liner section

bow and out of side retainers.

(3) Inspect liner section for damaged edges.

Installation

(1)

Position liner section on side retainers and

or

rear headlining sec-

or

rear window garnish

12

and

off

of

13)

at

roof

in

23-102

BODY

AND

FRAME

A

I

LISTING

WIRE RETAINER

alignment

(2)

with

Push

section up at center to seat

tainers.

(3)

Align

edges of section with moulding retainer

on roof

bows.

(4)

Install mouldings on

over ends.

/

---==+;-I

HARDTOP

*9S.A-FY

mating surface of roof

bow

retainers and caps

LIST1

1;

REAR WINDOW

SIDE RETAINER

Fig. 5-Listing Wire Retainers-Fury

WIRE RETAINER

NG

REAR WINDOW

UPPER RETAINER

bow.

it

in side

re-

Glove

The glove

15

and

Box

box

16).

Removal

(1)

Remove glove

(2)

Remove screws attaching

areas

of

opening (Figs.

(3)

Remove glove

instrument panel.

HARDTOP

is

a one piece folded

box

door (Figs.

14,

15

and

box

from under and to rear of

type

17,18

and

box

to top and side

16).

NU291

(Figs.

19).

14,

w

Fig. 6-Listing Wire Retainers-Satellite

NR347

NR346

Fig. 7-Rear Window Area Retainers-Satellite

A

4

DOOR MODELS

SUPPORT

BODY AND FRAME

VIEW ARROW A

2

DOOR HARDTOP

\

23-103

HEADLINING

u

LISTING WIRE

SECTION C-C

SECTION

Fig. 8-Headlining Application-Fury

LISTING

WIRE

B-B

SECTION A-A

NU293

VIEW

A

LISTING WIRE

Fig. 9-Headlining Application-Satellite

NR497

23-104

BODY AND FRAME

A

SUPPORT WIRE

LISTING

Fig. 1 0-Headlining Application-Valiant-Barracuda

Fig.

Installat

box

WIRE

\

SEC.

RETAINER SEC. A-A

D-D

1 1

-Listing Wire Retainers-Valiant-Barracuda

ion

(1)

From

in

rear

of instrument panel, position glove

opening, making sure screw mounting holes

SEC.

N

P575

B-B

are aligned.

(2)

Install attaching screws at sides to hold in

position.

(3)

Install glove box door assembly and attaching

screws at top.

SHELF

TRIM

PANEL

Removal

(1)

Remove rear seat cushion and back.

(2)

Remove defogger outlet and rear window side

garnish mouldings.

(3)

Loosen cemented end edges of trim panel.

(4)

Raise trim panel at front and remove retainers

from shelf panel.

(5)

Slide trim panel forward and up to remove.

(6)

Raise front edge of silencer pad and using a

putty knife separate the silencer from cement. Re-

move silencer.

(7)

Remove all cement from shelf panel.

Installat ion

(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.

(3)

Slide trim panel into position and press

re-

tainers into shelf panel holes.

(4)

Apply cement to

shelf

panel end extensions and

press into position.

rr

LAMP BRA

PANEL

RETAl NER

CKET

W

Fig. 12-Hardboard Headlining-Fury

NU292

A

Fig. 13-Hardboard Headlining-Satellite

BODY

Fig. 16-Glove Box-Fury

AND FRAME

23-105

SCREW

Fig. 14-Glove Box-Valiant-Barracuda

(5)

Install defogger outlet and window side garnish

mouldings and rear seat assembly.

SEATS

ADJUSTMENT

To

raise

or

7

lower the front seat (Figs.

~TEREO

Y

CROSSOVER

Fig. 15-Glove Box-Satellite

20,21

\--/---

SCREW

and

\?a\

N

R498

22)

Fig. 17-Glove Box Door-Valiant-Barracuda

loosen the adjuster mounting bolt nuts, under the

or

floor pan, and remove

adjuster base and

To

move seat “fore

Fig. 18-Glove Box Door-Satellite

floor

install shims between the

pan.

or

aft” reposition the adjuster

NR349

23-106

BODY AND FRAME

A

BUMPER-

Fig. 19-Glove

mounting bolts provided at each mounting bolt area.

in

the adjuster

Box

-

Door-fury

base.

NU187

Three holes are

FRONT SEAT

All two door vehicles having split back bench type

seats incorporate latches to prevent the seat back falling forward. latch assembly (Fig. the pivot pin.

Removal

(1)

Remove snap ring and flat washer from pivot

pin.

(2)

Remove end

latch assembly.

(3)

Remove spring from groove

(4)

Remove knob and cliD from end

BACK

To

LATCH

move seat back forward, move the

23)

until clearance

of

spring from latch and remove

of

pivot pin.

of

is

obtained at

latch.

e

ALLEN SCREW

Fig. 204ront Seat Adjuster-Valiant-Barracuda

SEAT FRAME

SPACER

RELEASE LEVER

I

ALL'EN

SCREW

FLUUK

Fig. 2 1

CENTER CUSHION

PAN

-Front

Seat

FLOOR PAN

Adjuster-Satellite

%A

,-

BUCKET SEAT' NU96

A

BODY

AND FRAME

23-107

Fig. 22-Front Seat Adjuster-Fury

installation

(1)

Position spring on pivot and align inner

end

of

spring in pivot groove.

(2)

Install latch assembly on pivot pin and

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.

RECLINING SEAT MECHANISM

For

ease of assembling, the following procedures

should be performed in sequence as listed.

VIEW

IN

CIRCLE

"A

insert

Bucket

Type

(1)

Insert adjuster assembly into rear of seat back

(Fig.

24)

with clevis end of adjuster over the bracket and rod end protruding through hole in bottom facing of seat back.

(2)

Align holes af adjuster clevis end with holes

in

bracket on seat back and secure with spring pin.

(3)

Push release handle shaft, from inside, through

hole in seat back.

Fig. 23-Front

Seat

Back Latch

NR291

Fig. 24-Reclining Seat Mechanism-Bucket

Type

23-108

BODY AND FRAME

A

(4)

Hook release handle on release wire and posi-

tion assembly on handle shaft.

(5)

Install spring washer and retaining ring on re-

lease shaft.

(6)

Position pivot brackets on seat back into stan-

chions on base assembly and secure with spring pins.

(7)

Position rod end of adjuster in base assembly

stanchion and secure in place with spring pin.

(8)

Assemble seat back, cushion, back stop bumper

and outer shield.

(9)

With seat back in upright position, compress adjusting clip to free release spring, press release handle down as far as possible.

(10)

Insert a

.060

inch shim between the cam and adjuster washer and pull release lever down until cam presses shim against adjuster washer.

(11)

Release adjusting clip and remove shim.

(12)

Test operation of mechanism.

(13)

Push seat back forward and pull seat material flap over base and attach with a hog ring to back of seat.

4

Door

Make certain spacer

juster assembly (Fig.

Models

is

installed on rod end of ad-

25),

otherwise seat cannot

be

assembled.

(1)

Insert adjuster and cable assembly into rear of seat back, with clevis end on bracket and rod end protruding through hole in bottom facing of seat back.

(2)

Route cable between edge of bottom facing and

Do

not

use

hole

back spring frame of seat back.

adjuster rod.

(3)

Position adjuster clevis end in bracket on seat

for

back and secure with spring pin.

(4)

Position seat back on cushion, with shoulder

SEAT BACK

\

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

of

handle, slide eye

adjuster cable over pin and fasten

with cotter pin.

(9)

Slide retaining clip over cable housing and fas-

ten to side of seat cushion with two screws finger 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 remove all slack.

(11)

Tighten screw to lock sheath in retaining clip

and remove shim.

(12)

Raise seat back to upright position and remove

spacer from rod end of adjuster.

(13)

Test operation of mechanism.

REPLACEMENT

Front

seat frame.

ers

mounting bolts, under

and remove seat.

Seat

The front seat cushion

All

seat frames are attached to the adjust-

is

an

integral part of the

by studs and nuts. Remove nuts from adjuster

floor

pan (Figs.

CUSHION

1

20, 21

SEATBACK

and

22)

Fig. 25-Reclining

Seat

Mechanism-4

SPRING

WASHE

Door

Models

Fig.

26-Rear

Seat

Cushion and Back

A

Rear Seat Cushion

The rear seat cushion

is

held in place (Fig.

26)

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 brackets welded to the floor pan.

BODY AND FRAME

23-109

Rear Seat

The rear seat back (Fig.

Back

26)

is held in place by 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 metal straps

which are attached to mounting brackets welded to

the rear floor pan.

Station Wagon-Second

Seat

Back

Removal

(1)

Remove screws attaching seat back to hinge as-

semblies (Fig.

(2)

Release catches from seat back and remove

27).

assembly.

lnsfallation

(1)

Position seat back on hinge assemblies.

(2)

Install hinge to seat back screws.

(3)

Test engagement of seat back catches and ad-

just as necessary.

Second Seat Cushion

Removal

(1)

Raise rear floor hinged panel at rear of seat

cushion assembly (Fig.

28)

to expose seat cushion

to

floor pan attaching screws.

(2)

Remove screws attaching cushion to

(3)

Move cushion slightly rearward to disengage

floor

pan.

locking bars at front bottom side of cushion and remove cushion.

lnstallation

(1)

Place cushion in position, making certain lock-

Fig. 28-Second

Seat

Cushion

ing 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.

Third Seat

Back

Removal

(1)

With third seat back in the UP position (Fig.

29)

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.

lnsfallation

(1)

Position back cushion on back panel and install

retainer screws.

(2)

Position seat back and support panel assembly

on hinge links and install retaining screws.

Fig. 27-Second

Seat

Back

Fig. 29-Third

Seat

Back and Cushion

23-110

BODY AND FRAME

A

Cushion

The third seat cushion (Fig.

are

hinges which in turn

attached to the quarter in-

29)

is

ner panels by screws.

Removal

(1)

Remove screws attaching hinges to quarter in-

ner panel.

(2)

Remove rear seat cushion assembly.

lnsiallaf

(1)

(2)

ion

Position cushion assembly on

rear

floor

Install hinges on quarter inner panel and tight-

en securely.

(3)

Test seat operation, inspect

fit

and alignment.

REAR SEAT BACK (BARRACUDA)

Hinge

The rear seat back hinge assembly (Fig.

attached to

pan.

30)

is

at-

tached to the seat back frame and over end release rod. The cam bearing

is

positioned on release

of

the

rod and into lower hole in hinge assembly. The cam

is

pressed into the release bearing and secured with

a screw.

Lock Mechanism (Fig.

30)

Disassembly

(1)

Remove release handle cover and screws.

(2)

Remove handle bumper and knob.

(3)

Rotate release handle in clockwise direction

and disengage handle release spring.

(4)

Remove handle link clips and link.

(5)

Remove set screw securing release

rod

assem-

bly to the release mechanism.

(6)

Remove release rod, lever and bearing.

(7)

Remove nut attaching handle to back panel and

remove handle assembly.

Fig.

30-Rear

Seat

Back

Hinge-Barracuda

b

BODY

AND FRAME

23-111

(8)

Remove sleeve, spring and bolt from handle.

Assembly

(1)

Lubricate areas contacted by mechanism.

(2)

Assemble handle loosely with bolt and spring to

bracket on back panel.

(3) Assemble sleeve to handle and tighten handle

nut.

(4)

Partially assemble release rod to panel through hole in seat frame right side against stop with lever and bearing.

(5)

Complete rod installation through hole in bracket and insert spring nut onto rod.

(6)

Push rod through hole in seat frame left side

against stop.

(7)

Nest bearing into bracket and lever into bearing.

(8)

Secure with set screw.

(9)

Assemble clips to release handle and lever.

(10) Assemble link to clips after rotating release

handle clockwise to engage spring.

(11)

Assemble knob to handle and install screw.

(12) Install handle bumper on bracket and cover

on back panel with screws.

Cover Material Installation

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 and medallions (where are pulled down securely and locked in position.

used)

As an aid in attaching the cover correctly, mark the areas on the spring where the original cover was

or

attached with hog rings, screws

drive nails.

SAFETY BELTS

Refer to Figures 31 through

areas of attaching the safety belts.

44

for methods and

POWER SEATS

Refer to the Electrical Group for tests, wiring dia-

grams and complete servicing procedures.

CENTER SEAT

BRACKET AND PLATE

INNER SHOULDER BELT-TIP END

(EXCEPT CONVERTIBLE)

INNER LAP BELT-BUCKLE END

CENTER LAP

BELT

(Wl'

IH CENTER SEAT)

-

I

.m

Lnr

BRACKET (SINGLE)

n,,rw,..

DUCKLE

VIEW IN CIRCLE

LAP BUCKLE BRACKET

(DOUBLE)

ALL BUCKET SEAT APPLICATIONS

(EXCEPT WITH CENTER SEAT)

V

(L

2

(ALL

BENCH

SEAT

APPLICATIONS)

ON1 SEAT LAP

OUTBOARD

BELT

Fig.

VIEW IN CIRCLE X

3

1

-Front Seat Lap Belts-Valiant-BarracudaSatellite

VIEW IN DIRECTION

OF

ARROW

Y

NU21

23-112

BODY AND FRAME

HEADLINING

\

A

VIEW

IN

CIRCLE

Fig.

CTC

CIRCLE

2

32-Front

DULI

Y

Sour

Shoulder Belts

BELT

(Except

SHOULDER BELT

SHOULDER

VIEW

IN

OF

ARROW

Convertible)-Satellhe

,

ANTI-RATTLE WASHER

BELT

DIRECTION

Y

'""

/

SCREW

NU26

SHOULDER

Fig.

33-Front Seat Shoulder Belts fConverttble)-Satellhe

BELT/

REAR

LAP

WASHER

BELT

NU18

A

Fig.

34-Rear and third Seat Lap Belts-Satellite

BODY

AND

3RD

FRAME

.

SEAT

NU20

23-113

Fig.

35-Front Seat Shoulder Belts (Except

Convertible)-Valiant-Barracuda

23-114

SHOULDER BELT SHELF PANEL

BODY AND FRAME

A

W

VIEW

IN

CIRCLE

SILENCER PAD

SHOULDER

WHEELHOUSE

VIEW

IN

CIRCLE

Y

STATION WAGON SEDAN-HARDKP FASTBACK NU23

Z

Fig.

36-Rear Seat Shoulder 6elts-Satell;te

BELT

EINFORCEMENT

OUTER LAP BELT

VIEW

IN

CIRCLE

SHOULDER

X

BELT

Fig.

37-Rwr

NU22

Seat Shoulder Beltr-Valiant-Barracuda

A

SHOULDER BELT

I

BODY

ANT)-RATTLE WASHER

AND

FRAME

23-115

Fig. 38-Front Seat Shoulder Belts (Convertible)-

Barracuda

NU25

Fig. 39-Front Seat lap Belts-Fury

23-116

BODY AND FRAME

SPACER

\

WASHER

/

IN

DIRECTION

ARROW

OF

Z

ANTI-RATTLE WASHER

FLOOR PAN

VIEW

IN

CIRCLE

A

Y

NU19

Fig. 40-Rear

VIEW

IN

OF ARROW

Seat

Lap Belts-Vallant-Barracudu

DIRECTION

Y

I

STUD

Fig.

41-Front

Seat Shoulder Belts (Except

Convertible)-Fury

VIEW

IN

CIRCLE

Z

NU470

A

STOWAGE

B

RACKETS

SHOUL

SPACER

ANTI-RATTLE

BODY AND FRAME

(THIRD SEAT)

WASHER

23-117

OF

ARROW

(2ND SEAT ONLY)

Z

Fig.

42-Rear

and

3rd

VIEW IN CIRCLE

SECOND SEAT

IN BOARD I NSTALLATION

Seat

Lap

Belts-Fury

X

VIEW IN

CIRCLE

NU472

Y

23-118

VIEW

IN

CIRCLE

BODY

Y

AND FRAME

.DER

BELT

SHOULDER BOLT

VIEW

IN

CIRCLE

Z

A

ANTI-RATTLE

WASHER

NU473

Fig. 444ront

Seat

Shoulder

WINDSHIELD AND

INDEX

Page Page

REAR

WINDOW

Polysulfide Adhesive Sealed Type

Weatherstrip

WlNDSH

I

Convertible

Type

...........................

ELD

.................................

............

122 Satellite 122 Va

118

SERVICE PROCEDURES

WINDSHIELD AND REAR WINDOW

FURY

hesive sealed (cemented-in) types. Service procedures for the two glass are comparable.

ensure a permanent watertight glass installation, use only the recommended adhesive sealer kit or its equivalent.

MODELS

The windshield and rear window are polysulfide ad-

Short cut sealing methods should not be used.

To

REPLACEMENT

Belts

(Convertible) Fury

REAR

Fury

WINDOW

.......................................

....................................

I

i

ant

.....................................

120

121

120

hesive material by pulling wire, in a sawing motion, up one side, across top, down opposite side and across bottom (Fig.

(6)

With an assistant, remove glass from opening

if

and

original glass is to be reinstalled, place on

1).

a protected surface.

(7)

All old adhesive should be removed from glass

and opening reveal using a putty knife

DO

NOT

blade.

adhesive.

use an oil base solvent

or

razor

to

remove

/.

Removal

(1)

Place protective coverings over the areas adja-

cent to the glass being replaced.

(2)

Remove window exterior mouldings using Tool

C-4009

steel wire

and inner garnish mouldings.

(3)

Secure one end of a two foot length of tempered

(.028

gauge max.) to a wooden handle.

(4)

Insert other end of wire through adhesive at lower corner of window and secure to another wooden handle.

(5)

With an assistant, carefully cut through ad-

x

/CUTTlF

ADHESIVE CAULKING NP188

Fig.

1

-CuWlng Adhesive Caulklng

/

A

(8)

Using steel wool, remove loose flakes of adhesive and old primer from reveal. Use light air pressure to clean reveal and surrounding areas.

lnstallation

(1)

Inspect moulding retaining clips. Remove and straighten clips bent more than

1/32

inch away from the body panel. Use block self-sealing screw-on type clips when necessary to replace. All clips must be

attached lightly.

(2)

Inspect rubber spacers in window reveals when

replacement of spacers

is

required, make certain they

are positioned in the exact areas removed from.

(3)

Clean interior surface of glass.

to clean the glass interior surface after installing glass and before adhesive has set up may result in

glass being pushed out of opening.

(4)

Install spacer dam

so

positioned

surface (Fig.

(5)

Attach suction cups to glass outer surface and

it leans toward edge on glass inner

2).

1/4

inch from edge and

Hand pressure

position glass in opening.

(6)

Inspect relationship of glass to fence completely 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.

(7)

Apply a piece of masking tape over each side

of glass and roof extensions. Slit tape vertically at

so

edge of glass

when glass is installed, tape on glass

can be aligned with tape on body.

(8)

Remove glass from opening and place on a

protected surface, with inside surface up.

(9)

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.

(10)

The adhesive begins to cure immediately upon exposure to air. The working life proximately as quickly as possible.

15

minutes. Perform the following steps

is

limited to ap

BODY AND FRAME

Fig. %Adhesive Application to Glass

(11)

Insert adhesive tube into a standard household

23-119

NP189A

caulking gun, install nozzle on end of tube, and puncture adhesive seal at nozzle.

(12)

Apply a smooth continuous

3/8

inch bead of adhesive on glass between glass edge and spacer dam (Fig.

(13)

3).

When positioning glass in opening, alignment must be exact to prevent necessity of moving glass after adhesive contacts fence.

(14)

With an assistant and using suction cups on glass,

certain glass will set on rubber spacers and install

glass in opening (Fig.

align tape on glass with tape on body, make

4).

(15)

Press glass

lightly

to adhere adhesive to fence

flange.

(16)

Run a flat wooden or fiber tool around entire edge of glass to force adhesive into opening between edge of glass and reveal.

(17)

Close car doors gently, do not slam

test window. Use a cold water spray,

heavy stream of water directly on freshly applied adhesive.

If leaks are evident, work applied adhesive

and water

do not run

a

Fig. 2-Spacer Dam lnstallation

NP185

Fig. 4-Window lnstallation

23-120

BODY AND FRAME

A

UPPERAND SIDE

Fig. 5-Windshield Outer Moulding-Satellite

R

VIEW A

-

into leak point. Additional material can be applied and worked into leak point.

(18)

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 pressure could

up

in

build

of

the opening.

a closed car to force the rear window out

WINDSHIELD

REPLACEMENT

Valiant-Barracuda-Satellite

Fig. 7-Windshield Weatherstrip-Satellite

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 wind-

shield, exert pressure, from inside car, to force wind-

shield 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

or

without burrs

(8)

Inspect weatherstrip for damage.

(9)

On Valiant-Barracuda Models

high spots

be

straight, smooth,

inspect weather-

strip lower filler strip.

Removal

(1)

Cover cowl, hood and fender area with a protec-

tive covering.

(2)

Remove windshield garnish mouldings.

(3)

Remove windshield outer mouldings (Figs.

and

6)

using Tool C-4009.

(4)

Unlock weatherstrip (Figs. 7 and

lip

of weatherstrip apart, inserting a fibre wedge, and

Fig. 6-Windshield Outer Moulding-Valiant-

--

MOULDINGS

Barracuda

8)

by prying

lnstallation

(1)

Remove all old sealer and cement from original

weatherstrip.

(2)

5

Apply sealer

of weatherstrip.

Fig. 8-Windshield Weatherotrip-Valiant-Barracuda

in

fence

and

glass groove portions

On Valiant-Barracuda

Models

install

A

filler

strip in lower part of weatherstrip.

(3)

Apply a

3/8

inch bead of sealer cement com-

pletely across cowl top panel lower windshield frame

area (Fig.

(4)

9).

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 upper 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, and completely around weatherstrip to seat glass in place.

(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

blades.

(12) Install garnish mouldings, wiper arms and

remove protective covering.

Convertible Models

Removal

(1)

Cover cowl, hood and fender area with a protec-

tive 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 (Fig.

(5)

Remove inner

(6)

Remove sun

trim cap

to

header.

(7)

Pry header moulding up slightly to clear mould-

-/

“A”

post side mouldings.

visors

and screws attaching header

10).

BODY AND FRAME 23-121

HEADER

LOWER MOULDINGS

ing from weatherstrip, disengage from header and remove.

models.

lnstallation

scribed for other models, then continue as follows:

weatherstrip, force moulding against weatherstrip,

and press rear edge down over header.

lightly tap with a rubber hammer to seat. Be sure cap

is

post moulding.

shield.

MOULD1

SEAL

WASHER

NN413

Fig. IO-Windshield Mouldings-Convertible

(8)

Remove windshield in same method

Install windshield (Fig.

(1)

Position header cap moulding up against

11)

in same manner as de-

as

other

(2) Install screws loosely to hold in position and

evenly spaced across header.

(3)

Tighten screws securely.

(4)

Water test windshield area.

(5)

Install windshield outside mouldings and

(6)

Install sun visor, wiper arms and clean wind-

LOCKING

TAB

“A”

-

SECTION

B-B

Fig. 9-Windshield Installation

Fig.

/’

J

I

-Windshield Installation-Convertible

NR137

23-122

BODY AND FRAME

A

SIDE AND

UPPER

MOULD1 NGS

LOWER

MOULDINGS

-_

Fig. 1 2-Rear Window Mouldings-Valiant-Barracuda

NR352

REAR WINDOW

POLYSULFIDE ADHESIVE SEALED TYPE

WINDOW

Satellite

Refer to the Fury windshield and rear window service procedures for replacement of the rear window.

Models

>/

MOULDING

VIEW

IN

CIRCLE

Fig. 13-Rear Window Weatherdrip-Valiant

HARDTOP

MOULDING

Z

6

VIEW

WEATHERSTRIP

IN-CIRCLE

v

NR505

W

EATH E RSTR I P TYPE

Removal

(1)

Place a protective covering over deck lid, quarter panel and rear window areas. Remove rear window mouldings (Fig.

(2)

Using a fiber wedge, unlock weatherstrip by prying weatherstrip apart and with a slight

move wedge around weatherstrip.

(3)

With an assistant supporting glass on outside, from inside car, push against glass at one of the upper corners and remove glass from weatherstrip.

(4)

Place glass on a cloth covered bench.

(5)

Remove weatherstrip from fence.

lnstal

clean, smooth and straight.

I

ation

(1)

Inspect weatherstrip fence to be certain

(2)

Flow a continuous ribbon of cement on each lip

REPLACEMENT

12)

using Tool

C-4009.

twist

it

is

CONVERTIBLE

INDEX

Page

ADJUSTMENTS

Cam

........................................

Control Door and Glass Alignment

Header

Link

................................

....................

.....................................

126 Latching Mechanism 125 Major

124

125

t

?

VIEW

IN

CIRCLE

Y

Fig. 14-Rear Window Weatherstrip-Barracuda

and around entire length of weatherstrip glass groove.

(3)

Install weatherstrip (Figs.

sure it is fully seated on fence.

(4)

With an assistant, position rear window in

weatherstrip.

(5)

With palm of hand, tap rear window glass

make certain it

(6)

Insert a fiber tool and working around weather-

strip, force locking tab into locked position.

(7)

Water test rear window area.

(8)

Install window mouldings, clean glass and

move protective covering.

Hi

nge-Front

is

fully seated.

...............................

13

and 14) making

........................

......................................

Minor

Roof

......................................

Side Rail Alignment

....................

.......

to

re-

Page

125 125 123 123

123

A

BODY AND FRAME

23-123

Shifting

Stack Height

COVER REPLACEMENT

ELECTRICAL TESTS FOLDING MECHANISM OPERATING THE TOP

REAR CURTAIN

Top

........

.......

...

.......

.......................

.

.......................

Page

.

126

.

126

.

127

.

126

.

123

.

123

SERVICE PROCEDURES

OPERATING THE TOP

Raise or lower top only when vehicle

still.

To Lower Top

Release safety catch, pull handle down and push

top free of the header.

Be sure the well compartment is free of articles.

Operate engine in neutral slightly above idle and hold

switch control to the

Down

position until top

lowered.

To

Raise Top

Remove boot, operate engine in neutral slightly

above idle and hold switch control in the

As dowels seat in their sockets, pull header down

firmly and push locking handles forward until catches engage.

is

standing

Up

position.

is

fully

RESERVOIR

DO

NOT

add fluid to a reservoir until it is installed

in

in its normal position

the reservoir in a position other than its normal in-

stalled position does not allow for fluid expansion and

damage

filling reservoir, raise and lower top several times to

expel air that may be trapped

to

the reservoir may result.

Measure fluid level only when top

Insufficient fluid in the system may cause slow rais-

ing

or

noise in the pump and motor. Measure fluid level and if low, look for a leak due to a broken line or a loose connection. Fill reservoir (use only AQ-ATF

“A”

Suffix

“Dexron” type transmission fluid) until

fluid runs out of filler hole.

the vehicle. Adding fluid to

is

lowered. After

in

system.

RESERVOIR STAY STRAPS WEATHERSTRIPS

Header

Roof

Side Rail

..................................

.....................................

Seals and Sealers

WELL LINER

..................................

................................

.............................

...............................

..........................

Page

123 126 127 127

127

ADJUSTMENTS

Minor adjustments

ing the top header 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 alignment 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 adjustments are necessary to improve roof side minor hinge and header adjustment do not completely correct the condition.

Roof Side Rail Alignment

The roof side rail structure (Figs. sists 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 vent wings, door and quarter glass to provide a good weatherseal. Alignment of the rails is controlled by the side rail structure mounting support assembly (Figs.

7),

cam, control link and the front hinge set screw

2,

3

and

(Figs.

PUMP

4).

AND CYLINDER

are provided to assist in align-

rail

LIFT

alignment

2,

3

and

-1J

5,

I

4)

con-

6

if

and

FOLDING TOP MECHANISM

The electric-hydraulic top folding mechanism (Fig.

1)

consists of two cylinders, a piping system, an electrict motor, a pump and reservoir assembly, and a double-throw rotary switch. The wiring and motor are protected by a separate external circuit breaker.

The cylinders The reservoir end plate pump cover plate rotors are serviced as a package with the

are

serviced only as an assembly.

“0”

ring

is

replaceable. The

is

serviced as an assembly and the

“0”

rings.

Fig.

I-Folding

lop

Mechanism

NU484

23-124

BODY

AND

FRAME

MOUNTING PLATE

SUPPORT4

VIEW

A

C

Fig.

The front hinge set screw on

Fury

2-Side

models

is

Rail

ac-

cessible only from the top of the side rail assembly

the

behind

SECTION

hinge.

A-A

B-B

NU483

Structure-Fury

DoorandGlassAlignmen,

After making top adjustments, doors, vent wings,

door glass and quarter glass must be properly aligned. Misalignment in any of these areas make it impossible

from

to obtain satisfactory results

top adjustments alone. Glass up-stop adjustments should be made after the correct roof ward travel ing between the roof

side

rail alignment to limit the up-

of

the glass and to assure effective seal-

side

rail weatherstrip and glass.

Fig.

%Side

Rail

strmu&Hdrtt.

NN7l9A

Fig.

4-Side

Rail

Structura-8arracuda

b

FOLDING TOP ASSEMBLY

BODY AND FRAME

23-125

NU485

Fig.

5-Mounting Plate Attachment-Fury

Latching Mechanism

Good sealing at the frontal area

is

dependent upon

proper positioning of the top header on the windshield header. The header locating nylon wedges are positioned in the latching mechanism housings and engage sockets in the windshield header to correctly

position header.

The latch hook should be adjusted to provide proper compression of the outer weather seal on the folding top header.

The locking and unlocking effort of the latching mechanisms are adjustable. Adjust the header catch to show five of six threads for initial setting.

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 attached

to

the side rails by two screws on each side

is

I

Fig. 7-Mounting Plate Attachment-Barracuda

(Figs.

2,

3

and

MOUNTING

4).

PLATE

NP525

Incorrect alignment between the top header and windshield finish mouldings may result in leakage, making models) or dowels (Satellite-Barracuda models)

it

difficult to engage the nylon wedges (Fury

in

their sockets or cause objectionable locking and unlocking effort. Inspect clearance for uniformity. The nylon wedges control the fore and aft position of the folding top header.

To eliminate interference between the header and finish moulding, rotate the cams on the side rail the cam lobes are forward.

lengthen the control links one or two serrations after the cam adjustment.

If cam lobes were already in the

It

may be necessary

so

to

full forward position, it may be necessary to loosen

the header-to-side-rail screws and adjust header to provide proper clearance.

Front Hinge Adjustment

To

facilitate front hinge adjustment, unfasten

header latches and partially lower the top before ad-

i

usti ng 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.

is

shows leakage

due to incorrect side rail alignment

If

inspection

at the front hinge, adjust set screw until front and center side rails provide the proper glass line. When the rails sag, it indicates the control link is too long.

MOUNTING PLATE

Fig.

6-Mounting Plate Attachment-Satellite

\

NP526A

Control Link Adjustment

The control links incorporate serrated adjusting links. Loosen screws just enough to permit 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. Tighten screws while

rail assembly is held in the position described above.

23-126

BODY AND FRAME

Cam Adjustment

The cam assembly (Figs. 2 and

8)

is

used to change

top header position in relation to the windshield head-

er.

The cam turns 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

is

the high side mum and when turned rearward the angle

creased. An increased angle increases the forward

"throw" of the entire top assembly.

fully forward, the angle

On Fury models, the cam lobe position

rails.

When

is

at the mini-

is

indicated

is

in-

by a single triangular mark on the cam. Three triangular marks on the side rail (all models except

Fury)

indicate the amount of cam rotation when ad-

justing. The marks are located at the full-forward

position of the high side, grees up. When adjusting,

45

degrees up and

the

cam high side position

90

de-

can be determined by referring to the notch and the triangular marks. Before adjusting, place top

raised position to remove all possible strain

cam. Make sure lock nut

is

loose. Tap cam threaded

in

off

half

the

end with a soft-faced hammer to loosen any paint

bond between cam and linkage.

On

Fury

models, the cams are adjusted in

45

de-

gree increments only.

A

\

STAY STRAP

Fig.

'\

*TACK

GSTAPLE

9-Siay

Straps-Fury

NU482

stack height after raising and lowering top.

Top Shifts

If

necessary to pull top to one side to engage locat-

ing dowels or wedges,

To

One Side

or

top shifts to one side when raising from the windshield header, inspect positions of control links. It may

necessary to adjust

the

be

control links unevenly to achieve proper alignment of the top.

Stack Height

Do

not move mounting plate positions until control

links have been adjusted.

Stack height should

have been adjusted as outlined.

be

correct

if

the control links

If

control link adjust-

ment does not correct stack height, loosen lower two

the

of

three mounting plate screws (Figs.

5,

6

and

7).

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

VIEW

IN

CIRCLE

/

NP

274

stay straps

Two

web straps attached to the

tacking strip are provided to keep

rear

bow

the

number 3 bow

and

the

from moving forward and wrinkling the top material. The

straps are attached to the tacking strip with

9

and

tacks and staples (Figs.

10).

ELECTRICAL TESTS

Refer to the Electrical Group

diagrams.

for

tests

and

wiring

NP524

Fig.

8-Cam

Assembly-Barracuda-Scrtellita

Fig.

I

0-Stay

Sirups-Barraeuda-S~efl~e

A

BODY

AND FRAME

23-127

WELL LINER

The well liner (Fig.

panel belt area tacking strip with stud snap-on type

fasteners.

When installing liner, ment to the front face of liner lower edge approximately two inches wide at area where liner attaches to upper face of rear seat back support. Apply ce-

ment to area contacting wheelhouse cap.

11)

is

attached to the quarter

apply a thin coat of ce-

WEATH ERSTRl PS

Roof Side

After roof side

rail weatherstrip to make seal at top of door and quarter glass.

If

justed. The retainer has elongated attaching screw

holes. Raise glass until top edge

weatherstrip inward just enough to contact inner lip.

Adjust up-stops to limit further upward travel of glass.

Top

Header Front Weatherstrip and Welts

Leakage between the top and windshield headers

is eliminated

and

13)

The forward edge of weatherstrip contacts the wind-

shield header outside moulding. On Satellite-Barra-

cuda Models, a rubber welt

flange.

Rail

rails

have been aligned, inspect side

sure

it

is

providing a good

not sealing properly, the retainer can

of

curls outer lip of

by

a tube type weatherstrip (Figs.

secured to the underside of the top header.

is

cemented to the header

TUD FASTENERS

be

ad-

12

RET4INER

NK970

A

Fig. 12-Header Front Weatherstrip-Fury

Seals and Sealers

Clean all areas thoroughly, before installing

weatherstrips and

When repairing

seals.

or

replacing a seal

or

weatherstrip

at the header and pillar areas, make certain they are

firmly seated, in correct alignment and free of twists.

COVER REPLACEMENT

Procedures for attachment at the top header and rear bow areas the same for Fury-Satellite-Barracuda models.

Removal

Inspect weatherstrips for damage

wear before removing the top cover. Test adjust-

ment of rear tension cables cover cables for being correctly connected and stay pads for excessive wear

or

of

the cover material

are

or

web straps. Inspect

moisture stains.

basically

excessive

Fig. 1 1-Well Liner

TACKING STRIP

SEAT BACK SUPPORT

/

VIEW

IN

CIRCLE

N

Fig. 13-Header Front Weatherstrip (Except Fury)

P523

23-128

(1)

BODY AND FRAME

Place protective covers over deck lid, upper

panel, hood and cowl areas.

(2)

Remove staples, attaching moulding retainer to

roof bow and remove retainer.

(3)

Using a sharp pointed tool remove staples and

tacks at rear bow.

material if original cover instances the staples ends may have become peened

over and if excessive effort

them, it pieces after cover has been removed, otherwise damage to the material may result.

(4)

each

is

advisable to cut the heads

Remove staples and tacks (one tack used on

side)

at binding areas attaching cover to the rear

Use care not to damage top

is

to

be

reinstalled. In some

is

required to remove

off

and remove

bow.

(5)

Remove the top boot.

(6)

Prop the top move moulding from top header. taching screws

(7)

Raise top of

off

of windshield header and re-

The

moulding at-

are

located under the weatherstrip.

the

1/2

open position and remove rear roof rail weatherstrip. Mark location of retainer screws on roof rail to aid in reassembling, and remove retainer.

(8)

Remove top and rear curtain material from

roof rail.

(9)

Raise top completely and remove trim in well area to permit removal of top material from tacking strips (Figs.

(10)

14,

15

and

16).

Remove staples, drive nails and tacks attaching

material to the header.

(11)

Mark location of top material bead on ends of

cover pads.

(12)

Loosen vent wing seals at the corners.

(13)

Remove front screws from front roof rail

weatherstrip retainers

ing flaps (Fig.

17)

and

remove top material lock-

from between retainer and

roof

rail.

TOP

eClmC

wm

ASSEMBLY

CTDlD

VlFW

7

TOP

ASSEMBLY

#

. . . _. . .

-

A

TACKING STRIPS.

NP564

Fig.

1

%Cover

(14)

Remove tension cables and attaching bracket assembly (Fig. bow.

If

original cover

17)

Tacking Strips-Satellite

at front roof rail and number

is

to be reinstalled tie a cord to

3

roof

one end of cables prior to removing. When cables are

be

removed, the cord should

left in listing to aid in

reinstalling cables.

(15)

Remove cover from folding linkage.

installation

Prior to installing cover, inspect bow pads moisture bows. The cover stay pads should damage and moisture.

is

attached to the

(1)

or

damage. The pads are a press fit in the

be

inspected for

The

backlight zipper top half

rear

bow

with

staples.

Insert cables in cover listings. Use cords to in-

for

stall cables in original cover.

(2)

Locate and mark center line on top header,

bow and at each end

(3)

Position cover on folding top structure.

(4)

Align center line marks on cover with marks

of

new cover.

rear

on structure.

(5)

Block top header

off

the windshield header ap-

proximately four inches to relieve all tension on

is

cover when it

(6)

Install cover on tacking strips with tacks spaced

approximately

(7)

Pull material into position at corner of wind-

being installed in the well area.

6

inches apart.

shield header and align cover bead with alignment mark on pad end.

Fig.

14-Cover

II

Tacking Strips-Fury

SIDE

NU481

STRIP

Fig. 1 &Cover

Tacking

-1

NP563

Strips-Barracuda

A

BODY

AND

FRAME

23-129

NU479

Fig. 17-Cover Locking Flaps and Tension Cable

(8)

Tack covers in position at corner and bead area

only. Space tacks approximately one half inch apart.

(9)

With cover in position at quarter panel and

center line marks in alignment, tack cover to corner

and bead area of roof bow only (Fig.

(10)

Repeat steps

(11)

Connect cover cables and brackets, lock header

in place and inspect

7, 8

and 9 on opposite side.

fit

of cover at rear bow and top

18).

header.

(12)

Raise top to one half open position and apply a

bead of rope type sealer to back of rear roof rail

weatherstrip retainers.

(13)

Apply cement to rear roof rail and between

fit

rear curtain and top cover at area where they

on

roof rail and position on rear pillar.

(14)

Position weatherstrip retainers on roof rails and using a sharp pointed tool align screw holes in curtain and cover material with holes in

to

On new covers use tool

(15)

Install retainer screws and weatherstrips. Raise

make holes in cover.

roof

rails.

top completely and lock into position.

(16)

Open and close both front doors several times

fit

of

and inspect

cover in relation to top of door glass

and vent wings. Should either vent wing or door glass

contact beading on edge of cover on one side, the cover may be loosened at the header and moved slightly toward the opposite side until clearance obtained. Should contact at both doors be made, it

is

will

be necessary to build up cover pads on both sides to

eliminate interference.

(17)

While keeping center line

in

alignment, tack one half of cover to the header.

of

cover and header

SECTION

COVE,R MATERIAL

Fig. 18-Tacking Cover

6-6

STAPLES

at

No.

3

SECTION

SEC

Roof

6-6

NU478

Bow

Space tacks approximately one inch apart.

(18)

Install a drive nail at lower front edge of cover and one long tack through cover beading to the header.

(19)

At rear bow on same side, make certain center

line

marks

of

cover and bow are in alignment and

tack cover into position spacing tacks approximately

1/4

inch apart. Install a large tack through cover

beading at rear bow.

(20)

Complete tacking of cover at tacking strips,

1/4

spacing tacks

(21)

Repeat steps Inspect alignment of cover and plete tacking operation at the header.

all wrinkles are removed at header during tacking operation.

Do

Tacks should be installed approximately

inch apart.

17, 18

not allow cover material to lap over.

and

19

for opposite side.

if

satisfactory com-

Make sure

1/8

inch

apart.

(22)

Position locking flaps at front outer edge

of

cover between weatherstrip retainers and front rail. Install retaining screws and weatherstrips.

(23)

Use

care not to allow cement outside

ing strip area

and apply cement across tacking area,

making sure each tack

(24)

Apply cement between outer edge and header.

(25)

Press

cover firmly down on header.

Position header moulding retainer on header

is

completely covered.

of

tack-

cover

Align moulding retainer clips with holes in header and install screws.

(26)

Apply cement to vent wing seals and press into place.

(27)

Apply cement to header weatherstrip, where loosened to expose moulding attaching screws, and press firmly into place.

(28)

Use care not to allow cement to extend outside

of

the tacking area

and apply cement to tacking area on rear bow making certain each tack is completely covered.

23-130

(29)

slightly narrower than width of moulding retainer across tacking area.

(30) (31)

ing in retainer from either end and install end caps.

BODY

Apply sealing tape, same color as cover, and

Install moulding retainer over tape. After retainer has been installed, insert mould-

AND FRAME

Press

firmly into place.

SEALING

INDEX

A

(32)

Position mouldings on quarter panels and rear

window moulding retainers and install snap retainer

Do

and screw assemblies.

(33) Test operation of top and inspect

door and quarter window areas.

(34)

Remove masking tape and protective covers.

not overtighten.

fit

at header,

Page

SEALER

Methods

APPLICATION

of

Applying Sealers

Fury

Dash Panel Inside Area

Pi

I

lars

..................................

Quarter Inside Panel Quarter Window AreaCtation Wagon

Tire

Well and

Underbody Area

Satel

I

i

te

Belt Bar Area

Cowl and Floor Pan Areas

Floor

.........................

...........................

.................

..................

....................

Pan-Station Wagon

................

....

..

131

130 131 130

133 137 132

138

135

Valiant-Barracuda

SEALERS

TESTING

GENERAL INFORMATION

The

procedures placement are incorporated with the procedures the component unit. leaks.

The sealing illustrations used in this section show

for

weatherstrip sealing and

re-

of

the area sealed during manufacture These areas should be considered when testing

SERVICE PROCEDURES

TEST1 N

Water Method

Normally a visual inspection of an area

the

spray simulating rain nozzle and regulate inch stream.

the

slowly moving up the joint, seam

SEALER BALLS

G

area for sealing. When testing

or

a garden

the

pressure to an approximate

All

water

bottom of the door opening

tests

must

or

will

indicate

with

water, use a

hose

without the

be

made starting at

weatherstrip and

or

suspected area.

Powder Met hod

To

3

Deck Lid-Tail Light Areas Drain Trough and Pillar Areas Station Wagon Rear Areas

Cowl-Dash Panel-Floor Pan Areas Deck

Lid

Door Frames and Drain Troughs

Floor Pan Areas

Pillar and Drain Trough Areas

Quarter

and Tail Light Areas

.........................

Inner Panels

AND

COMPOUNDS

..............

............

...............

............

..........

............

....................

...................

.....................................

of

test the sealing between

the

body and

Page

.......

the

vehicle.

139

134

136

138

139 133 140 137 138 131 130

for

the

NU366

SEALER

Dash Panel Inside Area-Fury

SEALER

v

/

I

NU364

Quarter Inside Panel-Fury

A

BODY

AND FRAME 23-131

HOLD GUN NOZZLE IN DIRECTION OF ARROW

0

-

APPLICATION BY FLOW

EXPOSED SURFACE

WORK SEAL ON

TO

SURFACE ADHESION EDGE

BE FEATHERED AS

HOLD GUN NOZZLE IN DIRECTION OF ARROW SEAL METAL JOINTS

GET

IN

ORDER

3

METAL THICKNESS

Methods

weatherstrips,

,HIDDEN SURFACE HIDDEN SURFACE

EXPOSED SURFACE

SEALER MUST BE APPLIED

SEAL BEYOND HOLE.

APPLICATION OF SEALING PUTTY

TO

EFFECTIVELY

APPLICATION OF SEALER WHERE SEAL

IS

REQUIRED BETWEEN WELDED PANELS.

of

it

is

advisable to use trace powder and

a test bulb. When the powder

OF SEALER

OR

!

SPRAY

DO NOT HOLD GUN NOZZLE IN DIRECTION OF ARROW, SEALER APPLIED AS SHOWN IS

Applying Sealers

DO NOT SPRAY SEALER IN THIS DIRECTION OR FLOW MATERIAL ADJACENT TO JOINT

INEFFECTIVE

2

METAL THICKNESS

is

sprayed at the point

OR

FLOW

NYIW

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

is

door

closed

if

a good contact exists.

SEALERS AND COMPOUNDS

Super Rubber Cement-May be used where a

strong bonding of rubber parts to painted

is

painted steel surfaces

desired, attachment

weatherstrip on doors and luggage compartment lid

or

for attachment of felt pads.

Windshield Rubber Seals-A heavy viscosity, rubber expander. Sealer can be used where rubber confined between a glass and metal channel, such as on the windshield and rear window glass assembled in one-piece type 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,

B-post welds, weatherstrips and

drying, the sealer forms a tough

floor

seams. Upon

skin

which can

painted with a touch-up brush.

Heavy Sealing Putty (For Interior Sealing)-A

heavy, fibrous, putty-like compound, which can formed

or

rolled into pellets

or

long string shapes.

or

un-

of

is

be

CENTER PILLAR

VIEW IN

V’i

CIRCLE

INCH SEALER

z

Pillars-Fury

VIEW IN DIRECTION

OF

ARROW

STATION WAGON

Y

SOLDER JOINT

NU361

23-132

BODY

AND

FRAME

A

Underbody

Areu-Fury

A

BODY AND FRAME

23-133

ALL MODELS

VIEW

IN

OF

ARROW D

--

VIEW

IN

--

OF

ARQOW A

DIRECTION

SEAL

DIRECTION VIEW

OF

Quarter Window Area (Station Wagon)-Fury

2 DOOR SEDAN

VIEW

OF

fmmL/

(EXCEPT SEDAN)

IN

VIEW

OF

ARROW

VIEW

IN

DIRECTION

OF

ARROW

IN

DIRECTION

ARROW

DIRECTION

Y

IN

DIRECTION

ARROW

ALL

B

SEDAN

MASKING

MODYLS

TAPE

SEALER

Z

PILLAR

VIEW IN DIRECTION

OF

Z

DOOR PANEL

SEALER

PILLAR

VIEW

4

DOOR

ARROW

IN

X

CIRCLE

R

i

NU125

Door Frames and Drain Troughs-Valiant-Barracuda

23-134

BODY

AND

FRAME

A

DRAIN TROUGH

CENTER PILLAR

QUARTER PANEL

DIRECTION

OF

VIEW IN DIRECTION

OF

ARROW

A

ARROWC

OF

ALL MODELS

ARROW

VIEW IN DIRECTION

LOWER

B

VIEW IN DIRECTION

OF

ARROW

2

DOOR SEDAN

D

QUARTER

PANEL’

VIEW IN DIRECTION

OF

ARROW D

STATION WAGON NU119

Drain Trough and Pillar Areas-Satellite

VIEW IN DIRECTION

OF

ARROW

2

DOOR SEDAN

E

A

DASH PANEL

BODY AND FRAME

FRONT FLOOR

23-135

SEALER

DASH PANEL - COWL SIDE - FLOOR

PAN - FRONT FLOOR

SE

WHEELHOUSE

I

-

OF ARROW

I

SEALER

DASH PANEL

SIDE - FLOOR PAN

APPLICATION

IN CIRCLE A

QUARTER PANEL

EXTENSION

I

B

SE

\

VIEW

IN

OF ARROW V

--

SEALER

REAR FLOOR PAN

EXCEPT STATION WAGON

VIEW INCIRCLE

DIRECTION

T

FLOOR PANS

Cowl and Floor

Pan

Areas-Satellfie

JLlI

J

FLOOR PAN -STATION WAGON

VIEW

IN

QWSEALER

.....-)

IN

CIRCLE

P

AND W

SEALER

CIRCLE

NU120

S

23-136

BODY

AND

FRAME

A

e

FLOURPAN

DIRECTION

OFARROW

-

V-

VIEW

OF

I

IN

ARROW

LOWER PANEL

QUARTER PANEL

F

AR FLOOR PAN IDE EXTENSION

TAILGATE

FLOOR PAN

QUARTER PANEL ARROW

VIEW

IN

DIRECTION

ARROW G FLOOR PAN

OF

VIEW IN DIRECTION

PILLAR

VIEW

c

IN

DIRECTION

OF

‘ILLAR

DIRECTION

OF

WHEELBASE PANEL

TIRE

ARROW

SPARE

HOUSING

TIRE

WELL AREA

QUARTER PANEL

VIEW

IN

DIRECTION

OF

E

VIEW IN DIRECTION

ARROW D

ALER

OF

SEALER

ARROW A

TAILGATE AND REAR

PILLAR AREA

Station

TAILGATE AND REAR

PILLAR AREA

TIRE

WELL AREA NU121

Wagon-Rear

Areas-Scrtellite

A

SEA

BODY

AND

FRAME

23-137

-

OF

ARROW

QUARTER PANEL

Z

TIRE WELL

!h

INCH SEALER

BALLS

VA

%

INCH SEALER

BALLS

b

%

Tire Well and Floor Pan (Station Wagon)-Fury

SEI

SEALER

m

NU362

SEAFR

\

E

'ILL BARRACUDA

Pillar and Drain Trough Areas-Valiant-Barmcuda

-----4Y

VM

IN DIRECTION

OF

ARROW A

2

DOOR

23-138

FRONT

SIDE

BODY

COWL SIDE PANEL

AND

FRAME

OUTER FRAME

DASH PANEL

)NT

FLOOR FRAME

Cowl-Dash Panel-Floor Pan Area-Valtant-Barracuda

A

OUTER OPENING

NU127

SIDE

I-

SILL

EXCEPT CONVERTIBLE

EALER

QUARTER PANEL

Quarler

Belt

Bar

Area-Satellite

SEALE

--

Inner Panels-Valiant-Barracuda

La.-

CONVERTIBLE

BELT

BAR AND QUARTER PANEL

\

WHEFLHOUSE

fi

~CENT;;;OOR

CONVERTIBLE

NU123

NU130

A

QUARTER PANEL

BODY AND FRAME

23-139

VIEW

IN

DIRECTION

ALL EXCEPT FASTBACK

OF

ARROW

LOWER PANEL

B

Deck

Lid--Tail

Light

Areas-Satellite

bPP;

QUARTER PANEL

DECK UPPER PANEL

OPENING

FILLER

UPPER PANEL

e

RTER

PANEL

NU124

Deck

and

Tail

VIEW

IN

DIRECTION

Light

OF

ARROW A

VIEW

IN

DIRECTION

OF

ARROW X

-

Arecrs-Valiant-Barracuda

CIRCLE

Y

OUTER PANEL

DECK LOWER

PANEL EXTENSION

QUARTER

23-140

VIEW

IN DIRECTION

ARROW

BODY AND FRAME

OF

B

A

:

A--

Floor Pan Areas-Valiant-Barracuda

:CK L"WtR

PANEL

VINYL ROOF COVERING

INDEX

Page Page

Air

Bubble Removal

. . .

. . . . . . . . . . . . . . . . . . . . . . . .

141

SERVICE PROCEDURES

COVER REPLACEMENT

Removal

(1)

Remove windshield, rear window and mould-

ings. On cemented-in-type windows, remove mould-

To

ings only. clip hole locations with a removable type marker.

(2)

Remove

of roof panel.

(3)

Remove all sealer from drain trough, wind-

shield and rear window reveals.

aid in installation of mouldings, mark

roof

side mouldings and pull cover

off

FRONT FLOOR

PAN

Cover Replacement

J

. . . . . . . . . .

. . . . . . . . . . .. . . . . . .

140

roof aligning centerline marks.

(5)

Apply cement to one half of

tension and to the cover half on same side (Fig.

(6)

When the cement becomes tacky position cover

roof

panel and ex-

2).

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

reveals using a dull pointed fiber tool (Fig.

(10)

Starting at top center, secure cover to wind-

rear

window

3).

lnstallation

Inspect old cement to make certain there are no

high

or

low areas,

(1)

Mask body (Fig. across upper reveal, top of deck upper and bottom of

or

areas without cement.

1)

from edge of drain trough

"A"

pillar, windshield and rear window

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

Fig.

I-Masking the Body

MASKING

MASKING PAPER

TA

NK5W

A

CEMENT

,VINYL COVER

BODY AND FRAME

23-141

Fig. 2-Positioning Cover

shield reveal using staples spaced (maximum)

(11)

or

tacks spaced

1/2

Position cover to roof panel extension making

r

on

Roof

1-1/2

inch apart (Fig.

NK984

inches apart

4).

certain all wrinkles are removed.

(12)

Starting at top center, secure cover to rear

1-1/2

window reveal using staples spaced

or

(maximum)

(13)

Trim fabric at base of windshield reveal, half-

tacks spaced

1/2

inch apart (Fig.

inch apart

4).

way between upper and lower edges of pillar mould-

ing (Fig.

(14) (15)

5).

Trim fabric at base of rear window reveal. Using a dull pointed tool, press fabric into

drain trough to achieve maximum contact of roof cov-

er material to drain trough (Fig.

(16)

Grasp outboard edge of cover and while pull-

6).

ing material outward and down, use upper edge of drain trough flange as a breakover for draping ma-

on

terial

6).

cover material

(17)

for full length of outboard sides of

(18)

trough flange about

flange (Fig.

(19)

moulding upper locating boss (Fig.

to outboard drain trough flange face (Fig.

Care must be taken to avoid

pulling

loose the

applied to base of drain trough.

Press material against drain trough flange face

roof

cover.

Trim excess material hanging below drain

1/8

inch above lower edge of

6).

Locate and drill index hole for front pillar

5)

(original instal-

lation only).

NK986A

Fig. 4-Stapling Cover at Window Reveals

(20)

Apply a bead of sealer to edge of cover and blend upward to form a seal over staples and cover edge. Extend sealer across trimmed edge on “A”

post (Fig.

(21)

5).

Locate and punch holes in cover at

roof

extension belt line.

(22)

Trim cover on a line

1/4

inch below belt line

moulding holes and curving upward to meet drain

trough.

(23)

Apply a bead of sealer to trimmed edge of

cover at roof panel and smooth out to form seal (Fig.

7).

Install sealer along entire length of outboard trimmed edges of cover material to seal exposed edge adjacent to drain trough flange.

(24)

Apply a

1/4

inch ball

of

sealer to index studs

of pillar mouldings.

(25)

Position moulding by inserting a locating pin

in index hole and align moulding.

(26)

Using hole in moulding as a guide, drill a

.120

diameter hole in pillar and fasten in place with a screw (original installation only).

(27)

Install side drain trough mouldings, wind-

shield and rear window mouldings.

(28)

Remove masking material and inspect cover

for air bubbles.

AIR BUBBLE REMOVAL

a

N

K985

Fig. 3-Positioning Cover in Window Reveals

(1)

Place strips of masking tape over surface

of

bubble.

A

Fig. 5-Trimming and Sealing Cover

at

Windows

23-142

BODY AND FRAME

A

DRAIN TROUGH

NN55

Fig. &Positioning Cover

(2)

Using a

syringe, insert

No.

19

hypodermic needle and suitable

3M

Vinyl Trim Adhesive

equivalent, into bubble area.

used to avoid depositing any adhesive on the top surface

of

the vinyl cover.

The perforation must be

at

Sides

No.

8064,

Extreme care must

or

be

made in center of bubble, through masking tape

0.5

and vinyl material. Approximately

mil of adhe-

sive per sqhare 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 tem-

perature.

(5)

Heat bubble area with relative low heat

160°F.)

until bubble area begins to enlarge in circum-

WOOD

(150"-

GRAIN OVERLAY

INDEX

.ER

Fig. 7-Sealing Cover

at

Sides

ference. Infra-red heat lamps provide a suitable source of heat.

(6)

Remove heat source and allow cover to cool.

will

A method of rapid cooling

(7)

Using a

ture cover

DRY

No.

4

times equidistant around outer circum-

be beneficial.

19

hypodermic needle, punc-

ference of bubble to provide an escape route for en-

trapped solvent and air.

(8)

After bubble collapses, press cover to metal

surface, starting from one side of bubble and work-

it

ing toward opposite side until

conforms to metal

surfaces and all raised surfaces disappear.

(9)

Keep car from hot sunlight and other direct

heat sources.

(10)

Examine top after a

24

hour period.

Page Page

Application

Inspection Surface Preparation

of

Overlay

.........................

....................................

...........................

143 Temperature 144 Wetting Solution 142

SERVICE PROCEDURES

S

U R FAC E PREPARATION

The body surface to which the overlay

plied must be free of grease, oil and other foreign

be

material. Sand all areas to

No.

360

lay using

paper soaked in water

covered with the over-

spirits. The area to be sanded should be approximately

overlay, except when the overlay and other comparable areas.

nibs must be removed prior to application of overlay.

lack

areas.

off

1/4

inch larger in all dimensions than the

is

turned at the door

All

metal and/or paint

all

dust and dirt particles from the sanded

will

or

mineral

be ap-

..................................

..............................

142 142

TEMPERATURE

The overlay

application surface temperatures are between 70 and

90

degrees.

heat lamps to warm the application surfaces.

is

most easily handled when the

For

applications below

70

air

and

degrees, use

WETTING SOLUTION

Thoroughly mix two to three level teaspoons

mild powdered household detergent

clean, warm

(80

to

90

degree) water

per gallon

in

a non-rusting

type retainer.

of

A

BODY AND FRAME 23-143

APPLICATION OF OVERLAY (Figs.

It

is

mandatory to remove the paper backing from the overlay and not the overlay from the backing, as possible stretching or tearing may result.

Cut overlay and lay on a clean flat surface with the paper backing surface up. Hold overlay firmly and remove backing

paper in a smooth humid conditions, a slight jerking motion paper backing removal.

Thoroughly wet application surfaces the adhesive surface

1/2

inch larger than area to be covered

180

degree motion. Under hot,

of

the overlay with the wetting

1

and

of

will

2)

aid in

body and

solution and immediately apply overlay, grained side

so

1/2

out, to the body. Adjust overlay terial shows beyond all edges and apply wetting solution to outer surface of overlay.

Flat

Surfaces

Use a plastic squeegee having a cloth sleeve, teflon coated and pressurize all flat surfaces with firm, overlapping strokes to remove all air bubbles, water, wrinkles and to assure a good adhesive contact. On vertical surfaces, pressurize and level

3

x

4

tire top edge first with a

work from top to bottom.

inch squeegee, then

inch of ma-

or

is

off

en-

Vi

INCH

SECTION C-C

Vi

INCH

SECTION

Vi

B-B

INCH

BEZEL

GAS

x

r

SECTION D-D

CEMENT APPLICATION TYPICAL

OVERLAY

A/LL

FLANGES

-

SECTION

F-F

SECTION

E-E

SECTION

A-A

Fig.

I

-Wood

4.

-

AREA DESIGNATED FOR OVERLAY.

7-

1

-

AREA DESIGNATED

f-

Grain Overlay Application-Satellite

FOR

SANDING.

NU251

23-144

SECTION

BODY AND FRAME

SECTION A-A

/!h

INCH

C-C

!h

INCH

!h

SECTION

B-B

7

-I

SECTION D-D SECTION E-E

INCH-

SECTION

1

L\

-F

-7-

F-F

AREA DESIGNATED

1

T

-

FOR OVERLAY

AREA DESIGNATED

t

FOR SANDING

VIEW

IN

CIRCLE

Z

CEMENT

APPLICATION

ALL FLANGES.

NU284

A

Fig.

2-Wood

Grain Overlay Appliccrtion-Fury

On horizontal surfaces, start at the center and work

3

x

4

toward the edges using a

apply pressure to edges that will be wrapped around doors, fenders, gas cap areas or to compound curve areas.

inch squeegee.

Do

not

Flange Areas

(1)

After being sure all metal and/or paint nibs and sanding residue have been removed, hand brush Vinyl Adhesive

8064

(Quart Size Only),

or

equivalent,

3M

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

off

all

material extending beyond flange.

(5)

Pressurize flange area with a 2 inch rubber

roller to be sure that overlay is well adhered to the

BODY

AND

FRAME ALIGNMENT

INDEX

Page Page

FORESTRUCTURE

Frame Dimensions

Rep lace men t

(STUB

(Fury

FRAME)

Models)

.............

................................

144 145

painted metal surface.

Contoured Areas

(1)

Warm the unapplied overlay with a heat lamp,

1/2

working on an area no more than

inch larger than

the squeegee.

(2)

Using the

surize and level

(3)

Repeat warming and pressurizing until entire

contoured surface is completely adhered and free

3

x

4

inch plastic squeegee, pres-

off

the small warmed area.

of

air, water and wrinkles.

INSPECTION

Upon completion of an area, inspect for blisters due to trapped air worked out with the squeegee,

sharp needle film adheres to the body surface. All edges must be adhered to the body surface.

Body to Frame Alignment

BODY

ALIGNMENT

(

Fury-Satel

I

i

or

water. All blisters should be

or

punctured with

or

pin and then pressurized until the

...................

DIMENSIONS

te-Val iant-Barracuda)

.............

146

a

SERVICE PROCEDURES

FR AM E D

The

may be used as a guide in measuring frame align-

I

M

E

N

S

IO

N S-Fu

ry

Models

various frame dimensions (Figs.

1,

2

and

3)

ment. Diagonal measurements should be taken when straightening frame.

Measure distance between points connected by line

“A”,

(Fig.

3).

This distance should agree within

1/4

A

Fig. I -Frame Dimensions-Fury 6-Cylinder

inch with distance between points connected by line

“B”.

The diagonals (Fig.

that may be checked.

sure that any

actly corresponding points

two

Minor frame alignment can usually be corrected by straightening bent frame parts. frame can in most cases be replaced more economical-

ly than by attempting repairs.

Fig. 2-Frame Dimensions-Fury 8-Cylinder

3)

represent only one of the few

Care should

diagonals compared represent ex-

on

be

each side

A

taken to make

of

the frame.

badly distorted

BODY AND FRAME

Fig. 3-Frame Diagonal Measurements

23-145

NK140B

FRAME REPLACEMENT

The forestructure (stub-frame), engine, transmission, steering and suspension can be removed as an assembly for further disassembly out of the vehicle by two methods.

First

method: remove hood and bumper, then remove fenders, wheel house panels, grille and radiator as an assembly, support vehicle at sill area and move frame assembly.

’

Second method: support vehicle and lower frame

assembly out of vehicle as follows:

(1)

Remove battery and air cleaner, drain cooling system, remove radiator and shroud, disconnect heater hoses from engine, and disconnect battery tray from frame.

(2)

Discharge air-conditioning system, (refer to “Group

24,

Air-Conditioning” for discharging and charging the system), disconnect air-conditioning lines at firewall, discharge line at muffler and suction line at evaporator.

tings and connectors.

(3)

Disconnect throttle and speed control cables at

Seal open ends

of

air-conditioning fit-

carburetor, vacuum hose controlling accessories at en-

gine 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

and steering column from support bracket and move column up approximately

(5)

Raise vehicle on twin post hoist, remove drive shaft, exhaust pipes, shift rod torque shaft, rear seat heater

3

inches.

or

clutch linkage at

or

air-conditioning clamps at side rail, wheel house bolts at frame side rails, radiator support brace, bumper assembly and hood lock vertical lower support.

re-

pan

23-146

(6)

BODY AND FRAME

Fig.

4-Body

Disconnect speedometer cable, electrical leads

to

Outrigger Mounting

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

inch x 7 foot wood beam across stands for extra

2

strength and

x 4 x 6 inch pieces of wood on top of

4

x

main support beam and to lower flat surface of the side sills. Then lower rear axle to lowest position to assist in balancing body weight when frame assembly

is

removed.

(8)

Position a hydraulic transmission jack under

the frame rear crossmember and remove the frame to

4

and

5),

body bolts (Fig.

and yoke to frame crossmem-

ber nuts and washers.

(9)

Remove the frame assembly from the vehicle by

lowering the front post and trasmission jack slowly at

the same speed.

(10)

If a twin post hoist

hicle can be supported on short stands about

is

not available the ve-

36

inches high and using the same wood blocking with

the use of floor jacks to support the transmission and

suspension the stub-frame assembly removal can be

accomplished.

(11)

If frame

is

to be replaced transfer serviceable

parts to new frame.

lnst

allation

(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 and washers and

75

tighten to

(3)

Install nuts and washers on studs at radiator

foot-pounds.

support lower flanges.

a

Fig.

&Body

(4)

Remove transmission jack and body support

stands.

(5)

Connect emergency brake cable, starter leads,

gas line and speedometer cable.

(6)

Install drive shaft, exhaust pipes, shift rod clutch linkage at torque shaft, rear seat heater 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.

(7)

Lower vehicle, install and adjust steering column, accelerator and speed control cables.

(8)

Install radiator and shroud, connect coolant lines, radiator and heater hoses, electrical wiring, vacuum and air conditioning lines.

(9)

Install battery and air cleaner, tem and charge air-conditioning system.

Body

To

Frame Alignment

The body to frame alignment measurement should be performed whenever the stub frame has been moved, replaced frame, when replacing frame, as a guide plishing body to frame alignment.

Align front suspension and aim headlights after body to frame alignment has been completed. For

body to frame alignment dimensions

Alignment Dimensions (Fig.

manufacturers recommendations and procedures.

BODY

ALIGNMENT DIMENSIONS

(Fury-Satellite-Valiant-Barracuda)

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. plumb-bob

on

tacting the floor. Mark the plumb-bob contact point

to

Crossmember Mounting

or

air-

fill

cooling

sys-

re-

or

repaired. Use shims from original

in

accom-

refer

to “Body

1)”.

Follow

1,

2

and

3)

and place the line of a

point “A” with the plumb-bob just con-

equipment

A

1

I

A

BODY AND FRAME

23-147

+-21.35+- 53.33

52.41 STATION WAGON

Fig. I-Body Frame Dimensions-Fury

1:

’

60.90 STATION WAGON

-

5.22 STATION WAGON

57.98

-------I

NK1166B

BOTTOM VIEW

SIDE VIEW

Fig. 2-Body Frame Dimensions-Satellite

“0’

LINE

NKl176B

23-148

BODY AND FRAME

FRONT SPRING

A

I

A

FR~NT

‘GAUGE

SPRING

HOLE

c

I

“K”

MEMBER ATTACHING BOLT

Fig.

3-Body Frame Dimensions-Valiant-Barracuda

on

floor.

Repeat process at points B, both sides of body. Snap a chalk as illustrated.

compared represent the corresponding measuring

points.

Care should

be

taken that all diagonals

C,

D, E and F on

line

between points

Compare the dimensions with the specifications.

matching point to point dimensions should agree with-

BOTTOM

SIDE

All

REFINISHING

VIEW

in

1/4

inch.

In

making any body opening measurements, always

compare the matching measurements the vehicle. welded joints

All

dimensions must be measured at the

of

the body to insure uniform measure-

ments.

PROCEDURES

‘W

‘F

NY1451B

of

both sides

of

ACRYLIC FINISHES

The vehicles are finished in an acrylic enamel. determine the correct color and part number of the enamel used on the car, refer to the code on the body number plate and then locate the corresponding code on the paint chart.

To

DEFINITIONS OF TECHNICAL TERMS

COAT-SI NGLE

This means one coat overlapping to give complete

coverage.

COAT-DOUBLE

A

double coat means to

first

spray a single coat

with vertical strokes and then across with horizontal strokes,

or

vice versa.

DRYING

The drying several stages. The first is the time required for a film to reach the condition where,

if

come imbedded, but may has hardened. The second stage

free” and is the time required for a film to reach the

condition where it may be touched with light pres-

of

sure

the finger. The third

time required

so

that it may

or

hardening of a film goes through

is

known as “dust-free” and

any dust settles on it, the dust will not be-

be

wiped

is

for

the

film

to become thoroughly hard

be

rubbed and polished.

off

after the film

is

known as “tack-

“harddry” and

is

the

A

BODY

AND FRAME

23-149

FEATH E R-E

This is the tapering of the edges of a finish when the finger is passed over felt. Feather-edging is usually done with water and sandpaper on a sanding block.

D

G

I

N

G

it

no break

so

will

that

be

FERROUS AND NON-FERROUS METALS

Ferrous metals are those which are made from iron (steel). Non-ferrous metals are those which are not made from iron surface, such as aluminum, aluminum alloys, brass,

copper and magnesium.

or

do not present an iron (steel)

\

FLASH

This

is

the term applied to a coat of a product

when enough of the solvent has passed off for

coating.

re-

MIST COAT

This

is

a coat of thinner to which may be added a small amount of retarder and applied as a final coat to increase flow and lustre of lacquer-type finishes.

PRIM1 NG

The function of a primer is to form a bond between

the surface and the succeeding product.

PUTTYING

A glazing putty is used for filling in small imperfections which are too deep to be taken care of by surfacer coats. It may be applied either before

after the last coat of surfacer.

or

REDUCERS

Reducers are mixtures reduce alkyd, synthetic and orthodox materials to the proper consistency for application.

of

volatile liquids used

to

TACK

in thin, nondrying varnish and then wrung out. It kept in a container but will remain tacky. The tack rag

off a surface

RAG

This is a piece of cheesecloth that has been dipped

is

so

that the varnish will not harden

is

used to wipe

or

remove dust.

THINNERS

Thinners are mixtures of volatile liquids used to

thin lacquer-type finishing materials to the proper

consistency for application.

UNDERCOATS

All products used to prepare the surface to receive the color coats are classified primers, surfacers, putties, primer-surfacers and sealers.

as

undercoats, such as

PAINT REPAIRS ON GALVANIZED METALS

To perform paint repairs on galvanized rocker panels or any other galvanized steel surfaces, care must be exercised when preparing the bare galvanized surface to properly accept the primer-surfacer and finish paint. Do not use short cut methods

inter-mixing of materials.

Metal Preparation

(1)

Thoroughly sand affected area to remove all corrosion products from exposed metal surface while carefully feathering all paint edges.

(2) Wire brush or steel wool entire metal surface

or

and remove all grease solvent.

(3) Treat bare metal panel with Galvaprep (Ditzler

or

DuPont) Zinc Conditioner or equivalent according to label directions.

(4) Rinse with clean water and blow off with com-

pressed air.

or

R-M

(Rinshed-Mason)

oil by wiping with a clean

802

Galvanize and

or

SANDING BLOCK

As a rule a sanding block is a flexible rubber

so

block,

securely.

Wherever possible sanding should be done with a block as it distributes the pressures and gives a more uniform surface.

arranged sandpaper may be fastened to

It

affords a good grip for the operator.

it

SURFACI NG

The function of a surfacer

surface for the color coats.

is

to prepare a smooth

Refinishing

(1)

Apply one light coat of Ditzco Zinc Dust Primer

659

DPE and within

(Ditzler) or equivalent.

(2)

Light Gray, DZL-3400 Dark Gray, DZL-7200 Red Oxide) or Ditzco Speed-Sand Synthetic Primer Surfacers (DPS-70 Red Oxide, Hi-Speed Primer-Surfacer, 403 Primer Surfacer Sealer

(3) Sand when dry and proceed with application of

(Ditzler) and as soon as thinner flashes off

30

minutes, apply a coat of Duracryl Sealer

Apply Ditzler A-L-E Primer Surfacer (DZL-3200

or

DPS-30 Gray) DuPont

or

Rinshed-Mason APS-

or

equivalent.

23-150

BODY

AND

FRAME

A

finish coats according to

paint manufacturers recom-

mendations.

RUST PROTECTION

Prior to applying any paint to

the

clean

entire area to

and grease remover.

be

repainted

Eliminate

ically treat all bare metal using a good metal conditioner.

This

conditions the exposed metal to resist

rust.

the

with

all

fingerprints.

sheet metal,

a good wax

Chem-

BUFFING AND POLISHING

Minor imperfections in the paint finish normally can be removed by sanding, buffing and polishing. The

following procedure should be used when work-

ing on these minor conditions:

(1)

Oil

sand by hand the affected area using

#600

paper which has been soaked in mineral spirits. Caution should be used not to rub too hard over any of the affected areas

(2)

Tack

off

(2)

Buff the entire area using a fine buffing com-

or

on ridges.

the area with a clean soft cloth.

pound.

(4)

Polish

the

area

with

a good wax polish.

REF1 N ISH I NG

Preparation Acrylit

Over

Old

Acrylic

(1)

Remove outside accessories, mouldings and

bumper face bars

(2)

Remove silicone polish, wax, face contamination with wax and grease remover. chemically clean surface allows and assures adhesion of the undercoats and finish color.

(3)

Sand old finish.

deterioration, feathers out scratches, nicks, stone

bruises,

sand with

(4)

eliminate dirt

as paint

(5)

color change

or

any other minor imperfections. Water

#360

grit paper or its equivalent.

Blow

off

entire car, using high pressure air to

or

dust from blowing out on to surface

is

applied.

Mask off areas not to

is

being made, mask off interior parts adjacent to door openings to prevent paint spray from soiling interior trim and upholstering.

(6)

Reclean entire area to

grease remover, eliminating workman's fingerprints.

(7)

Chemically treat bare metal. exposed metal to inhibit rust. Use a good metal conditioner.

Priming

The

Surface

This operation

~~WU'RM-

(if

necessary).

This

operation removes surface

be

is

the backbone

or

any other sur-

for

effective sanding

painted.

be

painted with wax and

If

a complete

This

or

foundation

conditions

A

for

the finish color. It primes

fills

sion and

minor surface imperfections.

the

metal to insure adhe-

Use

one of

the recommended lacquer primer surfacers.

(8)

Apply undercoats.

(9)

To expedite repairs of other surface imperfec-

tions, use spot putty, glazing putty or all-purpose

putty.

(10)

paper

(or

systems

Sand undercoats. Water sand with

its equivalent

are

employed).

if

other sanding methods

This

is

the

400

or

finer

or

key operation in refinishing. The final finish will be as good as the foundation over which it

(11)

Respray with primer surfacer any area that

is

applied.

may have been sanded through to bare metal in step

10. (12)

Resand undercoat with

(13)

When color

is

being changed, wash door jambs

400

or finer paper.

and door opening areas. Spray interior.

(14)

Remove overspray from exterior and reclean entire surface with wax and grease remover. This ensures positive adhesion.

(15)

Tack rag entire surface to remove lint and

dust.

(16)

Apply acrylic color. (Four to Refinishing in the field must

six

double coats.)

be

done with acrylic

lacquer. The acrylic lacquer can then be polished to

match original finish gloss. Care must be exercised

when selecting paint for refinishing Acrylic Metallics,

to

select the proper paint code. Acrylic metallics

carrys a different code than non-acrylics.

(17)

When color has dried hard, compound and polish.

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

pair

is

demanded, as it

without leaving an edge.

tion of the surface, by sanding the original finish about yond the area where the acrylic lacquer will

is

not practical where a spot

is

difficult to spray sealer

If

care

is

taken in prepara-

a

satisfactory repair

is

2

or 3 inches be-

re-

possible

be

ap-

plied. Apply the lacquer directly on the sanded orig-

inal finish, being careful not to overlap the color on the unsanded enamel.

APPLICATION OF COLOR COATS

Metallic color can appear to vary in richness. The variation can be described as: A closed pattern that appears lighter with fine metallic dispersion.

A

An

open pattern that appears richer with the metal-

lic flakes less noticeable.

A

closed pattern is best matched

DDL

color 150% equivalent, adjusting the air pressure at the 35 lbs. and applying medium wet coats.

An

open pattern pressure to 20-30 color 100% with a blend Retarder,

or

with

DTL-135 Acrylic Thinner,

is

achieved

lbs.

at the gun,

of

DTL-135 and DTX-1140

equivalent, and applying even wet coats.

by

reducing the

by

lowering the air

reducing the

PAINT CHARTS

EXTERIOR COLORS

VALIANT-BARRACUDA-SATELLITE-FURY

Paint Code

A4

B3 B5 B7 F3

F5

F8 L1

Q5

R6 T3 T5 T7

w1

x9 Y2 Y3 Y4

*Carry-over color

Color Name Code

Silver Metallic AY2EA4

Ice Blue Metallic AY2EB3 Blue Fire Metallic AY2EB5

Jamaica Blue Metallic AY2EB7

Frost Green Metallic AY2EF3 Limelight Meta

Ivy Green Metallic AY2EF8 Sandpebble Beige AYlBLl Seafoam Turquoise Metallic AY2EQ5 Scorch Red AYlER6

Honey Bronze Metallic AY2ET3

Bronze Fire Metallic Saddle Bronze Metallic Alpine White AYlEWl

Black Velvet AY 1TX9

Sunfire Yellow AYlDY2 Yellow Gold AYlDY3

Spanish Gold Metallic AY2EY4

I

lic AY2EF5

gun

DDL

BODY AND FRAME

The blending

in

percentage as necessary depending on the room

temperature.

of

thinner and retarder can be varied

or

to

Compounding Color Coats

Compound the sanded area that extends around the

refinish lacquer and then compound the lacquer,

blending

acrylic enamel will permit compounding without leaving scratches.

it

into the enamel.

Chrysler

AY 2 ET5 AY 2 ET7

The hard surface of the

23-151

Ditzler

Code

2016 2018 2019 2020 2023

2024 *43786 "22542 *13534

2029 2030

1

203

2032

2033

*9300 *a1574 *81575

2034

ACCENT STRIP COLORS-LOWER BODY

VALIANT-SIGNET-BARRACUDA-SATELLITE

Color Name

White

Black Brite Blue Green Brite Red

Chryrler

Code

ASlVWl

AS 1TX9 ASlBB2 ASlEF3 ASlBR5

CORPORATE IDENTITY COLORS

Corporate White Corporate Blue Single Tone-X9-X9 Two Tone-X9-Wl

Lower Deck Panel and Sill Area Argent Silver DX-8555

Ditzler

Code

43870 71498

12785

First

two

digits are Accent or Roof Color.

Second

For special colors (coded 999) Furnish special order

(SO)

car.

two

digits are Basic Body Color.

number and selling dealer with serial number

2033 9000

13074

8367

of

23-152

Used

Black Velvet Medium Dark Blue Metallic

Gold Metallic

Light Bronze Metallic Dark Green Metallic Brite Red

Used

Jewel Black

Baltic Blue Metallic

Golden Tan Metallic

Giallo Gold Metallic Bayou Green Metallic Rally Red

BODY

On:

Door and Quarter Upper Inner Frames. Door and Quarter Upper and Lower Garnish Mouldings and Pillars.

Color Name Codme Code-DDL Remarks

On:

2

AND

Door Sedan Quarter Garnish Extension and Lock Pillar Upper. 4 Door Sedan

FRAME

EXTERIOR GLOSS FINISH COLORS

INTERIOR COLORS

VALIANT

Chrysler Ditzler

AY 1TX9 9300 AY2EB7 2020 AY2EY4 2034 AY2ET3 2030 AY2EF8 43786 AYlER6 2029

GLOSS FINISH COLORS

Ditzler

Code-DIA

ABlTX9 9000 AB2EB7 13697 AB2ET3 23086 AB2EY4 23129 AB2EF8 43926 ABlER6 71685

“B”

Pillar Cap.

A

‘iB”

LOW GLOSS FINISH COLORS

Jewel Black AB5TX9 9028 Front Seat Manual

Adjuster Console.

Jewel Black (semi-gloss) AB3TX9 9293 Optional for Front

Seat Manual Adjuster.

Majesty Blue AB5EB9 13686 Console Only. Giallo Gold Metallic AB6EY4 23074 Console Only. Bayou Green Metallic AB6EF8 43929 Console Only.

SUEDE FINISH COLORS

Used

On:

Instrument Panel. Glove Box Door. Ash Receiver. Steering Column Assembly and Bezel Rear Shelf fogger.

Jewel Black

Baltic Blue Metallic AC39EB7 13705 Laser Gold Metallic AC39EY8 23062 Buckskin Tan AC38ET8 23076 Bayou Green Metallic AC39EF8 43925

Regatta Red AC38ER8 71688

AC38VX9 9324

INTERIOR COLORS

BARRACUDA

EXTERIOR GLOSS FINISH COLORS

Used

On:

Integral Doar Upper and Lower Garnish.

2

Door Hardtop Quarter Panel Lower Garnish.

Black Velvet Bright Blue Metallic Light Bronze Metallic Dark Green Metallic Bright Red

AY

1TX9 9000 AY2EB5 2019 AY2ET3 2030 AY2EF8 43786 AYlER6 2029

Ditzler

Code-DDL

De-

A

BODY

AND

FRAME

23-153

Used

On:

2

Door Hardtop Quarter Panel Upper Garnish Moulding. Fastback Headlining Retainer Moulding. Lower Wheelhouse Moulding. Rear Quarter Moulding.

Convertible Header and Defogger Intake Bezel.

Color Name

Jewel Black Thunder Blue Metallic Golden Tan Metallic Bayou Green Metallic Rally Red

Jewel Black Jewel Black (Semi-Gloss)

Majesty Blue Buckskin Tan Bayou Green Metallic Rally Red

GLOSS

FINISH

LOW GLOSS

SUEDE

FINISH

COLORS

Chrysler Ditzler

Code Code-DIA

ABlTX9 AB2EB5 13693 AY 2 ET3 23086 AB2EF8 43926 ABlER6 71685

FINISH

AB5TX9 9028 AB3TX9 9293

AB5EB9 13686

AB5ET8 23061

AB6EF8 43929

AB5ER6 71687

9Ooo

COLORS

Remarks

Console only Optional for Front Seat Manual Adjuster Console only

Console only Console only Console only

Used

On:

Instrument Panel. Glove Box Door. Ash Receiver and Steering Column Assembly.

Jewel Black Baltic Blue Metallic Sienna Tan Bayou Green Metallic Regatta Red

Color Name

White

Black Medium Dark Blue Metallic

Gold Metallic

Dark Bronze Metallic Platinum Metallic Dark Green Metallic Bright Red

AC38VX9 9324 AC39EB7 13705 AC38ET8 23076 AC39EF8 43925 AC38ER8 71688

INTERIOR COLORS

SATELLITE

EXTERIOR GLOSS

Chrysler

Code

AYlEWl AY 1TX9

AY2EB7 AY2EY4

AY

AY2EA4 AY2EF8 AYlER6

FINISH

2 ET7

COLORS

Ditzler

Code-DDL

2033

9300

2020 2034 2032 2016

43786

2029

Remarks

Sill panel and tail

gate garnish.

Sill panel and tail gate garnish.

Integral Door Garnish Integral “B” Pillars. Integral Quarter Garnish.

Integral “B” Pillars.

Integral Quarter Garnish.

Used

GLOSS

On:

(a) Roof rail 2 Door Hardtop.

(b) Quarter upper garnish 2 Door Sedan and Hardtop. Quarter belt garnish 2 Door Hardtop. (c) Station Wagon Rear Deck Seat Panel Assembly. Headliner Retainer Mouldings. “C” Pillar Cover

and Quarter Window Garnish. (d) Roof Bow Clips-Station Wagon. (e) Convertible Rear Seat Shroud.

FINISH

COLORS

23-154

BODY

AND FRAME

A

Color

Name

Aspen White

Dove White

Jewel Black

Baltic Blue Metallic Teak Tan Metallic Saber Silver Metallic

Bayou Green Metallic

Rally

Red

Used

On:

(a) Backlite Moulding Clips

Jewel Black

Jewel Black Jewel Black

Baltic Blue Metallic Desert Tan Bayou Green Metallic

Used

On:

Satin Black Baltic Blue Metallic

Chestnut Tan Metallic

Bayou Green Metallic Regatta Red

(low

(a) Instrument Panel. Steering Column and Components. Windshield Garnish. Rear Window Defogger

Bezel.

(b) Convertible Header and

(c) Glove Box Door-Inner.

gloss)

SEMI-GLOSS

(4

Door Sedan only)

SUEDE

“A”

Pillar.

FINISH COLORS

Chryrler

Code

ABlWl

ABlEWl AB 1TX9 AB2EB7

AB2ET7

AB2EA4 AB2EF8

ABlER6

Ditzler

Code-DIA

8362 8743

9000

13697 23087 32722 43926 71685

FINISH COLORS

AB5TX9 9028 *Convertible Top

Assembly.

*Front Seat Assembly

Adjuster.

AB3TX9 9293 Alternate for Adjuster.

AB5TX9 9028 AB6EB7 13670 AB5ET1 23079 AB6EF8 43929 a

AC38VX9 9324 a1b1c AC39EB7 13705 a1b AC38ET8 23076 a1b AC39EF6 43925 a AC38ER8 71688

a

a a

a

Bow

SPATTER FINISH

Three Tone Black and Gray AC48CAA DX-1768

Station Wagon 2nd. Seat

U

nde rsid e Plywood.

A

HEATERS AND AIR CONDITIONING

HEATERS GENERAL INFORMATION

SERVICE DIAGNOSIS

SERVICE PROCEDURES

..................

................

AIR CONDITIONER GENERAL

INFORMATION

......................

AIR CONDITIONER CONTROLS AIR FLOW FOR EACH PUSH BUTTON

POSITION

..........................

.....

..........

GROUP

24

CONTENTS

Page Page

1

ELECTRICAL CONTROLS AND CIRCUITS

1

OPERATING INSTRUCTIONS FOR

3

OWNERS

...........................

INSPECTION AND TEST PROCEDURES

11

SERVICE PROCEDURES

14

AUTO-TEMP FURY & VIP

................

...............

13-17

.

13-18

25

36

67

16

HEATERS

INDEX

Page

Assembly

Controls Control Cable Adjustment

Disassembly

General Information

Installation

Blower Motor

Controls Control Cable Adjustment

General Information

.....................................

..........................

Valiant-Barracuda

.(See

Instrument

Panels-Group

......................

..................................

...........................

...................................

Satellite

.................................

.(See Instrument

Panels-Group

......................

...........................

8)

GENERAL INFORMATION

All Plymouth models

1,

2

and

(Figs. the cowl grille and passes through a plenum chamber to the heater core. A temperature control heater housing directs the fresh air either through or past the heater core. The amount of “blend” is determined by the setting

instrument panel. Direction of the “blended air” is

controlled by the “Heat-Defrost” lever on the instru-

ment panel.

The blower switch determines the speed

3).

use

a “Blend

Fresh air enters the heater through

of

the temperature lever on the

Air”

type heater

door

of

in

the

Heater Core

9

Heater Doors

I

nsta I lation

Blower Motor

3

Blower Motor Resistor

8

Controls

1

8

Control Cable Adjustment General Information

7

Heater Core Heater Doors Installation

5 1

blower motor and the velocity of the air flow from the heater outlets

On Valiant models, two fresh air ducts, for warm

weather use, are located under each end of the instru-

ment panel. By opening the doors on these ducts, fresh air bypasses the heater and vehicle (Fig.

On all other Plymouth models, the ventilator doors

are controlled by knobs mounted on the instrument

panel.

er operation.

...................................

.................................

...................................

Fury-V.1

.................................

.P.

.........................

..........................

......................

...........................

...................................

.................................

...................................

.

is

4).

Make sure

these

doors are

closed

.(See Instrument

Panels-Group

rammed into the

during

Page

7

8

5

7

8

8)

4

1

7

8

6

heat-

INSUFFI

Condition

Cl

ENT

HEAT

SERVICE DIAGNOSIS

Possible

(a) Carpet obstructing outlet. (a) Reposition carpet to clear outlet.

(b)

Radiator hoses leaking.

(c) Obstructed heater hose.

(d) Temperature door not closed

ing.

(e)

Shut-off or defroster door improperly (e) Adjust the Heater-Defroster Control adjusted.

Cauu

or

leak-

Correction

(b)

Correct leak. Replace hoses sary and bleed system of air.

(c)

Replace heater hoses.

(d)

Adjust temperature control cable. See “Cable Adjustments.”

Cable. See “Cable Adjustments.”

if

neces-

EXISTING STUD

DEFROSTE

-

PASSENGER SIDE

HOUE

CRANK

HEAT SHUT OFF

DOOR CRANK

TO DEFROSTER

HEAT DEFROST

DOOR CRANK

\

\/

,6’?

RESISTOR BLOCK

HEAT

DISTRIBUTION DUCT

BLOWER MOTOR

TUN,

LOCAT I NG

SCREW

ENGINE SIDE HOUSING

Fig. 1 -Hwter-Fuy

and

PASSENGER SIDE HOUSING

NU252

V.I.P.

A

Condition Possible Cause Correction

TOO MUCH HEAT

Engine thermostat open.

Coolant too low.

Disengaged cable on temperature (a)

(a)

door.

in

Thermostat stuck

(b)

closed position.

HEATERS

Replace thermostat. See Group

(f

1

“Cooling System”.

Fill

(€9

(b)

the radiator to recommended

el. Connect or replace cable.

Replace thermostat. See Group “Cooling System”.

24-3

7,

lev-

7,

BLOWER MOTOR NOT OPERATING

(a)

Blown fuse. (a

(b)

Faulty electrical connection.

Fa

u

I

(C)

(d

(e)

ty blower switch.

1

Faulty motor.

Faulty resistor. (e)

SERVICE PROCEDURES

HEATER CONTROL CABLE ADJUSTMENTS

To adjust heater control cables, the adjustment

must be correct at the instrument panel control assembly first. It assembly from the instrument panel to make these adjustments.

Panels,” Group

Valiant, Barracuda Models

(1)

Disconnect the three cables at heater assembly.

is

necessary to remove the control

See

“Heater Controls” in “Instrument

8.

Check for excessive resistance

1

in

circuit and replace fuse. Tighten all electrical connections.

(b)

Replace switch.

(C)

Replace motor.

(d)

Replace resistor.

(2)

With control assembly removed from instru-

ment panel, position the three control cables

so

the

cable housing is flush with edge of the cable mount-

ing bracket (Fig.

(3)

Install control assembly on instrument panel.

(4)

Place top control lever in center

5).

Install new clips.

or

“Heat”

position and connect heater defroster cable (right

cable) to heater defroster door of heater assembly

while holding door in extreme clockwise position.

(5)

Connect fresh air cable (left cable) to air shut

Fig.

2-Heaters-Satellite

Models

24-4

HEATERS

DASH

PANEL

A

DEFROSTER

GRILLE

ROD

I

e

TUBES

Fig.

3-Hecr)er-Vafiant

off

door on heater assembly while holding door in

extreme clockwise position.

(6)

Place temperature control lever in extreme left, “Cool” position. Connect cable to right door of heater assembly while holding crank clockwise position.

Fury

and

V.I.P.

(1)

Disconnect the three cables at heater assembly.

(2)

With control assembly removed from instru-

Models

of

door in extreme

PLENUM CHAMBER

MOUNTING

(3)

NUT

-SEAL

/

RESH

AIR

lOOR

L

GROUND SCREW NN251

and Barracuda

ment panel, position the three control cables cable housing ing bracket (Fig.

(3)

Install control assembly on instrument panel.

(4)

Place top control lever in center tion and connect heater-defroster cable (left cable) to heat-defrost door (extreme left door) of heater assembly while holding crank wise position.

(5)

Connect air shut-off cable (right cable) to air shut-off

of

the heater), while holding crank in extreme clock-

wise position.

is

flush with edge

5).

Install cable mounting clips.

of

the

cable mount-

or

in

extreme counter clock-

door

of heater assembly (on the front surface

#JL-

CLIP

so

the

“Heat” posi-

Fig.

4-Fresh

Air

Duct-Driver‘s

Side

N P265

Fig.

5-Heater Control

Cabk

‘ER

NR565

Adjustment

A

(6)

Place temperature control lever in extreme

left, “Cool” position. Connect cable to right door of heater assembly while holding crank of door in extreme counterclockwise position.

Satellite Models

The Temperature control cable and the “Heat-

Defrost” control cable should be positioned, at the

so

control assembly,

that the ends of the cable hous-

ings are flush with the edge of the mounting plate. Final cable adjustments should be made at the heater ends of the cables.

To

adjust the “Heat-Defrost” cable, place the control lever on the instrument panel in the defrost position. Remove the cable clip at the heat-defrost door and hold the door in full counterclockwise position. Attach clip. Be sure that the instrument panel control lever remains in the defrost position while installing the cable clip at the heater. Test the heater operation.

To

adjust the “Temp” control cable, remove the cable clip at the temperature control door. Place the temperature control lever to the minimum heat position (closest to driver). Rotate the temperature control door shaft to the extreme clockwise position and

re-

install the cable clip. Be sure the instrument panel control lever remains in the minimum heat position during this adjustment.

Fresh Air Vent Control Satellite Models

Push the fresh air control knob in (leave about

bauie-

1/8

inch between knob and panel). Remove the control cable clip from the door control crank arm bracket. Rotate the crank arm of the door firmly to the closed position (left side counterclockwise; the right side clockwise) and reinstall the cable to the crank arm bracket.

Fresh Air Vent Control Cable-Fury and V.I.P. Models

(1)

Push the fresh air control knob in (leave about

1/8

inch between the knob and panel).

(2)

Remove the kick pad at the fresh air outlet.

(3)

Remove the control cable clip from the vent door cable bracket.

(4)

Rotate and hold the vent door firmly closed and

attach cable clip.

(5)

Reinstall kick pad.

H

EATER-Satellite Models

On models equipped with console

it

is

necessary to loosen and move the console rearward before removing the heater as follows:

(a) From inside console storage compartment

re-

move, two console mounting bolts and two metal

HEATERS

24-5

screws from the front sides in carpeting.

(b) Remove two shift indicator bezel screws, put

gear selector in “Drive” position, pull bezel back and

90

turn

degrees. Allow bezel to rest across top of

console.

(c) Remove two mounting screws at rear of gear selector bracket, disconnect back up light switch connector and remove gear selector light bulb. Move console back. Heater may now be removed.

After heater

is

installed, the console

is

installed as

follows:

(a) Align console to mounting brackets and install rear mounting bolts in console storage compartment,

in

rear of gear selector bracket and install two screws

in front sides of console carpet.

(b) Connect back-up light switch wire and install gear selector light bulb.

(c) Install gear selector bezel by engaging front tabs under console housing lip and securing with the two metal screws at storage compartment end lip.

Removal

(1)

Drain radiator and disconnect battery ground

cable.

(2)

Remove upper half of glove box.

(3)

In engine compartment, disconnect heater hoses at bulkhead. Plug hose fittings on heater to prevent any coolant from spilling on interior trim as heater assembly is removed.

(4)

From under instrument panel, remove heater to cowl support bracket.

(5)

Remove defroster hoses and disconnect wiring

from heater motor resistor.

(6)

Disconnect fresh air vent control and shut-off door cables at heater from under instrument panel. Reaching through glove box, disconnect temperature control door cable.

(7)

From inside engine compartment, remove three nuts that mount heater to bulkhead.

(8)

Rotate heater assembly until mounting studs are up and carefully remove heater from under instrument panel.

installation

(1)

Position heater assembly under instrument panel (mounting studs up) and connect temperature control door and defroster door cables. See “Control Cable Adjustments.”

(2)

Rotate heater into position on bulkhead and support heater housing with a suitable block of wood.

(3)

From inside engine compartment, install retaining nuts.

(4)

Install heater hoses (Figs.

(5)

Under instrument panel, install heater to cowl

6,7

and

8).

support bracket.

(6)

Connect and adjust fresh air control and shut-

24-6

Fig. 6-Heater Hose Connections-225 Cu. In. Engine-

off

HEATERS

All Models

door cable at heater from under instrument panel.

Connect temperature control door cable by reaching

through glove box opening. See “Control Cable Ad-

justments.”

(7)

Connect defroster hoses and wiring to heater

blower motor resistor.

(8)

Refill cooling system and connect battery

ground cable.

(9)

Install upper half of glove box.

(10)

Start engine, bleed system, inspect for leaks

and test operation of heater.

Fury and V.I.P. Models Passenger Side Housing

Removal

(1)

Disconnect battery negative cable and drain

radiator.

(2)

In engine compartment disconnect heater hoses

A

at dash panel. Plug hose fittings on heater to prevent any coolant from spilling on inside of vehicle as heater assembly is removed.

(3)

Slide front seat back to allow room to remove unit from vehicle and unplug antenna lead from side of radio.

(4)

Remove vacuum hoses from trunk lock if

so

equipped.

(5)

Disconnect electrical connectors from blower motor resistor block on face of housing.

(6)

Remove control cables from defroster door

off

crank and heat shut

(7)

Remove bottom retaining nut from support

door crank.

bracket and swing bracket up out of the way.

(8)

In engine compartment remove four retaining

nuts from studs on engine side housing.

(9)

Remove locating bolt from bottom center

of

passenger side housing.

(10)

Roll

or

tip housing out from under instrument

panel.

(11)

Remove temperature control cable retaining

clip and cable from heat shut

off

door crank.

Installation

NOTE:

housing to panel seal

Before pressing housing to dash panel, be sure

is

(1)

Position housing on front

not misaligned

floor

or

of vehicle under

damaged.

instrument panel and place temperature control cable in bracket. Place end of cable housing flush with end of bracket and install retaining clip.

(2)

Tip housing up under instrument panel and

press mounting studs through dash panel.

(3)

While holding housing in position, install locat-

ing screw. Then swing mounting bracket down onto

of

stud on face

(4)

In engine compartment install four retaining

nuts and tighten securely.

(5)

Connect electrical connectors to resistor block

housing and install mounting nut.

(24

inch pounds)

and connect control cables to defroster door crank and heat shut

off

door crank.

Fig. 7-Heater Hose Connections-272318 Cu. In.

Engines-All Models

Fig. 8-Heater Hose Connections483 and

Engines-All Models

440

Cu.

In.

A

(6)

Plug antenna lead into radio and connect vac-

uum trunk lock hoses

(7)

From engine compartment, remove plugs from

if

so

equipped.

core tubes and connect hoses to heater.

(8)

Fill cooling system and connect battery negative

cable.

(9)

Start engine, operate heater and bleed air from

system.

Engine

Side

Housing

HEATERS

BLOWER MOTOR-Satellite Models

Removal

(1)

Remove heater as outlined in “Heater Removal.”

(2)

Disconnect wiring from blower motor to heater

assembly.

(3)

Remove motor cooler tube.

(4)

Remove heater backplate assembly from heater.

(5)

Remove fan from motor shaft.

(6)

Remove blower motor from backplate.

24-7

Removal

NOTE:

from vehicle to service heater blower motor side housing. See Group

The right inner fender shield must be removed

or

engine

23

“Body and Frame” of this service manual for detailed illustrations of fender shield removal.

(1)

Drain radiator and disconnect battery

arnllnd

cable.

(2)

Disconnect heater hoses at core tubes.

(3)

Remove inner fender shield. (See note).

(4)

From under instrument panel, disconnect blower motor feed and ground wires. Push wires and rubber grommet through dash panel into engine

compartment.

(5)

From engine compartment remove four retain-

ing nuts and three screws from outer edge of housing

and remove housing.

lnstallation

NOTE:

Before pressing housing to dash panel, be sure

housing to panel seal is not misaligned or damaged.

(1)

Position housing on four studs on dash panel. Install four retaining nuts and three screws. Tighten securely.

(2)

Push blower motor feed and graund wires through hole in dash panel and secure rubber grommet.

(3)

From under instrument panel connect feed and ground wires.

(4)

Install inner fender shield, connect heater hoses to core tubes.

(5)

Fill

cooling system and connect battery negative

cable.

(6)

Start engine, operate heater and bleed air from

system.

BLOWER MOTOR-Fury and V.I.P. Models

The blower motor housing under the right front fender between the inner fender shield and the fender. The inner fender shield must be removed to service either the blower motor ar engine Frame” of this manual for detailed illustrations.

is

mounted to the engine side

side

housing. See group

23

“Body and

lnstallation

(1)

Install blower motor on backplate.

(2)

Install fan on motor shaft. Adjust for clearance

between motor and fan.

(3)

Install motor cooler tube.

(4)

Install motor and backplate on heater.

(5)

Connect blower motor feed wire.

nstall heater assembly as outlined in “Heater

ition”.

n

tH

I

ER CORE-Fury and V.I.P. Models

Removal

(1)

Remove passenger side housing from vehicle.

(See Passenger Side Housing Removal).

(2)

From inside housing, remove two retaining nuts from right side of heater core and four screws from outside of housing.

(3)

Remove core tube locating metal screw from top

of housing.

(4)

Carefully pull heater core out of housing.

/nstallation

NOTE:

Examine core to housing seal for damage or

misalignment before seating heater core in housing.

(1)

Position core on studs in housing and install

two retaining nuts.

(2)

Install four core retaining screws from outside

of housing and one core tube locating screw in top left of housing. Tighten all nuts and screws securely.

(3)

Install housing under instrument panel. (See

Passenger Side Housing Installation).

HEATER CORE-Satellite Models

Removal

(1)

Remove heater as outlined in “Heater Removal.”

(2)

Remove heater cover to expose heater core.

(3)

Remove screws that mount core to heater as-

sembly and remove core.

lnstallation

(1)

Position core in heater assembly and install

core mounting screws.

(2)

Install heater cover.

24-8

HEATERS

(3)

Install heater as outlined in “Heater Installa-

tion.”

(4)

Install motor cooler tube.

(5)

Connect wiring from heater assembly to motor.

HEATER-Valiant and Barracuda Models

Removal

To

service the heater core or blower motor, it is

necessary to remove the heater assembly from the

vehicle.

(1)

Disconnect battery ground cable and drain

radiator.

(2)

Disconnect heater hoses from heater and

move heater hoses at dash panel seal and retainer

plate (Fig.

(3)

(Fig.

(4)

seal from dash panel (Fig.

(5)

from heater assembly (Fig.

(6)

(7)

fresh air duct (Fig.

(8)

9).

Disconnect wires from blower motor resistor

3).

Remove heater motor seal retainer plate and

9).

Disconnect heater and defroster coutrol cables

3).

Remove defroster tubes from heater assembly. Disconnect heater housing support rod from

3).

Remove heater assembly.

re-

Fig. IO-Heater Hose Connections-273

Engines-Valiant and Barracudu Models

(5)

Connect heater hoses to heaters (Fig.

(6)

On passenger compartment side, connect heater

support rod to heater housing.

(7)

Connect wire to heater motor resistor.

(8)

Connect defroster tubes to heater.

(9)

Fill

cooling system, start engine and operate un-

til normal engine operating temperature

(10)

Test operation of heater assembly.

Cu.

In.

10).

is

obtained.

A

Installat

(1)

ion

Position heater assembly on dash panel

by

slid-

ing four mounting studs into their respective holes in dash panel.

(2)

Connect and adjust heater-defroster cable and temperature control cables to their respective control arms.

(3)

In engine compartment

side,

install heater to

dash panel seal, seal retainer and mounting nuts.

(4)

Position seal and seal retainer over heater tubes

and install attaching screws.

Fig. 9-Heater Mounting-Valiant and Barracuda

Models

Blower Motor Resistor ReplacemenfSatellite, Fury and V.I.P.

(1)

From

under instrument panel disconnect wiring

Models

to resistor.

(2)

Remove the two screws that mount resistor as-

sembly to heater and remove resistor.

(3)

Position new

or

repaired resistor in heater and

install the two mounting screws.

(4)

Connect wiring to resistor assembly.

Heater Door ServiceSatellite, Fury

To service the heater fresh air door, heater

lator door

and

V.I.P. Models

or

the heater defroster door,

the

regu-

heater must be removed from the vehicle and dissassembled. Refer to the “Heater Core” and “Blower Motor” Removal and Installation.

Disassembly-Valiant

(1)

Remove heater as outlined in “Heater Remov-

and

Barracuda

Models

al.” Remove seal from around heater motor mounting studs.

(2)

Remove spring clips holding spacers and heater

motor to heater housing.

(3)

Remove fan from heater motor.

(4)

Remove mounting support plate from heater

motor.

(5)

Remove heater motor resistor assembly

heater housing (Fig.

3).

from

A

(6)

Remove fresh air door seal from either inner

outer heater housing half only.

(7)

Remove retainer clips attaching heater housing

halves together.

(8)

Separate heater housing halves.

(9)

Remove screw attaching seal retainer and seal

around heater core tubes.

(10) Remove heater core tube support clamp.

(11)

Remove screws attaching heater core to heater

housing and remove core.

(12) Remove seal retainer and seal from heater

core.

Assembly

(1)

Position heater core in heater housing.

(2) Slide seal retainer and seal over heater core

tubes and up against housing. Install attaching screw.

(3) Install heater core to housing screws.

(4)

Position support clamp over heater core tubes

or

AIR

CONDITIONING

and install attaching screw.

(5)

Install support plate on heater motor.

(6)

Install fan on heater motor. Turn fan to make

certain it does not hit motor support plate.

(7)

Position heater motor and support plate over

mounting studs on heater housing.

(8)

Install spacers and retainers on heater motor

mounting studs.

(9)

Position both housing halves together and install retainer spring clips. Add sealer between two halves before reassembly.

(10) Install heater motor resistor assembly.

(11)

Position and cement seal around fresh air door

opening.

(12) Position heater housing to dash panel seal

around heater housing mounting studs.

(13) Install heater as outlined in “Heater Installa-

tion.”

24-9

AIR

General Information Vacuum Circuits

Fury

and VIP

Air

Flow for Each Push Button

Satel

I

ite

....................................

Fury

and VIP

Valiant

Anti-Freeze Recommendations

Blower Motor

Fury

Satel

Valiant Charging the System Correcting Low Refrigerant Discharge and Recharge Discharging the System Electrical Controls and

Satel I ite Fury and VIP Va I iant

Evacuate the System

Evaporator

Fury

Satellite Valiant

Expansion Valve

Fury,

Va Expansion Valve and EPR Valve Test (Single) Expansion Valve and EPR Valve Test (Dual EPR Valve (Evaporator Pressure Regulator) Gauge Set Manifold and Installation Handling Tubing and Fittings Heater Core

Fury

Satel

.....................................

and VIP

I

ite

....................................

.....................................

....................................

.....................................

and VIP

....................................

.....................................

VIP and Satellite

I

ia nt

.....................................

and VIP

I

i

te

....................................

..........................

...............................

.................

................................

..........................

Level

..............

......................

.......................

Circuits

...............................

..........................

................................

......................

Unit)

............

..................

................................

CONDITIONING

INDEX

Page

11

13

16

13

21 37

49 55

61 65

30

61 62

17

13

22 65

49

53

59 48

56

....

35

.

66

......

43

26 36

49

52

Valiant

Inspection and Test Procedures

Fury,

Valiant

Magnetic Clutch

Oil

Operating Instructions for Owners

Satel I ite

Fury

Va

Operation of all Controls

Satellite

Fury

Va

Push Button Control Chart

Satel I ite

Fury

Va Radiator Pressure Cap Refrigerant Leve Refrigerant Charge Remove Sweep-Test Charge Replace the Receiver

Safety Precautions Servicing the Compressor Sweep-Test Charge Testing the System for Leaks Test System Pressure

Vacuum Control Systems Adjustments and Tests

Satellite, Va

Water Temperature Control Valve Test

Satel

Fury

Valiant

.....................................

VIP

and Satellite

.....................

.....................................

..............................

Level-Compressor

....................................

and VIP

I

ian t

.....................................

...............................

....................................

and VIP

I

iant

...............................

.....................................

....................................

and VIP

I

i

ant

...............................

.....................................

........................

.........................

I

..............................

............................

....................

Drier

....................

.........................

.....................

............................

.........................

Fury

I

ia nt

I

ite

and VIP

.....................................

....................................

...............................

.....................................

.................

.......................

:.

Page

58

13-18

23 42

45 25

25 25

19 14

23

20

15 24 38 28 62 64

65

.

27 43 63

29-64

28

38

40

19 14

25

24-10

AIR

CONDITIONING

A

DEFROSTER

A/C DOOR ACTUATOR'

DUCT RECIRCULATING AIR DOOR

REAR HOUSING

FRONT HOUSING-

EXISTING STUD

d

\w

IN PLENUM

~'

\

HOUSING ASSEMBLY

/

A\

\\\\

\y

\

BLOWER MOTOR RESISTOR BLOCK

\

SUPPORT BRACKET

\

FRESHIRECIRCULATING

AIR

DOOR

ACTUATOR

TIME DELAY

RELAY-

/

RECIRCULATING AIR DOOR HOUSING ASSEMBLY

ENGINE SIDE HOUSING

Fig. I -Air Conditioner-Heater Assembly (Fury-VIP)

NU344

A

GENERAL INFORMATION

AIR

CONDITIONING

24-1

1

FURY

and

VIP

Three air conditioner options are available. The

l),

is

first option (Front Unit) (Fig.

a combination air conditioning and heating unit contained in two housings separated by the dash panel. The evaporator and heater core are inside the housing installed under the

instrument panel, this housing is called the “Passen-

ger Side Housing”. The blower motor and time delay

relay are installed on the housing attached to the

engine side of the dash panel, this housing is called the “Engine Side Housing”. The controls and cooling air outlets are integral with the instrument panel. This

system functions on the reheat principle.

In the “reheat” air conditioner unit all the air entering the system passes through both the evaporator coil and the heater core, regardless of whether the heater, defroster or air conditioning is in use. All output air temperatures are controlled by a single slide lever in the instrument panel, which operates

the heater water flow control valve through a vacuum

regulator. Airflow

is

controlled and directed through

the unit by a series of doors operated by vacuum

actuators and mechanical linkages. The blower

is

turned on by any of four push buttons.

The second option

is

the Automatic Temperature

Control System which automatically controls the heating and air conditioning operation of the vehicle to maintain a selected interior temperature. In cold weather, the system provides heat as soon as the warm air

is

available. When outside temperature in-

creases, the system provides cool dehumidified air.

The unit will heat or cool according to ambient temperature, interior temperature, and control setting; in varying degrees of either heating or cooling without any action on part of operator other than dialing desired temperature and setting system on “Auto.”

The basic air conditioning package has not changed. The controls have changed and various sensor components have been added and are described in detail in the “Automatic Temperature Control” section

of

this manual.

The third option (Station Wagons Only), includes

the first or second option plus a roof mounted evaporator assembly.

The roof mounted unit operates automatically in

is

conjunction with the front unit and

not available as

a single unit without the front unit.

Controls for the front system (Standard A/C) con-

sists of five push buttons, a temperature control slide

CENTER OUTLETS INSTRUMENT

PANEL

Fig. I A-Air Conditioning

NU508

Ducts

24-12

AIR

CONDITIONING

A

SOLID LINE

VACUUM

REGULATED

Fig. 2-Vacuum Circuit-Off-Max A/C Position

INDICATES VACUUM

BLEED WIRE

A/C -HEAT

lever and a three-position toggle-type fan blower

switch.

Control for the roof mounted system consists of a

rotary two speed switch.

Push Buttons-control the source and route of

“Off”

circulating air.

(turns

(maximum air conditioning);

off

system);

“A/C”

“MAX

A/C”

(fresh air-air

conditioning); “HEAT” (for heater use on1y);“DEF”

(windshield defroster).

Temperature Control

Slide

Lever-Maintains any

SOLID LINE

VACUUM

Fig. 4-Vacuum Circuit-Heat Poshion

desired temperature by sliding the lever right when operating either the heater

Fan Switch-Permits selection of low, medium

high blower speeds.

“LOW”

INDICATES VACUUM

or

left

or

air conditioner.

or

(far left); “MEDIUM”

(center) and “HI” (far right) used when operating

or

either the heater

Air

Directional Vanes-One at each end, and two

air conditioner.

in

the center of the instrument panel. These are adjust-

cool

ed manually to direct

of

the driver and passengers.

air to suit the requirements

VACUUM

SOLID LINE INDICATES VACUUM

Fig. 3-Vacuum Circuit-AIC Position

SOLID LINE

INDICATES VACUUM

VACUUM

Fig. 5-Vacuum Circuit-Defrost Position

A

AIR

CONDITIONING

24-13

The center outlets are units that can be rotated to

or

direct air up either side. (Fig.

The

outlets at each end of the instrument panel are also adjustable erated by a vertical slide lever

down; adjustable vanes direct air to

1A)

or

can be shut-off by a damper op-

or

a horizontal slide

lever depending on car model.

VACUUM CIRCUITS FOR EACH PUSH BUTTON POSITION (Fury

When testing tion system, tion of each door for each push-button position. It is also necessary to know which vacuum hoses are activated for each push-button position. In the following illustrations air flow tuator hoses are activated for each push-button posi-

tion (Figs.

Ventilation

While driving, outside air can be brought into the interior through the inlets in the side cowls. These inlets are opened by pulling the control knobs, located

it

is

2

through

or

adjusting the doors in the distribu-

necessary to know the correct posi-

is

5).

and

VIP)

indicated as the vacuum ac-

TEST PROCEDURES

on the lower edge of the instrument panel on both sides of the steering column. The knob to the left of

the column controls the air inlet on the left side of the car and the right hand knob controls the right side. The amount of air intake

is

regulated by the

distance the knobs are pulled out. Pushing the knobs

off

all the way in closes

Be sure the

way in before operating the

air

the air intake.

intake controls are pushed all the

air

conditioning system.

ELECTRICAL CONTROLS AND CIRCUITS

There are two switches, a push button switch (air

conditioner and heater vacuum switch),

(air

switch

conditioner and heater blower switch).

Push Button Control

The power feed circuit

is

shown in Figure

ampere fuse in the fuse block protects the circuit.

The compressor clutch circuit either the “Max. the

“A/C”

A/C”

(maximum air conditioning)

push buttons are depressed. The “OFF”

is

button turns off the system.

and a fan

6.

A

20

energized when

or

FURY

Satisfactory performance

ACCESSORY

PART

PANEL MAIN HARNESS

FEED

OF

INSTRUMENT

-------------

FRONT

AIR

CONDITIONING

BLOWER

COMPRESSOR

SWITCH

and

VIP

of

the combined air- proper operation and adjustment

STATION WAGON ONLY

conditioning and heating system

is

dependent upon

of

all operating

MOLDED GROMMET

FRONT AIR CONDITIONING

Fig.

6-Efectricaf

Control Circuits (Fury-VIP)

INSULATORS

FROM

TERMINAL

VIEWED

SIDE

NU117

24-14

AIR CONDITIONING

controls, as well as proper functioning of all refrigeration system units. The inspections, tests and adjustments should be used to locate the cause of a malfunction. The inspections and tests in this manual

have been arranged in a logical sequence that has proved to be the surest and shortest route to accurate

is

diagnosis. It

and

performed

recommended that they be followed in

the

Order

in

which

they

are

sent ed.

OPERATION

OF

ALL CONTROLS

Operating controls must be tested in the following

sequence.

(1)

Inspect and adjust compressor drive belt.

(2)

Open vehicle windows.

lever

to

(3)

Move

temperature

“Off”

position.

(4)

Start engine and adjust engine speed to

1130

rpm. Use a reliable tachometer.

(5)

Push the “A/C,” button in.

(6)

Fresh-recirculating

door

should be Open to fresh

air.

(7)

Test the blower operation at all three speed

If

positions.

the blower does not operate correctly, refer to “Electrical Controls and Circuits.” Leave the blower switch in the “Low” position.

A

(8)

The compressor clutch should be engaged, the

compressor operating, and the air conditioning

sys-

tem in operation. If the clutch does not engage, test the circuit as outlined under “Electrical Controls and Circuits.”

Push Button Operation

Reduce

the

engine

speed

to

normal

idle.

With

the

engine operating at idle speed, the vacuum will be high and the vacuum actuators should operate quickly.

If the actuator operation

is

slow, check the source

hose connection at the engine manifold.

Push each button to test the over-all operation of

the electrical and vacuum controls.

The “Push Button Control Chart” summarizes the actions that should take place when each button pushed. See 6CChart.99 Also

refer

to

66Vacuum

is

Circuits

for Each Push Button Position.”

If

all

the controls operate in the but the action of the dampers and doors is slow incomplete, inspect binding

or

improper linkage

for

mechanical misalignment,

ad,ustment.

proper

sequence

or

Vacuum Actuated Water Valve

The water temperature control valve

is

operated

by engine vacuum which is modulated by a regulator

on

the back of the temperature control lever. (Fig.

7)

NU416

HEATER AND

VACUUM HOSE

EXTENSION ASSEMBLY

A/C

BLOWER

MOTOR

A

AIR

CONDITIONING

24-15

PUSH BUTTON CONTROL CHART-FURY,

Button

Fresh

Air

Door Closed Closed

Recirculating Door Open

Air

Conditioning Door

Heater

Door

Defroster Doors Closed Closed Closed

Blower Speed Compressor Clutch

Movement of the control lever to the extreme right

(Heat) position allows full vacuum through the regu-

lator and full water flow through the water valve.

is

When the control lever

placed to the left

position, no vacuum will be present at the water valve

and water will not circulate through the heater core.

Time

Delay Relay

A

vacuum actuated time delay relay the face of the engine side housing in the engine compartment. The purpose of this relay

is

interior windshield condensation to an acceptable level.

When the ambient temperature

or

and the heat

defrost buttons are pressed, the air

conditioner will go on for a period of

If the system

is

shut down for less than

is

above

2

to

no delay will occur upon restarting. The relay will re-

set automatically after

Restrictor

10

minutes shut down.

The time delay system includes, in addition to the

time delay relay, a plastic restriction in the vacuum

hose leading to the heater door actuator. This re-

strictor provides some delay in the opening of the

defroster door after the “HEAT”

is

button

depressed. This delay gives the blower time

or

to expel condensation from the evaporator housing through the heater outlets before

it

can

the windshield.

Should it become necessary to replace the vacuum

hose leading to the heater door actuators, the correct

restrictor should be used.

SATELLITE

The air conditioner used on Satellite models

off

Max.

AIC

Open

Closed Closed Closed

Hi-Med.

Off

Low Low

On

a combination air conditioning and heating unit which

is

installed inside the passenger compartment behind

the instrument panel. The controls and cooling air

(OFF)

outlets are integral with the instrument panel. This system functions on the reheat principle.

In the reheat air conditioner unit all the air enter-

ing the system passes through both the evaporator

coil and the heater core, regardless of whether the

is

located on

heater, defroster put air temperatures are controlled by a single slide

to reduce the

lever in the instrument panel, which operates the

heater water flow control valve through a bowden

cable. Air-flow

25

degrees,

unit by a series of doors, operated by vacuum actuators and mechanical linkages. The blower is turned

10

minutes.

10

minutes

on by any of four push buttons.

Controls

Controls for the system consist tons, a temperature control slide lever and position toggle-type fan blower switch.

Push Buttons-Control the source and route of circulating air.

(maximum

conditioning); “Heat” (for heater use only); “Def”

“DEFROST”

(windshield defroster).

Temperature Control Slide Lever-Maintains any

desired temperature by sliding the lever right

be

blown onto

when operating either the heater

Fan Switch-Permits selection of low, medium high blower speeds-used when operating either the heater

or

air conditioner.

Air Directional Vanes-One at each end, and two in the center of the instrument panel. These are adjusted manually to direct cool air to suit the requirements of the driver and passengers.

is

The center outlets can be rotated to direct air up

AIC

Open

Closed Closed Closed

Open

H

i-Med. Hi-Med. Hi-Med.

On

or

is

controlled and directed through the

“Off’

air

conditioning);

VIP

Heat

Open

Closed

~~

Open

Closed

with

Air

Bleed

Low

Off

air conditioning

(turns

off

system); “Max-A/C”

“A/Cyy

Defrost

Open

~____~

Closed Closed

with

Air

Bleed

Open

Low

Off

is

in use. All out-

of

five push but-

a

(fresh

or

air conditioner.

air-air

three-

or

left

or

24-16

AIR

Fig.

CONDITIONING

8-Off

Position

Same

As

Max

A/C

down; adjustable vanes direct air to either side.

The outlets at each end

are

also adjustable

or

can

of

the

instrument panel

be

shut-off by a damper

operated by a slide lever.

FRESH

AIR

ACTUATOR

Fig.

IO-Hear

'

Position

plication and door positions are the same as position (Fig.

MAX

A/C

8).

NU141

MAX

A/C

A

AIR

FLOW FOR EACH PUSH

POSITION (SATELLITE

When testing

bution system,

or

adjusting

it

is

necessary to know the correct

Models)

the

doors

BUTTON

in

the

distri-

position of each door for each push-button position.

It

is

also

necessary to know which vacuum hoses are

the

activated for each push-button position. In

is

lowing illustrations air flow

uum actuator hoses are activated

button position (Figs. Control Chart" page

0

FF

The

OFF

button turns the system

8

through

15.

indicated as the vac-

for

each push-

11)

and "Push Button

off.

Vacuum ap-

fol-

The

MAX

A/C

button turns on the blower motor and

engages the compressor clutch.

is

tion

at the back

side

of all

The

vacuum applica-

three

actuators. The heater and defroster doors are closed and the airconditioning door ing door closes recirculating inlet (Fig.

is

opened. The fresh air-recirculat-

off

the fresh-air inlet and opens the

8).

A/C

When the car has been cooled to the desired temperature and the cation at the transferred to the rod side.

A/C

fresh

button

is

pushed,

the

vacuum appli-

air-recirculating door actuator

This

moves the door away

is

Fig.

9-A/C

Position

Pig. I I-Ddrost

Porttion

A

AIR

CONDITIONING

24-17

from the fresh-air inlet and closes the recirculating inlet. All other vacuum applications and door positions

are the same as for the MAX A/C button (Fig.

9).

HEAT

Pressing the HEAT button starts the blower, applies vacuum to the rod side of the air conditioning door actuator and the fresh air recirculating door actuator and to the back side of the defroster door actuator. The fresh air-recirculating door pivots away from the fresh-air inlet and closes

off

the recirculat-

ing inlet, supplying fresh air to the blower, which

forces it through the evaporator coils and the heater

is

core. Since the compressor clutch

not engaged, the evaporator has no effect on the airflow temperature. The amount of heat added to the air by the heater core depends on the setting of the water flow control valve (Fig.

10).

The air-conditioning door actuator forces the door

closed. A coil spring, attached to the air-conditioning

door linkage, pulls up on the heater door arm, opening the passage to the heater outlets in the bottom of the housing. At the same time a rod between the air conditioning door bell crank and the defroster door

pivot bell crank forces the defroster doors open

slightly, overcoming the defroster actuator, to provide

an air bleed to the windshield defrosters. This de-

froster bleed amounts to about

30

percent of the total

airflow.

DEFROST

When the heater section

30

there is a

percent bleed through the heater outlets. The vacuum applications at the air-conditioning door actuator and the fresh air-recirculating door actuator are on the rod side, the same as for heater operation. The application at the defroster door actuator ferred from the back to the rod side, opening the defroster doors all the way. As the defroster actuator

is

bell crank

pushed down by the rod, it carries the heater door arm with it, against the coil spring force, toward the closed position. The heater door stops short of the fully closed position, providing the

cent bleed to the heater outlets (Fig.

is

operating on defrost,

is

30

11).

trans-

per-

REHEAT COOLING CONTROL

The heater core inlet line divides into

12).

to feed the core, (Fig.

One branch feeds cent of the tubes, around the perimeter of the core. The other branch feeds the of the core. The center feed

70

percent in the center

is

equipped with a valve,

operated by the air-conditioning door, to shut

flow to the center tubes during air-conditioner opera-

30

tion. The outer

percent reheats the refrigerated

air to the selected temperature. The amount of re-

by

heating is determined

the slide lever of the water flow valve. The temperature can be controlled very closely, and the maximum refrigeration removes excess moisture from the air on extremely humid days.

two

branches

30

per-

off

the

CONDENSATION DRAIN TUBES

The system has two drain tubes running from the evaporator drain pan into the engine compartment. These tubes must be kept open to avoid an accumula-

tion of water, which would be blown out of the heater or air-conditioning outlets.

Ventilation

While driving, outside air can be brought into the interior through the left inlet under the instrument

panel. This inlet knob, located on the lower edge panel at the right side Amount the knob

of

is

pulled out. To stop air flow, push the knob

all the way in.

in before operating the air conditioning system.

is

opened by pulling the control

air intake

Be sure this knob

is

of

the instrument

of

the steering column.

regulated by the distance

is

pushed

all

the way

ELECTRICAL CONTROLS AND CIRCUITS

There are two switches, a push button switch (air conditioner and heater vacuum switch), and switch (air conditioner and heater blower switch).

The power feed circuit is shown in (Fig. ampere fuse in the fuse block protects the circuit.

The compressor clutch circuit

is

energized when

either the “Max.-A/C” (maximum air conditioning)

WATER

BY-PASS

“0”

RINGS

a

fan

13). A 20

AI

R-CO NDlTl ON I N G OPERATION

The air-conditioning refrigeration system operates

at full capacity constantly when either the

A/C”

or

“A/C” button

is

pushed. (Full capacity mean-

“MAX.

ing maximum refrigeration according to the existing ambient temperature and humidity.) The temperature of the air at the outlets

is

controlled by reheating the airflow after it has passed through the evaporator coils.

LINKAGE

Fig. 12-Heaier Core and By-Pass Valve Assembly

’

NK1399

24-18

AIR CONDITIONER

AIR

MOTOR RESIST CSA-14DGN-

CONDITIONING

14T

I

I-

91R CONDITIONER AND HEATER LAMP AND SOCKET

TIME DELAY

PANEL WIRING

AIR CONDITIONER

COMPRESSOR

or

the

“A/C,”

(fresh air-air conditioning) push but-

tons are depressed. The

Fig. I3-Electrical

“OFF”

button turns

FUSE

BLOCK

Control

off

system.

Blower Motor (Fan Switch)

The power feed line from the push-button switch

is

to the blower switch

is

tion

on and any push button, other than

energized only when the igni-

“Off,”

depressed.

The switch

lever from

is

controlled by moving the control

left

(low) to right (high).

Time Delay Relay

A

vacuum actuated time delay relay

the bottom of the fresh-recirculating

ing. The purpose of this relay

is

to reduce the interior

is

located on

air

door hous-

windshield condensation to an acceptable level.

When the ambient temperature

grees, and the heat

or

defrost buttons are pressed, the

is

above

25

I

Circuit (Satellite

air conditioner

the

de-

minutes.

utes no delay will occur upon restarting. The relay

will

Restrictors (Satellite Models)

The time delay system includes, in addition to the time

is

delay relay, a plastic restriction in each of the two vacuum hoses leading to the heater door actuator. These restrictors provide some delay in the opening

of the defroster door after the

FROST” button

blower time to expel condensation from the evaporator housing through the heater outlets before

be

Should it become necessary to replace either of the vacuum hoses leading to the heater door actuators, the correct restrictor should

18LGN

18DGN

oE2C-180-

LEGEND

WIRING SPLICE

INSULATORS VIEWED FROM TERMINAL SIDE

If

the

system

reset

automatically after ten minutes shut down.

-$-

Models)

will

go on for a period of 2 to

is

shut down

is

depressed. This delay gives

for

blown up onto the windshield.

be

less

“HEAT’

used.

COLOR CODE

NR281

than ten

or

min-

“DE-

the

it

can

10

INSPECTION

SATELLITE

Satisfactory performance

conditioning and heating system

Models

of

the combined air- justments should

is

dependent upon

AND

proper operation and adjustment of all operating

TEST PROCEDURES

controls, as well as proper functioning of all refrig-

tests

eration system units. The inspections,

be

used to locate the cause of a

malfunction. The tests in this manual have been ar-

ranged in a logical sequence that has proved to

and ad-

be

A

AIR CONDITIONING

24-19

the surest and shortest route to accurate diagnosis. It is recommended that they be followed and performed in the order in which they are presented.

If the actuator operation is slow, check the source

hose connection at the engine manifold.

Push each button to test the over-all operation of

the electrical and vacuum controls.

OPERATION

OF

ALL CONTROLS

Operating controls must be tested in the following

The “Push Button Control Chart” summarizes the

actions that should take place when each button

is

pushed. See “Chart.” Also refer to “Air Flow for

sequence. Each Push Button Position.”

(1)

Inspect and adjust compressor drive belt. If all the controls operate in the proper sequence

(2)

Open vehicle windows. but the action of the dampers and doors

(3)

Move temperature control slide lever to

position.

(4)

Start engine and adjust engine speed to

rpm for 6 cylinder engines and

1300

rpm for 8 cyl-

“Off”

1600

incomplete, inspect for mechanical misalignment, binding or improper linkage adjustment.

Water

Valve

Test

(Figs.

14

and

15)

is

slow

or

inder engines. Use a reliable tachometer. The temperature control water valve is mounted

(5)

Push the Max. A/C button in.

(6)

Fresh-recirculating door should be closed to

fresh air.

(7)

Test the blower operation at all three speed

If

positions.

the blower does not operate correctly,

refer to “Electrical Controls and Circuits.” Leave the blower switch in the “Low” position.

(8)

The compressor clutch should be engaged, and then back to the

the compressor operating, and the air conditioning

system in operation. If the clutch does not engage,

test the circuit as outlined under “Electrical Controls

and Circuits.”

from the engine compartment side

The sensing unit

corner of the air conditioning housing.

Remove the radiator cap to minimize pressure in

the car’s cooling system.

Move the temperature control slide lever on the

instrument panel to the extreme “Warm” position

Push the “Max A/C” button in, and with the blow-

er in the “Low” position, run the air conditioning system for five minutes, then test the water valve by momentarily disconnecting the heater outlet hose at

is

located at the lower right-hand

“Off”

position.

of

the dash panel.

the upper side of the heater.

Push

Button

Reduce the engine speed to normal idle. With the

Operation

CONTROL CABLE

(Turnbuckle)

(Fig.

14)

engine operating at idle speed, the vacuum will be high and the vacuum actuators sphould operate

quickly.

A

turnbuckle has been incorporated

ditioning temperature control cable.

in

the

This

turnbuckle

air

con-

TURNBUCKLE CABLE ADJUSTER (INITIAL INSTALLATION ONLY)

Fig.

1

&Water Temperature Control Cable Adjustment

CABLE FLUSH

WITH BRACKET

VIEW

IN

CIRCLE A

NU147

24-20

AIR

CONDITIONING

A

CABLE

TEMPERATURE CONTROL VALVE,

SENSING

is

used to adjust the length

UNIT-

Fig.

‘4

15-Water Temperature Control

of

the

cable housing

out removing it from the instrument panel control

--

\y

IN DIRECTION

with-

ARROW

or

OF

“A”

Lever

Adjustment

Coronet and Charger models to adjust). Replacement

will

cable

be of

the water valve. adjustment).

‘TEMPERATURE

at

Dash Panel

the

standard type.

“A”

CONTROI

(See

control cable

.

VALVE

NP703

Adjustment Control Cable Adjustment

To

If

the water valve does not fully open

control cable housing may

be

shortened

or

close,

or

lengthened

the

by rotating the turnbuckle (remove glove box on

adjust the temperature control cable, place the

in

water valve

the full open position and position

end of the control cable housing against the bracket

SATELLITE PUSH BUTTON CONTROL CHART

Button

Fresh

Air

Door

Recirculating Door

Air

Conditioning Door

Heater Door Closed Closed Closed

Defroster Doors Closed Closed Closed Air-Bleed

Blower Speed

Compressor

Clutch

Off

Max.

A/C

Closed Closed

Open Open

Off

~~

Open

H

i

.-Med.

Low Low Low Low

On

AI

C

Open

Heat Defrost

Open

Closed Closed

Open Closed Closed

Open

Closed

with

H

i.-Med.

On

Hi.-Med.

Off Off

Open

Closed

with

Ai

r-B

I

eed

Open

Hi.-Med.

the

Chrysler Valiant (1969) Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual