Mitsubishi Starion 1988 User Manual

Service Manual

Introduction and Master Troubleshooting ***-**0*-**0**~~*

CONQUEST L

Volume-l -~~~~~~-

Engine, -

Chassis & Body

._ FoREWoRD . ,. “” 1.“.

This Service Manual has been prepared with the

latest service information available at the time of publication. It is subdivided into various group categories and each section contains diagnosis, disassembly, repair, and installation procedures along with complete specifications and tightening references. Use, of this manual will aid in properly performG-rg any .servicing’ necessary to maintain or restore the high levels of performance and reliability designed jnto these outstanding vehicles.

Lubrication and Maintenance

mnt Suspension

Rear Axle ............................................

Service

Brakes - Parking

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling Engine -’

-jj-“. .-y; ,.+ .,,i

Intake and Exhaust System

Fuel System Propeller Shaft and Universal

Joints

Rear Suspension

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..-f....

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

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Chrysler Motors reserves the right to make changes in design or~to.

make additions to or improvements in its prodlicts without imposingany obligations upon jtself to install them on its products previously

manufactured,* @ 1987 Mitsubishi Motors Corp&ation Printed in Japan

Body Heaters and Air Conditioning Emission Control Systems

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

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HOW TO USE THIS MANUAL

’ CONTENTS

The preceding page contains GROUP INDEX which

lists the group title and group number.

*’

- iAGE NUMBERS

All page numbers consist of two sets &digits

p

separated by a dash. The digits preceding the dash

-identify the number of the group. The digits following the dash represent the consecutive page number within the group. The page numbers can be

found on the top left or right of each page.

TEXT

Unless otherwise specified, each service procedure

covers all models. Procedures covering specific

models are identified by the model codes or similar designation (engine type, transmission type, etc.). A description of these designations is covered in this

unit under “VEHICLE IDENTIFICATION”.

_ How to Use This Manual

Repair kit or set parts are shown. (Only very frequently used parts are shown.)

TROUBLESHOOTING

Troubleshootings are classified into master trouble-

shooting and group troubleshooting and located as follows: The master troubleshooting is prepared when the trouble symptom relates to two or more groups and given in MASTER TROUBLESHOOTING. The group troubleshooting guide is prepared for causes of problems related to that individual group only; a troubleshooting guide IS prepared for each

I appropriate group.

SERVICE PROCEDURES

The service steps are arranged in numencal order and attentions to be paid in performing vehicle service are described in detail in SERVICE POINTS.

DEFINITION OF TERMS

STANDARD VALUE Indicates the value used as the standard for judging

the quality of a part or assembly on inspection or the

-_value~to which the part or assembly is corrected and adjusted. It is given by tolerance.

LIMIT Shows the standard for judging the quality of a part

or assembly on inspection and means the maximum

or minimum value within which the part or assembly

must be k_ept functionally or in strength. It is a value

~~ esiablished outside the range of standard value.

Removal steps:

The numbers before part names correspond

to numbers In the illustration. and indicate the order of removal.

Disassembly steps.

The numbers before part names correspond

to numbers In the illustration, and indicate

the order of disassembly.

Installation steps:

This is provided if installation cannot be

made in the reverse order of “Remov& steps”;

order of “Removal steps” is possible.

Reassembly steps:

This IS provrded

made In the reverse order of “Disa$semblysteps” ; verse order of “Disassembly steps” is possible.

omitted if rnstallation in the reverse

if

reassembly cannot be

omitted If reassembly in the r&

Classification of SERVICE POINTS

- Removal * Disassembl

INTRODUCTION AND MASTER TROUBLESHOOTING - How *o “se This Ma”ua’

Indicates the incidental

operation to be. per-

Page number Group title

I

Sectipn title

formed before removal or after installation.

3

I

i

BRAKES

REAR BRAKE WHEEL CYLINDER

REMOVAL AND INSTALLATION

18-21 Nm

,..-/ 13-15ft.lbs.

- Rear Brake Wheel Cvlinder

I

N05”A-

Dravvng Brake Fluid

.

Post-installation Operation

pi2jijq-J

Indicates non-reusable part.

-

1

Removal steps

*+ 4. Wheel cylinder assembly

+e 5.

-

l

- l * l * 7. Piston cup

I

1. Brakedrum

2.

Bleeder screw

3.

Brake tube

Wheel cyhnder boot

* 6. Piston assembly

Wheel cylinder kit

NOTE (1) Reverse the removal procedures to reinstall. (2) a*: Refer to “Service Points of Removal”. (3) *a: Refer to “Service Points of Installation”.

14) p Non-reusable parts

SERVICE POINTS OF REMOVAL/

7. REMOVAL OF PISTON CUP

Using a screwdriver, remove the piston cup from the

I

This number corresponds to the number in “Removal. steps”, ” Disassembly steps”,

“installation steps” or “Reas-

sembly steps.”

NOWBAI

installation. disassembly and

INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicte Identification

VEHICLE IDENTIFICATION

NOOCA-

VEHICLE IDENTIFICATION NUMBER LOCATION

The vehicle identification number (V.I.N.) is located on a plate attached to the left top side of~the instrument panel and visible through the windshield.

VEHICLE IDENTIFICATION CODE CHART PLATE

NOOCB-

-

All vehicle identitication numbers contain 17 diaits. The vehicle = ~~

number IS a code which tells countrv, make, vehicle

type,

etc. ~~~~

0 J 2 000001 : 1988 Okazakl

3

I

C’hwk dealt” means a wale number or letter X used lo venfv the accuracy of trarwxptlon of vrlllcle Identifvzatlon number

VEHICLE IDENTIFICATION NUMBER LIST

V.I.N.

(except sequence number) (Package)

JJ3CC54HOHZ JJXC64HOHZ JJ3CC54NOHZ Federal JJ3CC54NCIHZ California’

- Can also be sold In Federal states,

Brand

Chrysler

DeStinatiQn

Federal

California*

Engine

displacement

2.555 liters

(155.9 C.I.D.)

plant 99E399

NOOCC- -

Models code

Al 87AMRFGL4 Al 87AMRFGL9 Al 87AMNFGL4 Al 87AMNFGL9

INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle identification

5

VEHICLE INFORMATION CODE

PiATE

NOOCD-

Vehicle information code plate is riveted onto the firewall in the engine compartment. The plate shows model code, engine model, transmission

model, final gear ratio, and body color code.

1. MODEL

2. ENGINE

3. TRANS-

A187AMNFGL4

---lIT~:;:l,,n,,i G54B

I Engine model

KM 132Cl3545

AXLE

-iI

Final gear ratio Blank

4:COLOR, TRIM

OPT

T-L

H84

I

I Monotone exterior

Transmission model

color code

-

CHASSIS NUMBER

NOOCE- .

STAMPING LOCATION The chassis number is stamped on the top center of the

firewall located in the engine compartment. CHASSIS NUMBER CODE CHART

A187MJZ000001

Vehicle line

A18- 7- M-

CONQUEST

VEHICLE SAFETY CERTIFICATION LABEL

Engine

displacement

Body type

2.555 liters 2-door

(155.9 C.I.D.) Hatchback

Refer to 10th thru 17th digits of V.I.N. plate

NOOCF- -

The vehicle safety certification label is attached to face of left door pillar. This label indicates the month and year of manufacture, Gross Vehicle Weight Rating (G.V.W.R.), Gross Axle Weight Rating [(&k$/.R.) front and rear, and Vehicle Identification Number F~

. . . .

i

x I

6

INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle identification

ENGINE MODEL STAMPING

NOOCG..

The engine model number is stmped at the right front side on the top edge of the cylinder block as shown in the followlng:

.Engine displacement

The engine serial number is samped near the engin model

number, and the serial number cycles, as shown below.

Engine serial number

BODY COLOR CODE

Exterior code

R04 R88 T87 wo9 x15 Y59

Red Maroon (Metallic) Blue (Metallic) White Black Yellow

NOOCH- .

e.

K’

Theft protection label

For ori$nal parts

For

replacement parts

OOK619

OOK621

NOOClAA

To provide protection against -theft, the vehicle identification number (V.I.N.) is stamped on or its label is affixed ta t_he following major engine, transmission parts arrd body outer panels-

Engine cylinder b&k, transmission housing, @rtder,Tquar@r panel, hood, rear hatch and bumpers. The theft protection label is aIS_o affixed to each=pf major bociy outer panels for servicing, while the same information as Ihe theft protection label is stamped on the engine and tfansmis sion for servicing:

Caution

1. Affix masking tape to the theft protection label before repainting the original part. After painting, be sure to remove the masking tape.

2. The theft protection label on the service part has masking tape affixed to it. Therefore, paint the part as is and remove the masking tape after painting.

3. Do not remove the theft protection label from the

original or service part.

INTRODUCTION AND MASTER TROUBLESHOOTING

LOCATIONS

- Vehicle Identification I ’

OOLO634

l

The theft protection label is affixed to the inside surface.

l

The illustration indicates left hand side, outer. Right hand side is symmetrical.

INTRODUCTION AND MASTER TROUBLESl400TING - Vehicle kkntification

Part name

Quarter panel

Hood

Target area

: for original equipement parts : for replacement pares

-

00L0638

l

The theft protection label is affixed to the inside surface.

l

The illustration indicates left hand side, outer. Right hand sideis symmetrical.

OOL0640

l

The theft protection label is affixed to the inside surface.

Rear hatch

3umpers

OOL0639

l

The theft protection label is affixed to the insidesurface.

Front bumper

0OL0635

-__ Rear bumper

D The theft protection label is affixed to the inside surface.

_

i ~-~

OOL0636

.I

~_

I

INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Service

PRECAUTIONS BEFORE SERVICE

PROTECTING VEHICLE

If there is a likelihood of damaging painted or interior parts during service operations, protects them with suitable covers (such as seat covers, fender covers, etc.).

OOY684

REMOVAL AND DISASSEMBLY

&fig

.a<

,,’ s

I

OOY192

?

P

0

OOY58?

FOO017

When checking a malfunction; find the cause of the problem. If

it is determined that removal and/or disassembly is necessary, perform the work by following the procedures contained in this Service Manual.

If punch marks or mating marks are made to avoid error in

assembly and to facilitate the assembly work, be sure to make them in locations which will have no detrimental effect on performance and/or appearances. If an area having many parts, similar parts, and/or parts which

are symmetrical right and left is disassembled, be sure to arrange the parts so that they do not become mixed during the assembly process.

1. Arrange the parts removed in the proper order.

2. Determine which parts are to be reused and which are to be

replaced.

3. If. bolts, nuts, etc., are to be replaced, be sure to use only

the exact size specified.

9

NOODAAD

0

FOOOll

000511

,SPE(XAL TOOLS

If other tools are substituted for the special tools to do service

or repair work, there is the danger that vehicle parts might be damaged, or the technician might be injured; therefore, be sure

to use$he special tool whenever doing any work for which the

use of one is specified.

3

PAR+ TO BE REPLACED

If any rof the following parts are removed, they must be replaced with new parts.

1. Oil rseals

2. Gaskets (except rocker cover gasket)

3. Packings

4. O-rings

5. Lock wa:hers

6. Cotter pins

7. Self-locking nuts

-s

--

i

-----;

-li_w - I-A.. i

IO

mm (in.)

INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Service

PARTS

When replacrng parts, use MCIPAR genurne parts.

=VEHICLE WASHING

If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to maintain the spray nozzle at a distance of at Jeast 300 mm (12in.I from any ‘; plastic parts and al! opening parts (doors, !u.rgg&e @mparJ ~ ment, sunroof, etc.).

so0059

::

~~~ ;~~

---=;-mz%

=j_c- .-

a= mw-

w

-

Indication ‘mark

\ -\

\ L

16C38(

-cl6381

SERVICING ELECTRICAL SYSTEM

1. When servicing the electrical system, pay attention to the following.

Never attempt. to modify an electrical unit or to change --_r wirings, which may otherwise cause not only a .vehicle failure but a vehicle fire due to over-capacity short-circuit.

2. Before servicing the- electrical system, disconnect the ‘I., z negative cables terminal fErn the battery. ’ :Z

Caution Before connecting or disconnecting the negative cable, be sure to turn off the ignition switch and the lighting switch. (If this is not done, there is the possibility of semicon-

ductor parts being damaged.)

WIRING HARNESSES

1. Secure the wiring harness9 by using clamps. However, for any harness which passes to the engine or’other vibrating parts of the vehicle, allowmVsome slack within a raj-rge that ‘= does not allow the engine_vibrations to cauEe the-harness 11: to come into .contact with any of the su~F8undEig pa~rts. e -

Then secure the harness- by using a clamp. ’

In addition, if a mounting indication

mark (yeflow

a harness, secure the indication mark in the-;specified -1 location.

2. If any section of a wiring harness contacts theedge of a ~-_ part, or a corner, wrap the section of the harnesswith tape

or something similar in order to protect it ~from damage. _I_

!oad %r Z

_z

~-

-em--

Gpe) is on c_

-

sI

GFe

G

F16171

.-

Correct

3. When disconnecting a-connector, be sure to pull only the --,: connector, not the harness.

Incorrect

16YO5’

638:

4. Disconnect connectors which have catches by pressing in the direction indicated by the arrows in the illustration.

Y1634;

OOY58

Cl6384

5. Connect connectors which have catches by inserting the connectors until they snap.

ELECTRICAL COMPONENTS

1. When installing any of the vehicle parts, be careful not to pinch or damage any of the wiring harnesses.

.

r RIlc&q

m&&+

~=

W% __..m-----

T-

-.__

: -

-- ii&

mODUCTION AND IhASTER TROUBLESHOOTING - Precautions before Sewice

i =-

_ - ~- --.

~~ ~~~____~ -~~ __ ~~-~~

2. Sensors, relays, etcr, are sensrtrve to st-rong~rmpacts. =~~= Handle them with care so that they are not dropped or

mishandled. ~~~

ooY5at

3. The electronic parts used--for relays, etc., are sensrtrve- to. .i_ .,, E heat. If any service which causes a temperature of 80°C __ (176°F) or more is performed, remove the part or parts in = _ question before carrying out the service. . .- ET

OO’i61

FUSES AND FUSIBLE LINKS

I.

If a blown-out-fuse is to be replaced, be sure to use only a

fuse of the specified capacity. If a fuse of azapacjty larger than that specified is used, parts may be damaged and the ~~._

circuit may not be protected adequately. Caution

1. If a fuse is blown-out, be sure to eliminate the cause of the problem before installing a new fuse.

IOA

Nominal

size

0.3

mm2 AWG22 - 5A

0.5

mm2 AWG 20 7A l3A

0.85

mmi AWG 18 9A 17A

1.25 mm’ AWG 16 l2A 22A

2.0

mm* AWG 14 16A 30A

3.0

mm2 AWG 12 21A 40A

5.0

mm2 AWG 10 31A 54A

SAE

gXe

compartment areas

15A

OOY58!

Permissible current

In engine

Other

2. Check the condition of fuse holders. If rust or dirt is found, clean metal parts with a fine-grained sand-

paper until proper metal-to-metal contact is made. Poor contact of any fuse holder will often lead to

voltage drop or heating in the circuit and could

result in improper circuit operation.

2. If additional optionafequipment is

f0

be installed in the ~~_ =

vehicle, follow the procedure listed in the apf%opriate - -~ -~. E

instruction manual; however, be sure to pay careful attention to the following: points: (I) In order -to avoid ovrrrloading the !&iJg. J&e.i..,&_ zsI -I=.&

electrical current load_af the optional equipment into mm consideration, and determine the appropriate wire size.

(2) Where possible, route the wiring through the existing em: ~~ !

harnesses,

(3) If an ammeter or srrnrlar Instrument is to~.be connected. --ii

to a live-wire crrcurt. use tape to protect the wrre, use a clamp to secure:the wire, and make sure that there IS .~;

no contactwtth any other parts.

(4)

Be sure to provide a fuse for the load circuit of the. -< __.~ ?-

optronal equipment.

.

e

!!!5

-.-

zt

E.-

_a --

-.

-

_.- ~~

Z~

-~~

F= E

m g*

-5 E

-=a

nm4

z E

k

m= t;:

s-

INTRODUCTION AND MASTER TROUBLESHOOTING

bb

~-

- Precautions before Service (- lik

OOY58F

FOOOZE

TUBES AND OTHER RUBBER PARTS

Be careful to avoid spilling any gasoline, oil, etc., because if it adheres to any tubes or other rubber parts, they might be adversely affected.

LUBRICANTS

In accordance with the instructions in this Service Manual, apply the specified lubricants in the specified locations during assembly and installation.

BRAKE FLUID

Be careful to avoid spilling any brake fluid on painted surfaces, because the paint coat might be discolored or damaged.

1:

-\ ’

OOY58E

DOING SERVICE WORK IN GROUPS. OF TWO OR MORE TECHNICIANS

If the service work is to be done by two or more technicians

working together, extra caution must be taken.

G,” I4 INTRODUCTION AND MASTER TROUBLESHOOTlNG

NOTE ON INSTALLATION OF RADIO EQUIPMENT

The computers-af the electronic control system has been I designed so that external radio waves will not interfere with _ their operation. However, if antenna or cable of amateur transceSer etd. is:-” routed near the computers, it may affect the operation of the

computers, even- if the output of the transceiver is no more than 25W. To protect each of the computers from interference by transmi‘tter (hum, transceiver: etc.), the following should be observed.

1. Install the antenna on the roof or rear bumper.

2, Because radio waves are emitted from the coaxial cable of

the antenna,-= keep it 2M mm (8 in.1 away from the computers and the wiring harness. If the cable must cross the wiring harness, route it so that it runs at right angles~to the wiring harness.

3. The antenna and the cableshould be well matched, and the standing-wave ratio+ should be kept low.

4. A transmitter having a lame output should not be installed in the vehicle.

5. After installation of transmmer. run the engine at idle, emitradio waves from the transmitter and make-sumthat the

engine is not: -affected-

“o,tageLvz;!;age

Voltage

High-frequency

power supply

=- -. -. .

Cable

Antenna

00Y!730

*STANDING-WAVE RATIO

If an antenna and a cable having different im@edanties se connected, the input impedance Zi will vary in accordance with the length of the cable and the frequency of the transmitter, and the voltage distribution will also vary in accordancewith the location.

The ratio between~ this maximum voltage and minimum voltage

is called the standing-wave ratio It can also be represented by

the ratio between the impedances of the an‘lenna FU-I~ the cable. The amount of radio waves emitted from the cable increases EE the standing-wave ratio increases. and this increases the possibility of the electronic -components being adversely

affected.

- Precautions before Service

NOOEA..

INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoistin< ,$-

TOWING AND HOISTING

WRECKER TOWING

1. This vehicle cannot be towed with sling-type equipmt

2. If a vehicle is towed from the front, use wheel lift or flat be equipment.

3. If a vehicle is towed from the rear, use flat bed equipment.

SAFETY PRECAUTIONS

1. Any loose or protruding parts of damaged vehicle such as hoods, doors, fenders, trim, etc., should be secured prior to moving the vehicle.

2. Operator should refrain from going under a vehicle such as hood, doors, fenders, trim, etc., unless the vehicle is adequately supported by safety stands.

3. Never allow passengers to ride in a towed vehicle.

4. State and local rules and regulations must be followed when towing a vehicle.

HOISTING

POST TYPE

Special care should be taken when raising the vehicle on a frame contact type hoist. The hoist must be equipped with the proper adapters in order to support the vehicle at the proper

locations. (Next page) Conventional hydraulic hoists may be used after determining that the adapter plates will make firm contact with the front/rear crossmembers.

FLOOR JACK

A regular floor jack may be used under the front/rear crossmembers.

Caution

1. A floor jack must never be used on any part of the underbody.

2. Do not attempt to raise one entire side of the vehicle by placing a jack midway between front and rear wheels.

This practice may result in permanent damage to the

body.

EMERGENCY JACKING

Jack receptacles are located at the body sills to accept the i scissors jack supplied with the vehicle for emergency road service. Always block opposite wheels and jack on level surface.

r=

-=

INTRODUCTION AND MASTER TROl

ME CONTACT SUPPORT LOCATION

4

1.225 mm (48 in.)

JBLESHOOTlNG

- Towing and Hoisting

LIFTING, JACKING SUPPORT LOCATION

Wheel base

2,435mm f95.9in.) ~.”

’ ~;~ 5

e

~~~~~~~ Frame contact hoist

m F’oor Jack

Twin post hoist or scissors lack (emergency) locatlons

0

/If

INTRODUCTION AND MASTER TROUBLESHOOTING - General Data and Specifi( <

GENERAL DATA AND SPECIFICATIONS

‘

4

‘i

:

Items

Vehicle dimensions mm (in.)

Overall length Overall width Overall height

Wheel base Tread Front

Overhang Front

Rear

Height at curb mass (wt.)

Front bumper to ground Rear bumper to ground

Minimum running ground clearance Angle of approach Angle of departure

Ramp breakover angle

dehicle weights kg (Ibs.)

Curb weight Gross vehicle weight rating Gross axle weight rating Front

Rear

Seating capacity

Rear

Al 87AMRFGL4 Al 87AMRFGL9 Al87AMNFGL9

0 4,400 (173.2) 4,400 (173.2) 0 1,735 (68.3) 1,735 (68.3) 0 1,275 (50.2) 1,275 (50.2) 0 2,435 (95.9) 2,435 (95.9) g 1,465 (57.7) 1,465 (57.7)

1,455 (57.3) 1,455 (57.3) CD 970 (38.2) 970 (38.2) @ 995 (39.2) 995 (39.2)

@I

63 370 (14.6) 370 (14.6) 0 115 (4.5) 115 (4.5)

0 0 63

355 (14.0) 355 (14.0)

16” 19” 19” 12” 12”

1,405 (3,097) 1,375 (3,031) 1,840 (4,056) 1,840 (4,056)

885 (I ,951) 885 (1,951)

955 (2,105) 955 (2,105)

5 5

Al 87AMNFGL4

16”

OOY653

INTRODUCTION AND MASTER TROUBLESHOOTING -

General Data and Specifications

-.

Items

Engine

Model No. Type

Number of cylinders Bore mm fin.) Stroke mm tin.) Piston displacement

cm-’ (CID) Compression ratio Firing order Basic ignition timing

1

Manual transmission

Model No. Type ~-~ Gear ratro 1 st

2nd 3rd

4th

5th Reverse

Al 87AMRFGL4 Al 87AMRFGL9

Al 87AMNFGL4

Al87AMNFGL9

._= .z

G54B with turbo

In line OHC In line OHC ==~~~

4 4

91.1 (3.59) 91 .‘I 0.59)

98.0 (3.86) 98.0 (3.86)

2,555 (I 55.9) 2,555 (155.91 1

7.U 7.0

1-3-4-2

l-3-4-2

IO” ETDC IO” BTDC

KM132

5-speed manual

3.369

2.035 I.366

1.000

0.856

3.578

dutomatic transmission

Model No. Type

Gear ratio 1 St

‘inal drive gear ratio

._,I-~.

llutch

Type ~~

2nd 3rd 4th

Reverse

JMGOD

-

4-speed automatic ~~

2.458

-

1.458

1.000

0.686

2.182

-

3.545 11

-7: .~.~ __

Dry-single disc & ~ Dry-single disc & diaphragm spring

diaphragm spring

INTRODUCTION AND MASTER TROUBLESHOOTING -

General Data and Specificatib, 6

Items

Chassis

Tire

Front suspension

Type

Rear suspension

Type

Brakes

We

Power steering

Gear type

Gear ratio

Fuel tank capacity

Front Rear

Al 87AMRFGL4 Al 87AMRFGL9

Front Rear

205/55VR16 225/50VR16 2257506VR16

Radial

Independent strut

integral type

(Recirculating ball nut)

(Constant ratio gear) 75 liters (19.8 gals.)

245,4:VR 16

Radial

Disc Disc

14.3

A187AMNFGL4 Al 87AMNFGL9

Front

205/55VR 16

225/5%/R 16

Radial

Independent strut

Integral type

(Recirculating ball nut)

(Constant ratio gear)

75 liters (19.8 gals.)

225/50VR 16

245,4%R 16

Disc Disc

14.3

i

Rear

Radial

HTENING TORQUE

Description

6 x 1.0 2.2-2.9 ~~~

8 x 1.25 5.8-8.7 ~_~~ IO x 1.25 12 x 1.25 35-53 .-

14 x 1.5

16 x 1.5 18 x 1.5 180-230

20 x 1.5

NOOJA- _

Internal thread: Aluminum Internal thread:~ Cast irenT

PT I/4

PT 3/8

NPTF ?/8 7.9 - 12 5.8 - 8.7 Internal thread: Aluminum

16- 19 12-14

NPTF l/4 19-30 14-22 Internal thread: Aluminum

34-45 25-33 ~~ Internal thread: Cast iren .L-_ ~~ ~~

Internal thread: Aluminum Internal thread: Cast iron ~c

Internal thread: Aluminum Internal thread: Cast ircYn. <-

Internal thread: Aluminum Internal thread: Cast ire17

Internal thread: Cast iron ~.:; -z-

~;

INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting “-~,

MASTER TROUBLESHOOTING

ENGINE OVERHEATS

Symptom

Engine overheats

Probable cause

Cooling system faulty Incorrect ignition timing

Water leaks

l

Loose cylinder head bolt

l

Damaged cylinder head gasket

l

Cracked cylinder block

l

Cracked cylinder head

Loose intake manifold bolts or leaking from gasket

Cracked intake manifold

Faulty automatic transmission oil cooler operation

l

Blocked or collapsed hose and pipe

l

Loose hose and pipe connection

ENGINE WILL NOT CRANK OR CRANKS SLOWLY

Symptom

Probable cause

Reference page or remedy

7-6

8-l 44

g-30,43 g-29,42 9-65 9-42

1 l-5 1 l-6

21-76 21-75

Reference page or remedy

Engine will not crank or cranks

Starting system faulty

slowly

ENGINE WILL NOT START OR HARD TO START (CRANKS OK)

Symptom

Engine will not start or

hard to start (Cranks OK)

Probable cause

Ignition system problems Compression too low No fuel supply injector Injection system problems

Vacuum leaks

l

Purge control valve hose

l

Vacuum hoses

l

Intake manifold

l

Injection mixer

l

EGR valve

8-l 29

Reference page

or remedy 8-l 42 9-l 5 (9-l 3)

14-81 14-27

Repair as necessary

INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting

’ ROUGH IDLE OR ENGINE STALLS

Symptom

Rough idle or engine stalls

l

Purge control valve hose

l

Vacuum hoses * Intake manifold * Injection mixer

ENGINE HESITATES OR POOR ACCELERATION

Symptom Probable cause

Ignition system

l

Purge control valve hose

l

Vacuum hoses

l

Intake manifold

l

Injection mixer

problem

Reference page 3r remedy

f

25-27 Repair as necessary

Refer to “Engine

Overheats”

t

INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshoo*ing

ENGINE DIESELING

Symptom Probable cause

Engine dieseling (runs after

ignition switch is turned off)

Incorrect ignition timing

EXCESSIVE OIL CONSUMPTION

Symptom

Excessive oil consumption

L

Probable cause

Positive crankcase ventilation line clogged Valve stem worn Valve stem seal worn or damaged

Piston ring worn or damaged Oil leak

23

Reference page or remedy

8-144

Reference page or remedy

o-14 g-45,46

9-47 9-53 Repair as necessary

POOR FUEL MILEAGE

Symptom

Poor fuel mileage

NOISE

Symptom

Probable cause

I

Air cleaner clogged

Brakes drag Clutch slips Ignition problems Compression too low Fuel injection system problems

Tires improperly inflated Fuel leak

Probable cause

Reference page

or remedy

o-13

5-l 9

6-5 8-142 9:15 (9-13) 14-30

22-2

Repair as necessary

Reference page

or remedy

Noise

I

Engine noise Loose bolts and nuts

9-13

Retighten as necessary

-.

--..___-

24

INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting

HARD STEERING

POOR RETURN OF STEERING WHEEL TO CENTER

POOR RIDING

Symptom

Probable cause

INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting

ABNORMAL TJRE WEAR

Symptom

Abnormal tire wear Improper front or rear wheel alignment

Probable cause Reference page

Loose wheel bearings

Malfunctioning shock absorber Improper tire pressure lmbalanced wheels

ROAD WANDER

Symptom

I

Road wander Improper front or rear wheel alignment

Probable cause Reference page

Poor turning resistance of lower arm ball joint Loose or worn lower arm bushing Loose or worn wheel bearings

or remedy

2-7, 17-7

2-9, 10, 11,

3-20

2-15, 17-16 22-2,4

or remedy

1 2-7, 17-7

2-20 2-9, 11, 20,22

Excessive play of steering wheel Improper tire pressure

VEHICLE PULLS TO ONE SIDE

Symptom

Vehicle pulls to one side

Probable cause

Improper front or rear wheel alignment Excessive turning resistance of lower arm ball joint

Wheel bearing seizure Deformed lower arm

Bend drive shaft lmbalanced or worn tires Uneven tire pressure

) 19-9

Reference page

or remedy 2-7, 17-7 2-20 2-9, 11 2-20 3-25 22-2,4

._ _

*Bs

..A .Y

26

INTRODUCTION AND MASTER TROUBLESHOOTING

STEERING WHEEL SHIMMY

Symptom

Steering wheel shimmy

- Master Troubleshooting

Broken or weakene nt or rear st

BOTTOMING

Symptom Probable cause Reference page

Bottoming Broken or weakened coil spring 2-15, 17-16

_

Malfunctioning shock absorber

Overloaded vehicle

or remedy

Correct

INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting

WHEEL BEARI.NG TROUBLESHOOTING

27

Trouble

Pitting

Flaking

Cracking

Flat spotting When large load is applied, race and roller

Nicks Instead of rolling along race surface, rollers

Smearing

Rust, corrosion

Symptom Pitting occurs because of uneven rotation of

race and bearing surfaces Excessive load

The surface peels because of uneven rotation End of bearing life of the race and bearing surfaces

Chipping or cracking of cage or roller edges

contact surfaces compress, forming

indentations

slide, thus damaging surface

Damage or wear caused by minute particles adhering to surfaces results in rough movement and such high temperatures that parts of surface melt

Appears on various areas of the bearing

Probable cause Excessive bearing preload

Improper bearing assembly Impact when bearing was installed

(such as being hit with a hammer) Excessive bearing preload

Excessive load Vibration when bearings are not used, such as during shipment on freight cars, transport trucks, etc.

Insufficient grease

Excessive bearing preload

Excessive load

Faulty oil seal

Excessive variation of loads on bearings

Use of grease other than that specified

Insufficient grease

Use of grease other than that specified

Faulty oil seal

Presence of water or moisture

Wear Wear of surface areas caused by friction

Discoloration Grease discoloration.results from grease

deterioration which causes particles of pig-

ment contained in grease to adhere to surfaces Heat discoloration will appear as a deep brown Excessive load

or purple

Insufficient grease

Foreign matter

Rust or corrosion due to moisture

Use of grease other than that specified

Faulty oil seal Use of grease other than that specified

Faulty oil seal

Excessive bearing preload

BODY

CONTENTS

23-I

AERO PARTS . . . .._. _ .____t___.. _ ___.._._...__....__._ _ __.__._.___... 82

AUTOMATIC SEAT BELTS . . . . . . . . . .._...t....._ _ _.... ___. 106

BUMPER . . . . . . . . . . . . . . . . . . . . . . . _ ._....___...__..._._....__...___.__.... _

DOOR ASSEMBLY . . . . . . . . .._..._._...___.. ___ . . ..__...__...__ _.__ 62

DOOR MIRROR . . . . . . . . . . . . . . . . . . . . . . . . .._....__. _ . . . . . . . . . . . .._... 77

DOOR TRIM . . . . . . . ..t_..... _ . . . .._....._....._....__. _ .___.. _ __...__.,.

FENDERS . . . . ..I__.. _.__ __..._....__...._....... _.____._ .___..____..._...

FLOOR CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._..... _ . . . .._. 93

FRONT DOOR GLASS AND REGULATOR . . . . 66

FRONT DOOR HANDLE AND LATCH FRONT DOOR WEATHERSTRIP

FUEL FILLER DOOR . . . . . . . . .._._.._.__...___._____._.__.___._.. 34

GRILLE AND MOULDING . . . . . . . . .._..._.__...__...___.._.__. 50

. . . . . . . . _._ . . . .._....._. 75

_....._._... 71

42

64

47

SERVICE ADJUSTMENT PROCEDURES

Door Fit Adjustment ................................... _. .. . 30

Door Glass Adjustment

Floor Pan Inspection ........... . ... _._._ ..................... 31

Hood Fit Adjustment ......................... ..-.-..- ....... 29

Inside Handle Play Adjustment .................. . ..... 30

Outside Handle Adj&tment ............................ 31

Rear Hatch Fit Adjustment ................................ 29

SPECIAL TOOL

SPECIFICATIONS . . . . . . . . . . . . ..___ _ . ..__......................... 2

General Specifications . . . . . . . . . . . . . . . . . . . . . . ..a...........

Lubricants . . . . . . . . . . . . . . . . . . . . . =.._ __....._._....__,_.._ _ . . . . .._........ 4

Sealants and Adhesives . . .._____.___ ..: _._.___... _ __....__. 4

Service Specification . . . ..____.. ____._ .~__...........,....... 3

Torque specifications . - . . . . . .._.*............................-.. 3

SUNROOF . . . . . . . . ..__.........~.....~.....~.................~......... 79

TRIMS . . . . .._.__.._. _ .___.___.___.______...~..............~~ ___._I_ _..._._, 95

. . . . .._....._.._..__....~...................~... _... 4

............ .._.._ .._ . .._..._ ..... .._ 30

........ 29

2

HEADLINING . . . .._._.__._...__....._...._....___....__..__........._ 101

HOOD ..,....._._ _ __.. ___ _...____.._._..._.....__....._._..__....._....__. 32

INSTRUMENT PANEL QUARTER WINDOW ..,.._._..___..._________..___ _..._ __I...__ _

REAR HATCH . . . . _ . . . . .._........................._..................

REAR SEAT BELTS _...,.._....._....._ _ . . . . . . . . . . . . . . . . . . . . . . . 124

SEATS _.._._.___.._ _ ___.__._...____..._..........................~.. _ . . . . . 103

. . . . . . .._....__...._..................... 87

60 36

TROUBLESHOOTING . . . . .._._...__...._....._.._.........___ 5

Automatic Seat Belt

Central Door Locking System Power Windows Remote-controlled Mirror

Sunroof Water leaks

Wind noise

Troubleshooting of Wind Noise

WINDSHIELD

WINDSHIELD AND QUARTER WINDOW . . . . . . . . 53

. . . . . .._....__.........__....___...___...._......_..._._ 55

-

23-2

BODY - Specifications

SPECIFICATIONS

GENERAL SPECIFICATIONS

Construction Regulator system

Windshield glass Quarter window glass

Rear hatch window glass Door window glass

N23CA-.

Front-hinged, sash construction

Type

Revolutions under load

At 1 Nm (0.72 ftlbs.) At 2 Nm (1.45 ftlbs,)

Range of voltage used V Locking current A

Type

Rated current mA

Remote control mirror switch

We

Rated load mA

Regular up-down or right-left direction

rpm -

Permanent magnet type (built-in circuit breaker)

4or less

Ferrite magrxet motor

BODY - Specifications

Items Specifications

Automatic seat belt motor

Type

No-load speed

No-load current A

Load current at 125 Ncm (11 in.lbs.) A Load speed at 125 Ncm (11 in.lbs.) Lock test current A 38 or less

rpm

wm

Ferrite magnet motor 180

4 or less

6.4 - 6.8 125-225

23-3

SERVICE SPECIFICATIONS

Items

I

Standard value

Play of inside handle Play of outer handle

TORQUE SPECIFICATIONS

Items Hood hinge

Hood latch

Hood hook

Rear wiper arm locking nut

Windshield wiper arm locking nuts

Door hinge

Body side Door side

Hatch hinge

Hatch side Body side

Hatch latch

Air spoiler (center) attaching nuts

Front seat mounting nuts Front seat mounting bolts Rear seat cushion mounting bolts Rear seat hinge bracket mounting bolts Rear seat striker Front/rear seat belt anchor plate

Rail guide Outer casing (B) Rail guide bracket attaching bolts Retractor

For shoulder belt

For lap belt Buckle Shoulder belt sub anchor

Specifications

4-10(.16-.39) 3-8(.12-.31)

Nm ft.lbs.

’ 9-14 6.5- 10

7-11 4-6 ’ 2.9 -4.3 6-9 4-7

IO- 16 7-12

13-26 17-26 12-19

5-8 4-6

IO-15 7-11

4-6 2.9 -4.3

3.5 - 5.0 24-36 35-55 25-40 4-6 9-14 6-10 4-6 3-4 35-55 25-40

4-6 2.9 - 4.3

4-6 8-12 5.8 - 8.7

17-26 12-19 35-55 35-55 25-40 35-55

N23CB- -

mm (in.)

I

N23CG -

5-8

9‘- 19

2.5 - 3.6 17-26

3-4

2.9 - 4.3

25-40

______-

B$zz,

BODY - Specifications / Special Tool

LUBRICANTS

Sliding portion of rear hatch link Sliding portion of rear hatch hinge Sliding portion of rear hatch latch Sliding portion of front door hinge Sliding portion of door glass guide

SEALANTS AND ADHESIVES

Rear hatch glass to rear hatch

garnish contact surface Flange parts of the fender

Between windshield and body Stud hole Between windshield and moulding

Between quarter window and body

Waterproof film

Door openingweatherstrip

Part Number 2932524 MOPAR Multi-Purpose Grease Lo

Part Number 2932524 or MOPAR Multi-PurposeGrease -

Part Number 2932524 qr equivale;t MOPAR Multi-Purpose Grease ~

Part Number 2932524 or equivalent

Urethane adhesive_CEssex Urethane “E”

. . Auto Glass Sealant] Dry sealant _ Urethane adhesive.LEssex Urethane “E”

,. Auto Glass Sealant) Urethane adhesive (Essex Urethane “E”

,,. Auto Glass Sealant) ~~

Urethane adhesive_fEssex Urethane “E”

Auto Glass Sealant)

MOPAR Rope Caulk Sealer 3116 x80” As required roll Part No. 4026044

equivalent

As required

N23CD-.

N23CE..

E;

--

1

Roof lid female hinge

Air spoiler (center)

SPECIAL TCK9L

MOPAR Vinyl-Acrylic Sealant Part Number 4026043-or equivalent

NOZDA- .

BODY

- Troubleshooting

23-5

TROUBLESHOOTING

Symptom Sunroof

Water leaks

Wind noise

Door glass fails to

operate up and down

Door glass operates

up and down hardly

. Probable cause

Deteriorated roof lid weatherstrip Excessive roof lid-to-body clearance and

improperly fitted weatherstrip Loose or deformed deflector Dismount window glass regulator Detached sash

Broken sash Collapsed sash Collapsed window glass regulator arm Broken window glass regulator Improper window glass position Collapsed sash Collapsed window regulator arm

N23EAAO

Remedy

Replace

Adjust

Retighten or replace Adjust Attach

Replace

Repair or replace

Repairor replace Replace Adjust

Repair or replace-

Repair or replace

Wind noise from around door

Rear hatch is “heavy” ahen opened/closed; abnormal noise is leard from hinges

tiind noise from~ around rear hatch

Insufficient weatherstrip holding force Improper-weatherstrip installation or

deteriorated weatherstrip

Incomplete door closing Adjust

Improper door installation Adjust Improper gap between door glass and weatherstrip Deformed door Repair or replace Insufficient grease on hinges Apply chassis grease

Insufficient weatherstrip holding force Improperweatherstrip installation or

deteriorated weatherstrip

Uneven clearance between body and rear hatch

Deformed rear hatch

Adjust door installation

Repair or replace

Adjust

Adjust rear hatch installation

Repair or replace

Adjust

Repair or replace

18Y1715

TROUBLESHOOTING OF WIND NOISE

(1) Apply cloth tape to all potential sources of wind noise such =_

as panel joints, protrusions, moulding joints, glass to body

joints in the-dirrection from which noises- are heard.

(2) Drive under this condition to make sure that wind noises ~:

are eliminated. .

(3) Remove tape one after another until wind noises are

produced again.

Remove

ex. Noise produced here

Cut tape into pieces

18Y1715

18Y1716

(4) If removal ofI% tape causes norse generation, apply tape

again to that location and remove other tapes one after another to check that no noise is produced.

(5) The location with tape left applied to the last is responsible

for wind noise.

-

(6) Cut the left tape into smaller preces and remove piece after

piece in the:same manner as before to localize suspected _ source. ~=

(7) Remove the last piece Jett and check that its removal _

causes wind noise and its application stops wind noise. -:

(8) Apply butyl tape or body sealer to the thus located area to -:

minimize gq?

POWER WINDOW

CIRCUIT DIAGRAMS

BODY

- Troubleshooting

8-W

A-82

n

23-7

5-w ,@

To motor antenna relay 4

To turn signal flasher unit 4 0*85-RL

0.85-i-O

4

YL

-r

c-33

TAC unit

Remarks (1) For details of grounding points (ex.: I), refer to page 8-10.

(2) The circuit lines ended with number 0. @and so on are in

continuation to those with the corresponding number on opposed page. (i.e., the line @ on the left-hand page is connected to the line @ on the right-hand page.)

Wire color code B: Black Br: Brown

L: Blue Gr: Gray

LI: Light blue 0: Orange P: Pink

R: Red W: White Y: Yellow

G: Green

Lg: Light green

..-

23-8

BODY

Power window relay

- Troubleshooting

------I

Power wlndow maln switch

I

I-32

/RW\ (RWI- IRCi

C-ii

m

(L.H.1

Door switch

(R.H.i

I

B-32 [ . _ . 1

Power wIndoN motor (L.H.1

Power wlndow

1,7-C-27

Power wlndow sub switch

BODY

- Troubleshooting

OPERATION

l

When the ignition switch is turned to 7iON”,

current flows through fuse No. 13, the power

window relay (coil), and ground, closing the

power window relay contacts.

l

When the power window switch is set at the

“UP” or “DOWN” position with the ignition switch turned to “ON”, current flows through the power window relay (contact), the power window switch, and ground, and the power window motor revolves to raise or lower the door window glass.

l

If the lock switch of the power window main switch block is set at “ON”, however, the door window glass can neither be raised nor lowered by operating the sub switches.

l

For operation of the power window timer, refer

to GROUP 8 ELECTRICAL - ETACS.

TROUBLESHOOTING HINTS

1.

The door windows cannot be operated by using the main switches.

l

Malfunctioning main switch

The door windows can be operated by using the

2. main switches, but cannot be operated byusing

the sub switches.

l

Malfunctioning sub switch

3.

The door windows can be operated (by using the sub switches) even though the lock switch is at

“ON“.

l

Malfunctioning main switch lock

--

23-10

BODY - Troubleshooting

CENTRAL DOOR LOCKING SYSTEM

CIRCUIT DIAGRAM

Battery

20-BY

Door switch (L.H.1

Sub fusible llnk 2

Doorfock

Door lock relay Door unlock relay

actuator (L.H.1

I

Door swatch (R.H.)

Key reminder switch

0 ,rGW

-+-ii3

le?m L

D-l

Sell-dtagnosls L connector

B iiiack LI Ltghf blue

Br Brown

0 Orange

IpEiy-yJ

Inn\ 1

r‘nmh,n.T+.n..

\,‘,lIL,,1,l”,l”l,

mrtpr

ti. Green

P.

Pink

WI II

I I I I I I I

TAC unit

Gr I;rav

R tied

L Blue

W While

Remark

For details of grounding points

Lg. Light green Y Yellow

(ex : mi. refer to page 8-10.

actua~tor (R.H J

rkdhl

ml

37Y mm

-’

-

OPERATION AND TROUBLESHOOTING HINTS Refer to GRCKJP 8 ELECTRICAL- FTACS for operation and trqubleskootlng hints for the

system.

central

door locking.

BODY

REMOTE-CONTROLLED MIRROR

CIRCUIT DIAGRAMS

- Troubleshooting

23-I I

Batters

q

Main fusible link

A-80

El

Sub fusible Iink 1

Ignition switch

m A

I-

q

3-BR n

A-35

tLRlcO

0.85-B o

r

:

2-B @

2-BR :a

control unit

n v n

LR

m r:

d

T

iI

B

w

c-34

a

r

TAC unit

Defogger relay

0.85-LR n0.85-LB

I

u

*o

23-12

Remarks

111 For details ot aroundlnq points (ex.: EJ). refer to page 8-10. (2) The clrcult lines ended with number, I 8, z 1 and so on are In

Irrvvlnuatlon to those with the corresponding number on clpposea page. (I.e., the Ilne 11 /on the left-hand page IS c~.annected to the line c 1 I on the nqht-hand page.)

ILRJ

;:::0.85-B

-

BODY

D-14

- Troubleshooting

Detoqgerswitch, Remote-controlled mirror (L.H.)

-

m LI Ea

LY Y B

m

I

,51~ 0.85-LB

Remote-controlled mirror switch

Wire color code

B: Black Br: Brown Gr: Gray

L

R: Red

Remote-controlled mirror (R.H.)

L: Blue

W: White

Lg: Light green

Y: Yellow LI. Light blue 0: Oranqe

B-09

B-31

-16

BODY - Troubleshootinn

OPERATION TROUBLESHOOTING HINTS

When the remote-controlled mirror switch is operated while the ignition key is in “ON”

position, current flows through fuse No. 13,

remote-controlled mirror switch, remotecontrolled mirror, switch, and ground, causing the mirror to move.

For operation of the heated remote-controlled mirrors, refer to the “DEFOGGER TIMER” section in GROUP 8 ELECTRICAL - ETACS.

remote-controlled mirror

Neither right nor left mirror operates.

1. Also turn signal lights do not operate either. * Check the fuse.

2. Check the remote-controlled mirror switch.

l

Check the remote-controlled mirror switch.

23-13

AUTOMATIC SEAT BELT

CIRCUIT DIAGRAMS

- :7

Clrcutt breaker

B-01

lgnrtion swatch Battery

QQQ I

Spool release lever switch

3-LW -(&

3-RY 3-RW :@

@

Combrnation meter

C-24

Key reminder

switch

Remarks

(I) The crrcutt lines ended with number (9, (2) and so on are in conttnuatton to those wtth thecorrespondtng number on opposed

page. (I.e.. the line Ltj on the left-hand page

(2) For-detaifs of groundtrig points (ex.: E!If. refer to page 8-10.

Buckle swatch (L.H.stdel

IS

connected to the IlneQ) on.the right-hand page.)

\

Y

Motor

(R.H. side)

I

Release switch (L.M.)

Fasten switch

(L.H.)

-

BODY

- Troubleshooting

Door lock switch (L.H. side)

23-15

C-06

-38

Release switch (R.H.)

Wire color code

B:

Black

LI: Light blue 0: Orange

Br: Brown G: Green

Fasten switch (R.H.)

P: Pink

Door lock switch

.-..

(K.H. side)

Gr: Gray L: Blue

R: Red

W: White Y: Yellow

Automatic seat belt control unit

371599

Lg: Light green

,A .a-

23-16

“release” position (spool replace the fuse No. 1

release switch is turned

BODY

- Troubleshooting

ECU: Electronic Control Unit

d or disconnected

BODY

- Troubleshooting

23-17

Trouble symptom Cause

The system performs Damaged or disconnected Check by using check chart Repair the harness or

fastening operations but wiring of door lock switch No. 3 (P.23-22) replace the door lock not unfastening operations, input circuit switch, fasten switch or or vice-versa. release switch

Damaged or disconnected Check by using check chart Repair the harness or

wiring of motor drive input No. 4 (P.23-24) replace the motor

circuit Malfunction of ECU

Even after turning the

. .~ ~~~~

ignrtron switch from “LOCK” wiring of “fasten seat belt” or “ACC” to “ON” without indicator light and buckle

fastening the L.H. seat lap switch input circuit belt, neither the “fasten

seat belt” indicator light Damaged or disconnected Check by using check chart Repair the harness or goes on nor does the wiring of buzzer circuit No. 8 (P.23-28) replace the buzzer buzzer sound.

The “fasten seat belt” Damaged or disconnected Check by using check chart Repair the harness or

indicator and the spool release indicator light indicator light and buckle and buckle switch

neither go on nor blink, and switch input circuit the buzzer does not sound when the ignrtron swatch Damaged or disconnected Check by using check chart Repair the harness or is turned from “LOCK” or wiring of buzzer circuit No. 8 (P.23-28) replace the buzzer

“ACC” to “ON” while the spool release lever remains in its “release” position (spool release switch is turned off).

.~,~ ~~ .

Damaged or disconnected Check by using check chart Repair the harness or

Damaged or disconnected Check by using check chart Repair the harness or wiring of ECU power supply No. 1 (P.23-20) replace the fuse No. 1 and ground circuit

Malfunction of ECU

wiring of “fasten seat belt” No. 6 (P.23-26)

Check method

-

No. 6 (P.23-26)

-

Replace the ECU

replace the indicator light

and buckle switch

Replace the ECU

replace the indicator light

Remedy

ECU: Electronic Control Unit

2348

BQDY

- Troubleshooting

CIRCUIT BREAKER RESETTING

(1) Insert wire in the reset hole and push lightly.

(2) Check the circuit breaker for continuity across

breaker terminals. If the=-is no continuity, replace the I circuit breaker.

(3) If the circuit breaker blows again, the circuit is-shorted. ,I

the circuit

I

TO

batterv

I

To ignltlon

switch

Door lock switch IL H.l

Door lock swmzh

(R H.I

switch

18Y1811l

r

+--++ switch

Iclose) h Y

* 1

I

To battery d

ECU: Electronic Control Unit

-. - -

ECU _

(ECU connector termmats)

CHECKING CIRCUIT Index of Check Chart

BODY

- Troubleshooting

23-19

Chart No.

1 ECU power supply and ground circuit 23-20 2 Ignition switch (ON) input circuit 23-21 3 Door lock switch, fasten switch and release switch input circuit 23-22

4 Motor power supply and drive circuit 23-24 5 Spool release lever switch and indicator light circuit 23-25 6 7 8 Buzzer circuit 23-28

Buckle switch and “fasten seat belt” indicator light circuit Key-reminder switch input circuit 23-27

Circuit name Page No.

23-26

23-20

Sub fwble IInk box 2

BODY

- Troubleshooting

rE(:lJ connector terminals)

Step p- p-

Condition Check object Normal _ Malfunction

1 ECU terminal Battery voltage ov

2 Disconnect ECU’s Continuity of Continuity m LZ Harness damaged Repair the harness

harness connector ECU ground or disconnected

ECU: Electronic Control Unrt

Check method Judgement

voltaae (21 --Ground)

Harness damaged Repalr the harness or dlsconnected

circuit (16 - Ground)

BODY

2. Ignition Switch (ON) Input Circuit

Ignition switch

Sub fusible link 2

Battery T

f

- Troubleshootina

ECU

-----

/

(ECU connector terminals)

23-21

Step

2

Condition Check object Normal Malfunction

IG SW: ON ECU terminal Battery voltage 0 V

Check method Judgement

1

IG SW: Ignition Switch ECU: Electronic Control Unit

1613666

Cause Remedy

Fuse @ blown Repair the harness

voltage or disconnected

(18 - Ground)

Harness damaged Repair the harness

or disconnected

-mms

BODY

- Troubleshooting

3. Door Lock Switch, Fasten and Release Switch Input Circuit

L)oor loch switch

iL H.)

CLOSE OPEN

J

C-06

\rlJ -

(VW)

.

c-02 a

,(YW)

E

a

ECU

48

To lgnltlon

switch

Release switch

Ii3.H.l

C-06

FtL

GW

a3

(Roof har .ness side)

(Rear harness side) (Door harness side)

C-13

-Id A-1

C-13

C-02

Fasten swttch (R.H.)

l&-i- -18i)-c-l

c-19

Door lock switch

(R.H.)

itCU connector terminals)

BODY

- Troubleshooting

23-23

Step

1 C-02 and C-l 9 Continuity be-

connectors:

Disconnected C-l 9 connector (Refer to P.23-71.) Door lock switch: terminals CLOSE H OPEN

2 C-21 and C-38 Continuity be- OR++mCl Remains Fasten switch Replace the fasten

connectors: tween C-38 con- Ofiormfl damaged switch Disconnected nectar terminals Fasten switch: (GL- GB) ON -OFF Continuity be-

3 C-06 and C-l 3 Continuity be- OR-mR Remains Release switch Replace the release

connectors: tween C-06 con- 0~1or~n damaged switch Disconnected nectar terminals (Refer to P.23-119.) Release switch: (RL- GW) ON f--2 OFF Continuity be-

4 C-02 and C-l 9 Continuity 0 0 - cm II Remains 00 0 Harness damaged Repair the harness

connectors: between ECU

Connected C-38 and C-21 left and right

connectors: door lock switch circuited

Connected Left door lock ECU connector: switch Disconnected

Check method

Condition Check object Normal Malfunction

OR++CQR Remains Door lock switch

tween C-02 and Ofiormfl damaged lock switch

(B-G). (B - RI

tween C-21 con-

nector terminals (YB - G)

tween C-l 3 connector terminals (R -VW)

terminals and

(9 - Ground) Right door lock switch (2 - Ground)

Judgement

Remains 0 f1

Cause

or disconnected Harness short-

Remedy

Replace the door

(Refer to P.23-119.)

5 C-06 and C-l 3 Continuity OR*+~n Remains ~0 bZ Harness damaged Repair the harness

connectors: between ECU or disconnected Connected terminals and C-02 and C-l 9 left and right Remains 0 fI Harness shortconnectors: door lock switch circuited Connected Left door lock ECU connector: Disconnected Door lock switch: Right door lock

OPEN switch

Release switch: (3 -Ground)

ON e OFF

ECU: Electronic Control Unit

switch

(8 - Ground)

23-24

BODY

- Troubleshooting

1 4. Motor Power-supply and Drive Circuit

Circuit breaker

To batterv

ECU

C-37

C-24

1

Motor tL.H.1

n

-Motor (R.H.) M

E!l

C-24

iRear harness side)

Step

1

C-37 and C-24 connectors: Disconnected

2

C-37 and C-24 connectors: Connected

ECU connector:

Disconnected

3

C-37 and C-24 connectors: Connected ECU connector: Disconnected

Check method Judgement

.~., I

Check object Condition

Conttnuity be-

tween C-37 and

C-24 connector terminals

A (LW - RW)

B (LY - RY)

Continuity between ECU terminals L.H. motor side (7 - IO) R.H. m’otor side (4- 1)

ECU connector

terminal voltage

(I 1 - Ground)

0 f-2 Remains-cc f1

Battery voltage OV

(ECU connector terminals)

Malfunction

Remains

0 f2 or m 0

Remains 0 n

Motor damaged

Cause

Remedy

Replace the motor (Refer to P.23-1 19.)

Repair the harness

(Refer to P.23-18.

4 Continuity be-

C-37 and C-24 connectors: Connected ECU connector: Disconnected

ECU: Electronic Control Unit

tween ECU terminal and ground (6 - Ground)

“”

BODY

- Troubleshooting

23-25

5. Spool Release Lever Switch

lever indicator

c-40

LO B

LR LB

B El

c-41

q

and

Indicator Light Circuit

To door lock swrtch (R.H.)

ECU

-(i:ii (ECU connector terminals)

(Rear harness side)

T

Step

1

2

3

4

Condition

C-41 connector: Disconnected

C-40 connector: Disconnected

C-41 connector: Connected Spool release switch: ON ++ OFF ECU connector: Disconnected

C-40 connector: Connected

IG SW: ON ECU connector:

Disconnected

Check method

T

Check object’

Continuity between C-41 connector terminals (LB-B)

Continuity between C-40 connector terminals (LR - LO)

Continuity between ECU connector terminal (15 - Ground)

ECU connector terminal voltage (19 - Ground)

T

OCI

Judgement

Normal Malfunction

Remains

Oflorm3

Remains 00 fl Spool release

Remains a 0 Harness damaged

Remains 0 0 Harness short-

Cause

Spool release

switch damaged

lever indicator light damaged

or disconnected

circuited

lSY1846

Remedy

Replace the spool release lever switch (Refer to P.23.119.)

Replace the spool release lever indicator light

Repair the harness

Replace the fuse

Repair the harness

IG SW: Ignition Switch ECU:Electronic Control Unit

--. .-.____

/,.-A. *I . . _ ..,. dU

23-26

BODY - Troubleshooting

6. Buckle Switch and Fasten Seat Belt indicator Light Circuit

Buckle switch

;wltch

T

B-22

B-23

ECU

- - . . . _~

r

l-----

Ster

C-30 connector: Disconnected Buckle switch. ON -OFF

B-23 and B-22

connectors:

DIsconnected

C-30 connector: Connected

ECU connector: Disconnected Buckle switch: ON -OFF

B-23 and 8-22 connectors. Connected ECU connector: DIsconnected IG SW: ON

(ECUconnector terminals)

(Front harness sIdeI

Check method

Condltlon Check object / Normal Malfunction I

Contlnulty be- ocz- x 12 tween C-30 connector terminals (RG - B)

Continuity between B-23 and

B-22 connector terminals (RB - GB)

Continuity between ECU connector terminals (17 - Ground)

ECU connector terminal voltage (20 - Ground)

0 c1 Remains x 0

I

Battery voltage

tl?car harness srde)

Judgement

Remains

0 iI or r 12

Cause Remedv

Buckle switch damaged

belt” indicator

or short-circuited

Replace the buckle switch (Refer to P.23-? 19.)

Replace the “faster

seat belt” indicator

light

IG SW: lanltloli Switch ECU. ELctronic Control Unit

BODY - Troubleshootiw

7. Key-reminder Switch Input. Circuit

Knv-reminder

B-49

23-27

To fasten switch (L.H.)

(ECU connector terminals)

(Front harness side) (Door harness side)

I

Step Remedy

Condition Check object Normal

B-49 connector:

Disconnected

Key-reminder

switch: ON (Key)

-OFF (No key) C-02 connector:

Disconnected Door lock switch: CLOSE * OPEN

B-49 connector: Connected ECU connector: Disconnected IG SW: ON

C-02 connector: Connected ECU connector:

Disconnected

Door lock switch: CLOSE * OPEN

Check method Judgement

Continuity between B-49 con-

nector terminals (YG - RB)

Continuity be-

tween C-02 con-

nector terminals (G - 8). (B-R)

ECU connector

terminal voltage

(12 - Ground)

Continuity between ECU connector terminals (13 - Ground) Remains 0 0 / F$n;;;short-

T

Battery voltage

Remains

OQormfl damaged

ov Fuse @ blown

Remains ~0 0 Harness damaged

I

Lause

Door lock switch

Harness damaged disconnected or short-circuited

or disconnected

5

I-

Replace the keyreminder switch (Refer to P.8-156.)

Replace the door lock switch (Refer to P.23-71.)

Replace the fuse

Repair the harness

18Y1848

IG SW: Ignition Switch ECU: Electronic Control Unit

. I

____

____ -

23-28

1 8. Buzyr &cyit 1

Buzzer

Key-

rernrnder

SLZ/IICh

Door lock switch (L.H.1

Spool release

lever switch

BODY

- Troubleshooting

Buckle

switch

B-41

LO

I3

B

[Front harness side)

Ster

Condition

1

Separate the B-41 connector

Connect the B-41 connector Separate the ECU’s harness connector

Check method Judgement

Check object Normal Malfunction

B-41 connector Battery voltage 0 V (front harness side) terminal

voltage

(LO - Ground)

I

ECU harness side Battery voltage 0 V ‘~ connector terminal voltage

(14 - Ground)

(ECU connector terminals)

--.

.-

IXY

IMY

ECU: Electronic Control Unit

BODY

- Service Adjustment Procedures

SERVICE ADJUSTMENT PROCEDURES

23-29

N23FAAI

HOOD FIT

1. Adjust the longitudinal and lateral positions of the hood by utilizing the oblong holes in the hinge.

2. Adjust the vertical position of the hood by adjusting the hood bumper either up or down.

3. Adjust the position of the hood lock so that it is in proper alignment with the hook.

NOTE Apply specified grease to the sliding part, the rotating part and the spring of the hood lock.

Specified grease: MOPAR Multi-purpose grease

4. Adjust the length of the hook bolt.

ADJUSTMENT

Part No. 2932524 or equivalent

I I I

18Y15341

REAR HATCH FIT ADJUSTMENT

1. Loosen the hatch hinge mounting nuts on the body side.

2. Adjust the hatch by moving it so that the clearance is equal on all sides.

Caution Do not loosen the hatch hinge mounting nuts more

than two full turns.

3. Adjust the position of the hatch striker so that it matches that of the hatch latch.

N23FLAA

23-30

BODY -

Service Adjustment Procedures

4. Adjust the posrtron of the hatch latch

so that It

matches that

of the hatch striker.

DOOR FIT ADJUSTMENT

N23FEAi.I

1. Loosen the hinge mounting bolts on the body side, and then move -the =door upward, downward, forward and backward to adjust it so ~that the clearance around it is equal. ~_

2. Loosen the hinge mountin&bolts of the door stde,-and then

_

move the door to the left and right to adjust the surfaces.

Caution Attach protection tape to the fender edges near the

place where the hinge is installed.

3. Adjust fit between the front fender and hot-&door panel by loosening the door side attaching bolts and_increasing or ;=;;

decreasing s&-r%.

4. Adjust engagement between the striker and~dooFlatch by, ;_ increasing or decreasing striker shims and/or sliding the 1

striker vertically or horizontally.

_

S18641

S1864

DOOR GLASS ADJUSTMENT

N23FFAE

1. Remove the-door trim and waterproof film. (Refer to ~_ P.23-64.)

2. Raise the door glass fulls and then adjust the following I items so that the door glass fits evenly into the door glass

channel all the way around:

(1) Loosen the door glassmounting nuts, and then

adjust -

-

the door glass by moving it forward, backward, upward, downward, and- to the left and right.

(2) Adjust the tilt of the door glass by tightening-the door -_

glass mounting nuts. =

INSIDE HAND/E PLAY ADJUSTMENT-

N23fGAD

1. Remove the door trim and waterproof film.

2. Move the mounting position of the inside handle longitudi- _

nally in order to adjust the play of the inside handle. Standard value (A): 4 - 10 mm (.I6 - .39 in.)

-

BODY -

Service Adiustment Procedures

23-31

Front floor pan

Rear floor pan

Cl8517

c : Drain plug position ,8y1778

-I

OUTSIDE HANDLE ADJUSTMENT

1. Remove the door trim and waterproof film.

2. Remove the outside handle rod from the outside handle, and then adjust the play of the outside handle by turning the top of the rod.

Standard value (B): 3 - 8 mm (.I2 - .31

in.)

NOTE Be sure to install new rod snap.

FLOOR PAN INSPECTION

A common result of bodyleaks is a soaked floor mat pad or carpet, and it’s not unusual to find that the water is getting in

through the floor pan to some other low point in the body. It is

possible however, for water to enter higher up and run downward to soak the mat. Since a soaked mat should be removed for drying, it’s a good

way to start your check. Of course, mat removal means you’ll

have to take off door sill plates and pull out seats or seat cushion. But, this gives you a clear field for action so you can

check body seam sealing and the plugs in the floor pan.

It’s usually not practical to water test for floor pan or wheelhousing leaks unless a special underbody water spray arrangement is available. As an alternate, the best way to locate these leak points is to look for rusty seam edges or other traces of leaks after the mats and cushions are removed. Traces of mud are an indication that the water is coming in from below.

N23FHAD

N23FIAA

.-

IS\/1779

23-32

BODY - Hood

-

HOOD

REMOVAL AND INSTALLATION

4-6Nm

2.9-4.3 ft

N23tiAAH

7-11 Nm * 5-8 ft.lbs.

Hood panel removal steps

I. Hood weatherstrip, front

2. Hood hook

3. Heat protector

4. Hood weatherstrip, rear

5. Hood damper

6. Hood bumper

+I)

7. Hood support rod

8. Hood switch

9. Hood panel

I-/

._=

1811803

Release cable removal steps

10. Hood lock plate

11. Hood Lock

12. Hood release handle

13. Release cable

NOTE (1) Reverse the removal procedures to reinstall. (2) +I): Refer to “Service Points of Remoygl”.

SERVICE POINT OF REMOVAL

8. REMOVAL OF HOOD SWITCH Remove thE hood switch as shown.

BODY -

Hood

INSPECTION

HOOD SWITCH (1) Disconnect the hood switch connector.

(2) Check the continuity between the terminals.

23-33

18R0665

Terminal

Hood switch unpressed Hood switch depressed

NOTE

O-O indicates that there is continuity between the terminals.

1 2

0 0

HOOD HINGE REPLACEMENT

When replacing the hood hinges, use a hood hinge kit by the following procedure:

(1) Remove the hood from the hood hinges.

Caution Protect the front deck with a cloth so that the hood

protrusions do not damage it.

(2) Remove the hood hinges by breaking the spot welds

fastening the hinges to the front deck by using a drill 8 mm (.32 in.) in diameter.

Caution

Be careful not to drill holes in the deck panel. NOTE

After removing the hinges, make sure that the hinge

mounting surfaces on the front deck are flat and level.

(3) Mark the hinge mounting positions on the front deck by

using a punch.

(4) Drill the holes by using a drill 8 mm (.32 in.) in diameter.

(5) Remove the access hole cover together with the boost

sensor and the wiper motor. (Refer to GROUP 8 ELECTRICAL - Windshield Wipers and Washer.)

(6) Insert the brackets from the inside of the front deck, fit the

hinges, and tighten the nuts temporarily.

NOTE The work of installing hinges will be facilitated if adhesive is applied to the surfaces of the brackets in contact with the front deck.

(7) Install the hood.

i

(8) Adiust the hood alianment.

23-34

BODY

- Fuel Filler Door

FUEL FILLER DOOR

REMOVAL AND INSTALLATION

N23JAAJ

6

Removal steps

+* *+ I. Scuff plate

+I)

++ *+ 3. Trunk room side trim

2, Quarter trim

4. Lock release panel

5. Lock release cable

6. Filler door panel

7. Stop assembly

8. Filler neck cover

9. Grommet

IO. Soft vinyl tube

WY1044

-

NOTE (1) Reverse t& removal procedures to reinstall. (2) +*: Refer 10 “Service Points of Removal”.

(3)- I)+: Referto “Service Points of Installatron”.

BODY - Fuel Filler Door

SERVICE POINTS OF REMOVAL

1. REMOVAL OF SCUFF PLATE / 2. QUARTER TRIM / 3. TRUNK ROOM SIDE TRIM

Refer to P.23-95.

SERVICE POINTS OF INSTALLATION

3. INSTALLATION OF TRUNK ROOM SIDE TRIM / 1. SCUFF PLATE

Refer to P.23-95.

23-35

23-36

BODY - Rear Hatch

REAR HATCH

REMOVAL AND INSTALLATION

Post-installation Operation

l Adiustina Rear Hatch Fits

1 (Refer to”P.23.29.)

Rear hatch

** 1.

4* I)+ 13. 4, I)+ 14.

Lock release cable removal steps *I) *+ 17. Scuff plate

4* 4~ I)+ 19. Trunk room side trim *+ I)+ 20. Rear end trim +* I)+ 21. Rod snap +I) r)+ 221 Rear hatch link assembly

** a+ 23. Rear hatch latch

glass removal steps

Rear wiper arm

Rear hatch trim

32:

Rear wiper motor

4.

Rear hatch striker

5.

High mounted stop light connector connection

Roll bar trim

Defogger terminal connection Rear hatch stopper (with stay switch) Ball joint Rear hatch hinge Protector Rear hatch garnish

(with rear spoiler)

Rear hatch upper moulding Rear hatch side moulding

15.

Rear hatch opening weatherstrip

16.

Rear hatch glass

18. Quarter trim

24. Rear hatch handle

25. Lock release cable

26. Rear hatch lock key retainer

27. Rear hatch lock kev cvlinder

IO-15 Nm-

7-l 1 ftlbs.

5--8Nm -“,-.--E

4-S ftlbs.

15

N230AAG

6-9 Nm

-44ftlbs.

18Y1858

4-6Nm

2.94.3ft.lbs. ,8y,8,5 /

23

NOTE _ (1) Reverse the removal procedures to reln<t&. (2) +*I Refer to “Service Points of Removal”. (3) ++: Refer to “Service Points of Installation”. (4) CiT: Non-reusuable parts.

BODY

- Rear Hatch

SERVICE POINTS OF REMOVAL

6. REMOVAL OF ROLL BAR TRIM Refer to P.23-95.

8. REMOVAL OF REAR HATCH STOPPER (WITH STAY SWITCH)

(1) Remove the rear hatch stopper from the body.

23-37

Tool A

Tool B

mm (in.) 18Y1561

12. REMOVAL OF REAR HATCH GARNISH (WITH REAR

SPOILER) Align the tools shown in the illustration along the glass,

press them in with a plastic hammer or similar tool, and cut the adhesive.

Remove the rear hatch garnish.

Caution Remove foreign material from the gap between the glass and the garnish with compressed air. Be careful not to scratch the glass.

18Y170r

13. REMOVAL OF REAR HATCH UPPER MOULING /

14. REAR HATCH SIDE MOULDING Remove the rear hatch mouldings while using tool A to cut

the adhesive.

18Y156:

23-38

BODY

- Rear Hatch

17. REMOVAL OF SCUFF PLATE / 18. QUARTER TRIM / 19. TRUNK ROOM SIDE TRIM / 20. REAR END TRIM

Refer to P.2395.

21. REMOVAL OF ROD SNAP (I) Disconnect the rod snap and the left and right rods from

the rear hatch link assembly.

(2) Disconnect the lock release cable from the rear hatch it

link assembly.

c

Rear hatch link assembly /

R.H. side

Rear hatch latch

18Y152;

22. REMOVAL ~OF REAR HATCH LINK ASSEMBLY / 23. REAR HATCH LATCH

(1) Remove the rear hatch link assembly. (2) Removethe left and right rear hatch latches together

with the rod.

INSPECTION

STAY SWITCH (I) Disconnect the stay switch connector. Then, with the rear

hatch closed (with stay switch turned ON), check the stay

switch for continuity across terminals.

Stay switch

BODY

- Rear Hatch

REAR HATCH SWITCH (1) Unlock the rear hatch link.

(2) Check the continuity between the terminals.

23-39

Terminal

Rear hatch link locked

I

Rear hatch link unlocked

.

18Y181C

NOTE

C-O indicates that there is continuity,between the terminals

A

I I I I I -+- I

B

I

REAR HATCH KEY CYLINDER UNLOCK SWITCH (I) Turn the key to unlock the lock cylinder.

(2) Check the continuity between the terminals.

16Y3608

NOTE

O-O indicates that there is continuity between the terminals.

l

Check the rear hatch hinge for cracks and damage.

l

Check the rear hatch stopper for deterioration. Check the rear hatch link assembly for wear, damage or

l

malfunction. Check the rear hatch latch for wear, damage or malfunction.

l

Check the rear hatch striker for wear.

l

Check the rear hatch opening weatherstrip for cracks,

.

damage or deformation.

SERVICE POINTS OF INSTALLATION

23. INSTALLATION OF REAR HATCH LATCH / 22. REAR HATCH LINK ASSEMBLY / 21. ROD SNAP

(1) Install the rear hatch latch.

NOTE Be sure the rear hatch latch is unlocked. Install the rear hatch link assembly1

(2) Install the left and right rods and secure them with the,

clip.

(3) Apply the specified grease to the moving parts of the

rear hatch link assembly and rear hatch latch assembly. Specified grease: MOPAR Multi-purpose grease

Part No. 2932524 or equivalent

20.lNSTALLATlON OF REAR END TRIM / 19. TRUNK ROOM SIDE TRIM / 17. SCUFF PLATE

Refer to P.23-95.

23-40

Hatch glass

Nut

18Y156r

h

sh

18Y170E

BODY

- Rear Hatch

14. APPLICATION OF SEALANT TO REAR HATCH SIDE MOULDING / 13. REAR HATCH UPPER MOULDING

Install the rear hatch mouldings after applying the specified ._

sealant (from the kit) to the entire circumference at the _ positions indicated in the illustration.

~

Specified sealant: Urethane adhesive (Essex Urethane

“E” . . . Auto Glass Sealant)

12. APPLICATION OF SEALANT TO REAR HATCH GARNISH

(WITH REAR SPOILER) (1) Apply the specified sealant (from the kit) to the entire _

circumference of the rear hatch garnish in the positions I shown in the illustration.

Specified sealant:

Urethane adhesive (Essex Urethane “E” . . . Auto Glass

Sealant)

(2) Align themounting po-ion of the rear hatch garnish so ~_

that the left and right clearances between the garnish -1 and the rear hatch glass, and between the garnish and the rear hatch side moulding. are equal, and tighten the

nuts. 1,

Back plate

18Y154(

10. APPLICATION OF GREASE TO REAR HATCH HINGE Apply the specified grease to the rear hatch hinge. Specified grease: MOPAR Multi-purpose grease

Part No. 2932524 or equivalent

Caution --

-

When installing the hatch glass, be sure that the rib of

the packing projects from the glass surface so that the

back plate does not contact the glass directly.

18Y51E

BODY

- Rear Hatch

8. INSTALLATION OF REAR HATCH STOPPER (WITH STAY SWITCH)

(1) Install the ball joint on the body. (2) Install the stopper on the rear hatch, and then push the

bottom tip of the stopper into the ball joint.

Caution

1. Never attempt to disassemble the rear hatch stop-

per or dispose of it in a fire.

2. When disposing of the rear hatch stopper, first drill a hole at the label position to allow the gas inside it

to escape.

1. INSTALLATION OF REAR WIPER ARM Refer to GROUP 8 ELECTRICAL - Rear Window Wiper and

Washer.

23-41

23-42

BODY

- Bumper

BUMPER

REMOVAL AND INSTALLATION

Front

N232AAM

=.

Front bumper removal steps

I. Front combrnation light bezel

2. Front combinatron ltght

3. Licence plate bracket

4. Air guide panel Wehrcles with a manual transmrssron)

5. Arr guide panel (Vehicles

++

with an automatic transmrssron)

6. Front bumper assembly wrth front skrrt panel (Parts 7 through IO)

7. Front skirt panel

8. Bumper reinforcement

9. Bumper core

10. Bumper face

Rear bumper removal steps

+I)

11. Rear bumper assembly (Parts 12 through 15)

12. Bumper plate

13. Bumper reinforcement

14. Bumper core

15. Bumper face

16. Bumper guide plate

18Y1841

Rear

NOTE (I 1 Reverse the removal procedures to rernstall. (2) **: Refer to “Service points of Removal”.

BODY - Bumper

23-43

SERVICE POINTS OF REMOVAL

6. REMOVAL OF FRONT BUMPER ASSEMBLY WITH FRONT SKIRT PANEL

(1) Remove the bolts (indicated by arrows) which attach

the front skirt panel to the fender.

D

18Y1840

(2) Remove the stay bolts.

II I

18Y1504

/

18Y1503

11. REMOVAL OF REAR BUMPER ASSEMBLY Remove stay bolts from inside the trunk and from the rear

end crossmember.

URETHANE BUMPER REPAIR

REPAIRABLE RANGE

HOLES

The damaged area must be shaped to a round or oval hole so

that it can be easily filled with the putty; however, the diameter

or length of the hole must be within 50 mm (2.0 in.). CRACKING - SPLITTING If the two sides of the crack have not separated, the length

must be within 200 mm (8.0 in.).

If one end of the crack extends to the edge of the bumper, not only must the length of the crack be within 200 mm (8.0 in.), but also the length of the crack must be less than one-half of

the bumper in the damaged area.

-.& .-.

z-

23-44

Hole

9

IO-15mm i.4 - .6 In.)

18Y93;

URETHANE BUMPER REPAIR PROCEDURE

1. If the damage is a hole, use a knife or similar toolto shape -~ the hole into a round or-oval opening.

2. If the damage-is a crack orsplit, use a knife or similar tool to I z widen the opening to approximately 2 mm (.08 in.).

3. G~rind the damaged area totapering shape of approximately 10 to 15 mm (.4 to .6 in,) in width with a sanding disc

(approx. #36[to #50).

,

4. After initial grinding, the 3~ basic types of reparrs should be mi as shown in the illustrations.

.~

- rz:

p

-*-

--_ = 6:

YB

_

IE

m

-. =z

=-

--~

-

.j; +$,,,

m

30-35 mm/ (I .2 - 1.4 in.)

5. Using a disc, remove the surface coatmg around the damage, feather-edging the boundary line between the -r finish and the urethane at the same time. Try to feather-edge for 30 mm (I. 18 in.) around the damage. 1,

6. After feather-edging, the 3 basic types of repair should be = as shown in the illustraiions.

7. Remove.anydirt adhering to the damaged-area wrth a rag ~1 soaked in benzine.

Caution Do not use a lacquer-type thinner.

BODY - Bumper

8. Cover the back surface of the damage with a piece of aluminum tape.

9. Prepare the adhesive, and apply it to the damaged area using a spatula.

NOTE

If the damage is large, apply two coats of adhesive. Apply

the adhesive by moving the spatula from the edge of the damaged area toward the center, so that the damaged area

will be filled with adhesive.

23-45

IO. After applying the adhesive, let it dry.

11. Polish the repaired area, using a double-action sander with a

disc. NOTE

Sand repaired hole or cracks for about five minutes with the

disc.

12. Finish the surface of the repaired area with a hand sanding block.

NOTE

The area should be carefully sanded so that there is no step at the boundary line between the adhesive and the undamaged surfacce coating.

13. To improve the grip of the paint, wet-sand the entire surface of the bumper face while using #400-grit waterresistant sandpaper and a rubber pad.

18Y945

23-46

BODY - Bumper

14. Cover the uncoated portion of the bumper face with masking tape.

15. Clean away any dirt from the bumper face with a rag soaked

1

in benzine.

,

16. Spray a co%of primer on the damaged area.

17. Mix an appropriate combination of color coat and clear coat, and then spray the whole surface of the bumper face.

-

I:;

-------“------^-

-

18Y94i

BODY - Fenders

23-47

FENDERS

REMOVAL AND INSTALLATION

N23KAAQ

18Y1722

\

IO-16 Nm

10 7-12 ftlbs.

Removal steps c*

4* 8. Front fender side stay 4* 9. Front bumper assembly with front

4*

+* I)* 14. Fender

1. Radiator grille

2. Front corner garnish

3. Header panel

4. Front combination light bezel

5. Front combination light unit

6. Air guide panel (Vehicles with a manual transmission)

7. Air guide panel (Vehicles with

an automatic transmission)

skirt panel

I)* 10. Wiper arm

II. Front deck garnish

12. Front bumper plate

13. Fender liner

18Y1842

NOTE (1) Reverse the iemoval procedures to reinstall. (2) +*: Refer to “Service Points of Removal”. (3) I)+: Refer to “Service Points of Installation”.

C : Screws

L7

----.--___

SERVICE POINTS OF REMOVAL

1 . REMOVAL OF RADIATOR GRILLE

Remove screws, force out the clips from inside the engine IT room and remove the radiator grille.

8. REMOVAL OF FRONT FENDER SIDE STAY Remove the IsFde stay bolts (indicated by arrows) and

remove the ~front fender-side stay.

18Yl841

9. REMOVAL OF FRONT BUMPER ASSEMBLY WITH

FRONT SKIRT PANEL (1) Remove the bolts which attach the front skirt panel to

fender.

(2) Remove the bumper stay bolts and then remove the L

bumper assembly with front skirt panel.

17,REMOVAL OF FRONT DECK GARNISH

Using the trim stick, remove the front deck garnish by ;

prying at the cljp positions.

-

--

Fender

seal

packing

BODY

14. REMOVAL OF FENDER

- Fenders

Remove the fender mounting bolts.

SERVICE POINTS OF INSTALLATION

14. INSTALLATION OF FENDER (1) Mount the fender seal packing in the position shown in

the illustration.

(2) Temporarily mount the fender in position, check

whether clearance is uniform at all points, and then tighten securely.

(3) Apply specified sealant to the flange part of the fender

when installing the fender liner. Specified sealant: Dry Sealant or equivalent

IO. INSTALLATION OF WIPER. ARti

Refer to GROUP 8 ELECTRICAL - Windshield Wiper and

Washer.

23-49

23-50

BODY -

Grille and Moulding

GRILLE AND MOULDING

REMOVAL AND INSTALLATION

IO-16 Nm 7-12 ftlbs.

N23R.40

Radiator grille removal

++ Front deck garnish removal steps

1. Radiator grille

2. Wiper arm

+?)

Air outlet garnish removal steps

3. Front deck garnish

4. Quarter trim

+* 5. Air outlet garnish

-.~

18Y1830

Chipping protector removal

I)* 6. Front quarter film chipping protector t+ 7. Rear quarter film chipplng protector

Rear panelparnish removal steps

8. Rear end trim S_Rear combination lamp

10. Rear panel garnish

NOTE -:

(1) Reverse the removal procedures to reinstall

13) +I): Refer to “Service Points of Removal”. (3) l *: Refer to “Service Points of Installation”. (4) q , Non-reusable parts.

.

BODY

- Grille and Mouldinn

SERVICE POINTS OF REMOVAL

1. REMOVAL OF RADIATOR GRILLE Remove radiator grille mounting nuts and clips and remove

the radiator grille.

23-51

I & : Screws

18Y1743

3. REMOVAL OF FRONT DECK GARNISH Using the trim stick, remove the front deck garnish by

prying at the clip positions.

5. REMOVAL OF AIR OUTLET GARNISH Remove the air outlet garnish mounting nuts, and then

remove the garnish outward.

Front quarter film

chipping protector

mm (in.)

18Y2062

T

3ear quarter film :hipping protector

mm (in.)

18Y206

SERVICE POINTS OF INSTALLATION

7. INSTALLATION OF REAR QUARTER FILM CHIPPING

PROTECTOR / 6. FRONT QUARTER FILM CHIPPING PROTECTOR

(1) Use lead-free gasoline to clean the mounting positions. (2) After removing the paper protecting the back, .affix the

chipping protector at the correct location, paying heed

to the measurements shown. Caution

1. The application should be done in a place with little or no dust, and at an ambient temperature of 20 - 40°C (70 - 100°F).

2. If the ambient temperature is below 20°C (7O”F), warm both the chipping ljrotector and the body

FoppF;ation surfaces) to within 20 - 40°C (70 -

23-52

Stripe tape \,

spatula

‘_

\

t

‘&

‘a

1

Chipplnq ’ protector

___--

Good

BODY - Grille and Moulding

(3) Use the stripe tape spatula to press on the chipping

protector beginning at the center and moving evenly to ,; both the hop and bottom, in order to remove any

trapped air bubbles. _ Caution

Be sure to press on the chipping protector with enough force to prevent it from coming off.

18C15t

(4) Pull the paper protecting the front straight and slowly. (5) If there are any air bybbles in the chipping protector

after the Application is finished, use a sewing needle to ~ make small holes in the bubbles, and use the corners

the spatula to press the air out.

of l

BODY

- Windshield and Quarter Window

ADHESIVE KIT AND RESERVE ITEMS

23-53

WINDSHIELD AND QUARTER WINDOW

N23LAAF

GENERAL

The windshield glass is attached by an urethane-base-adhesive to the window frame. This adhesive not only provides rrnpt%%d glass holding and sealing, but also permits use &of -body openings having a greater structural strength.

Adhesive kit and reserve items

Applications

Quantity

Adhesive kit

(Essex Chemical Corporation)

Urethane adhesive (Essex Urethane “E” . . . Auto Glass Sealant)

Dispensing nozzle One Glass blackout primer As required Dauber for applying blackout primer One

One cartridge

Reserve items

Wire (dia. x length) for cutting adhesive Five pieces of wire

Adhesive gun for adhesive application One

Isopropyl alcohol Wiping rags As required Window weatherstrip sealant for prevention of water leaks and As required

(MOPAR KIOI CEMENT Part No. 383769) gathering after adhesive application

MEK (Methyl Ethyl Ketone) or Toluene

Grow Chemical Solvent GS-35 for cleaning

Glass holder Two Window moulding remover (Special Tool

MB9904491 Spacers (Service Part)

Dam (Service Part)

Tectyl 506T (Valvoline Oil Company)

for cleaning jointing surfaces As required

0.6 x 1 mm (024 x .040 in.)

As required As required

One

Two As required

As required

NOTE MEK (Methyl Ethyl Ketone), Toluol (Toluene), Grow Chemical Solvent GS-35 can be obtained directly from a chemical house handling these chemicals.

BODY

WINDSHIELD INS’ TALLATION PROCEDURE

- Windshield and Quarter Window

(wire)

BOdV

--

r

I

,&,

spacers and studs

Application of solvent

(MEK or Toluene)

_-_-, I-----------

I

I I I

+-g+q;

c

I I I

Installation of glass

Glass

1

If reusing glass/

r---------

$?_emo-va! of adhesive and dam,

_ 1----- ____ -__I

I I

[:+$ni $&ass_ -2

(Toluene or paint thinner!

I

r---------

------------1

I

J ----

I t------

inspection of glass

l-

(Isopropyl alcohol)

Application of primer

(glass blackout primer) a

I I

pGGzdGq/

L.-~-~-~~--~~~~

(urethane adhesive)

----.----+,

- - --_-- ---------- -___ 4

(Grow chemrcal solvent GS-35)

If water leaks

BODY

- Windshield

23-55

WINDSHIELD

REMOVAL AND INSTALLATION

N23LBAH

Removal steps

1. Sunvisor

2. Dome light assembly

3. Inside rearview mirror

4. Assist grip

5. Front pillar trim

6. Headlining

7. Front side moulding

8. Front upper moulding

9. Window moulding clip

10. Moulding retainer

+I) l + 12. Windshield

11. Windshield moulding retainer

I)+ I 3. Window glass spacer B

l

+ 14. Window glass spacer A

l

* 15. Window dam

NOTE

(I) Reverse the removal procedures to reinstall.

(2) l *: Refer to “Service Points of Removal”. (3) l +: Refer to “Service Points of Installation”

(4) q : Non-reusable parts

18YA17

23-56

BODY

- Windshield

SERVICE POINTS OF REMOVAL

5. REMOVAL OF FRONT PILLAR TRIM Refer to P.23-95. -_

6. REMOVAL OF HEADLINING Remove the headlining from the roof panel to provide space

for extending wire between the top and bottom edges ot -1 windshield.

-

m E

Clir,

Moulding.

Cloth tape

7. REMOVAL OF FRONT SIDE MOULDING / 8. FRONT UPPER MOULDING / 9. WINDOW MOULPING CLIP

(1) Remove?he mouldi_ngs by using the special tool _

(MB99Q449).

(2) Remove the mouldtng clips by using the special tool

(MB990449).

12. REMOVAL OF WINDSHIELD (1) ‘Using a sharp-pointeddrill, make a hole in the adhesive _

area aft the windshi&j.

Insert a wire through the hole from the inside. 1

Caution Use cloth tape to protect the painted body surfaces.

/

Y1805C

Glass holders

BODY - Windshield

(2) From inside the vehicle, insert one end of wire through

adhesive at the upper edge of the windshield.

(3) Insert the other end of wire from inside the vehicle

through adhesive at the lower edge of the windshield. (4) Secure each end of wire to a wooden handle or the like. (5) Carefully cut through adhesive by pulling wire along the

windshield from outside the vehicle in a sawing motion.

Caution

In order to protect the body from damage, apply

cloth tape to all body areas around the installed

glass before cutting the adhesive.

(6) Make mating marks on the glass and body if the glass is

to be reinstalled.

(7) Take out the glass with glass holders.

NOTE

If the glass being removed is to be reinstalled, place it

on a protected bench or holding fixture.

(8) Use a screwdriver or similar tool to pry up and remove

the moulding clips.

23-57

‘/ ’

\

18Y55E

INSPECTION

Check the moulding clips and studs. Replace them if they are

damaged.

NOTE

If a moulding clip stud has been broken, drill a hole of 3 mm (.I 25 in.) in diameter in the stud, apply specified sealant to this hole, and then install the moulding clip with a self-tapping screw.

Specified sealant: Urethane adhesive (Essex Urethane “E”

. . . Auto Glass Sealant)

Caution After installing the clip, apply antirust solvent to the screw

head and the clip to protect them from rust.

Y18831

SERVICE POINTS OF INSTALLATION

15.-INSTALLATION OF WINDOW DAM (1) Wipe surface of glass, to which bead of adhesive will be

applied [within 25 mm (1 in.) from the edge of glass] with a cloth dampened in isopropyl alcohol.

Caution

Do not touch surfaces that have been degreased

with isopropyl alcohol.

23-58

nm (in.)

Spacer A Spacer B

18Y1551

bw3 off

Y1855H

BODY - Windshield

(2) Remove Vie back paper from the dam, and attach the ~:

dam to the glass.

(3) Apply glass primer to the entire bonding surfaGe of the

glass, both to the inside surface and the edge of the z glass Allo_w to dry for ten minutes.

Caution

Use care to avoid spilling primer solution on trim or

a painted surface. Wipe away any spilled solution

immediately, because the primer will damage trim

or painted surfaces.

Do not touch the primer coated surface.

14. INSTALLATION OF WINDOW GLASS SPACER A / 13. WINDOW GLASS SPACER B

(1) Using a clean lint-free_ cloth liberally dampened with

solvent (MEK or Toluene), briskly rub over old adhesive material remaining onpinch-weld flange.

(2)

Cut off an-amount from spacers A and B equal to the thickness of the adhesive remaining [within 2~mr-n (.08 in.)] on the pinch-weld flange.

~~

1

mm (In.1

1. Spacer A 2. Spacer B

(3) Attach the spacers In- the proper directions on the

flange. 1

Y186S

12. INSTALLATION OF WINDSHIELD (1) Using a sharp knife, remove old adhesive on the body

opening pinch-weld flange evenly to a thickness of

within 2 mm (.08 in.7 all around. Finish the flange

surfaces So that they are smooth.

Caution

Be careful not to remove more adhesive than

necessary, and also not to damage the paintwork on the body surface with the knife. If the paintwork is damaged, repair the damaged area with touch-up paint or antl-rust solvent.

Apply specified sealan

mm (in.) 18Y98E

PI 852s 3

BODY

- Windshield

(2) With an adhesive gun, apply the specified adhesive to

the entire windshield mounting surface along the dam.

Specified. adhesive:

NOTE Cut the nozzle tip into a V shape to facilitate adhesive application. Adhesive material begins to cure after fifteen minutes when exposed to air.

(3) Using a glass holder, place the glass on the body

opening.

Press the glass gently so that no adhesive appears. Caution

Do not move the glass after installing it to the body. Place the glass in the previously marked position. Use care not to close the water groove (in the lower corner of the pinch-weld flange) with adhesive.

(4) Wipe away excess adhesive from the glass. (5) Test for water leakage. (6) If there is leakage, fill the leaking area with specified

sealant. Specified sealant: MOPAR KIOI CEMENT

Caution Do not apply water directly to the bonded area.

(7) Install the clips to the body. (8) Apply tectyl to the clips. (9) Attach the mouldings to the clips by tapping.

Urethane adhesive (Essex Urethane “E” . . . Auto Glass Sealant)

Part No. 383769 or equivalent

23-59

Removal steps

1. Rear pillar trim

2. Upper quarter trim

3. Rear side shelf

+*

4. Quarter window moulding

I)+ 5. Quarter window glass

6. Quarter window spacer

7. Sealant

NOTE ~(1) Reverse the removal procedures to reInstall. (2)

**: Refer to “Service Points of Removal”.

(3) l *: Refer to “Service Points of Installation”. (4) q : Non-reusable parts

L

18Y1527

-_

SERVICE POINT OF REMOVAL

4. REMOVAL OF QUARTER WINDOW MOULDING (1) Open the hatch.

(2)

Remove -the quarter window moulding mounting -1

screws and bolt.

-

lAYA

mi--

(3JmWithm the special

tool mB990449), remove the quarter ~~ window moulding by-prying at the clip position of the quarter window moulding.

Caution

Be careful not to scratch the painted surface of

body.

the

+ 5 mm (.2 in.)

BODY - Quarter Window

Auto window sealer

23-61

(4) Remove the quarter window mounting bolts. (5) Cut the butyl tape and remove the quarter window

glass.

SERVICE POINT OF INSTALLATION

5. APPLICATION OF ADHESIVE TO QUARTER WINDOW GLASS

When the window glass is installed, apply the specified

adhesive all around the circumference of the inside of the glass.

Specified adhesive: Urethan adhesive (Essex Urethane

“E” . . . Auto Glass Sealant)

.--.

-1

re: ‘1 -

.,! 1

rt

. 1,

,-~-IL

23-62

BODY - Door Assembly

DOOR ASSEMBLY

REMOVAL AND INSTALLATION

N23MAAJ

Door removal steps

1. Door wiring harness connection

2. Upper hinge cover

I)+ 3. Door upper hinge

4. Door upper hinge shim

5. Lower hinge cover

*+ 6. Door lower hinge

‘8. E;o,; lower hinge shim

Striker removal steps f

9. Striker

10. Striker shim

18Y1801

-

-~

Door switch removal steps

‘1 I.- Door opening switch cap 1’2. Door switch

NOTE r:m: -

(I) Reversethe removal p%cedures to reinstall. (2) *+: Refer to “Service Points of Installation”.

INSPECTION

DOOR SWITCH

Operate the switch, and check the continuity between the

terminals.

-

NOTE rI&0 Indicates tf-& there IS conmurty between the terminals.

@ Cracks, damage, or abnormal norse of door hinges 9 Looseness of

l

Damage or-deformation-of door panel

door

hinge attaching bolts

BODY

18Y1727

- Door Assembly

23-63

SERVICE POINT OF INSTALLATION

6. REMOVAL OF DOOR LOWER HINGE / 3. DOOR UPPER HINGE

Apply specified grease to the door hinge sliding portions.

Specified grease: MOPAR Multi-purpose grease

Part No. 2932524 or equivalent

BODY

- Door Trim

DOOR TRIM

REMOVAL AND INSTALLATION

N23MBAI

Removal steps

I. Door corner trim

2. Inside handle cover

3. Door grip

+I) 5. Door sash trim 4, +I) 7. Door lower trim

4. Power window switch

6. Door upper trim

8. Door light

9. Speaker garnish

IO. Door grip bracket

11. Trim clips

18Y1802

NOTE (I) Reve@ iBe removal procedures to reinstall. (2) **: Rgfer to “ServicePoints of Removal”. (3) C denotes clip posItIon

-.

SERVICE POINTS OF REMOVAL

5. REMOVAL OF DOOR SASH TRIM Remove the front door sash trim mounting. scrqws, and

then remove the trim by pulling it upward.

-

BODY

- Door Trim

6. REMOVAL OF DOOR UPPER TRIM Remove the clips with the trim stick.

From the outside of the vehicle, remove the trim by pulling it upward while holding the sheet-metal part of the door upper trim.

7. REMOVAL OF DOOR LOWER TRIM Remove the clips from the edge of the door lower trim by

using the trim stick.

23-65

Main switch

Sub switch

16Y173i

INSPECTION

POWER WINDOW SWITCH Operate the switch, and check for continuity between the

terminals. MAIN SWITCH

Drivefsw;, ci;dow Passenger’s

window switch

2 1 4 6 2 3 7 6

NOR-

MAL

LOCK

DOWN o----O

o----o 0 0

SUB SWITCH

a j

g&5

--

-__.

23-66

BODY

- Front Door Glass and Regulator

FRONT DOOR GLASS AND REGULATOR

REMOVAL AND INSTALLATION

Removal steps 4+

I. Door trim

+I) *+ 2. Waterproof film

4II) 4+ +I)

3. Door drip moulding

4. Door belt moulding

5. Door window rear sash moulding

6. Door belt inside weatherstrip I)+ 7. Door glass stabilizer (inner) I)+ 8. Door glass stabilizer (outer)

4+ I)+

+I) Ib4

4d

9. Front door glass

IO. Power window regulator

11. Power window motor

NOTE (I ) Reverse the removal procedures to relnstall. (2) +I): Refer to “Serwce Potnts ot Removal”. (31 1)4: Refer to “Servrce Points of Installation”

BODY

- Front Door Glass and Regulator

SERVICE POINTS OF REMOVAL

1. REMOVAL OF DOOR TRIM Refer to P.23-64.

23-67

I I II III

2.0 (.8) I

Thickness:

1 LO4)

mm (in.)

I I

2. REMOVAL OF WATERPROOF FILM Cut away the non-drying adhesive around the waterproof

film with a cutter or similar tool. Caution

If the clip for the door trim is still in the mounting hole in the body, remove it with the tool shown in the illustration.

3. REMOVAL OF DOOR DRIP MOULDING / 4. DOOR BELT MOULDING / 5. DOOR WINDOW REAR SASH MOULDING

Insert the trim stick at the position of the moulding clips,

and then pry the mouldings to remove them in the following

order: (1) Door drip moulding (2) Door belt moulding (3) Door window rear sash moulding

9. REMOVAL OF FRONT DOOR GLASS (1) Turn on the ignition switch and operate the windows.

Be sure to turn the ignition switch off after finishing. (2) Remove the door glass stabilizer. (3) Remove the glass mounting nuts. (4) Pull the glass upward and remove it.

.lO. REMOVAL OF POWER WINDOW REGULATOR

(1) Remove the door glass guide..

BODY

&g-i

p-;=~

EEzY

~______~.

E-

- Front Door Glass and Regulator

(2) Remove’the

while moving the lower edge of the guide forward. ~-

(3) Remove the- motor connector.

(4) Remove the regulator- mounting bolts. ~~

(5) Remove the. regulator through the access hole.

11. REMOVAL OF POWER WINDOW MOTOR Remove then power window motor from the regulator I:

assembly. Caution

When loosening the connecting screws of the regulator and the motor assembly, the compressed force of the regulator spring may cause the regulator arm to spring

up.

door

glass gurde through the acqass hole ~_

EE=

ez

INSPECTION

POWER WINDOW MOTOR (1) Remove the Ipower window motor and regulator.

(2) Connect then-motor ~terminals directly to the battery and

check that the motor operates smoothly. Next, reverse the polarity and check that the motor operates-smoothly in the reverse direction.

To check the circuit breaker built in the motor, -install the

motor and regulator to the body and then proceed as r follows: r (‘iI Press the UP switch to wide open thee door window : ~

glass and hold down the swatch for about 1 Q-seconds. I

Upon releasrng the UP-switch, press the DOWN switch.

;$I The crrcuit breaker is,Tudged good if the door window I

glass starts to openTn 60 seconds or less.

’

y SL e

=r_ .

ST-

BODY

- Front Door Glass and Reaulator

POWER WINDOW RELAY (1) Remove the power window relay.

16Y15401

(2) Check continuity between terminals 1 and 3 when the

battery voltage is applied to terminal 2, and terminal 4 is grounded.

23-69

Guide pie

16LO312

Door glass guide

16WSOE

Voltage applied Voltage not

Terminals 1 - 3 Conductive

Terminals 1 - 3 Non-conductive

applied

Terminals 2 -4 Conductive

SERVICE POINTS OF INSTALLATION

10. APPLICATION OF GREASE TO POWER WINDOW REGULATOR

Apply the specified grease to the door glass guide and guide piece.

Specified grease: MOPAR Multi-mileage lubricant

Part No. 2525035 or equivalent

18Y149E

9. INSTALLATION OF FRONT DOOR GLASS (1) Lower the power window regulator until the door glass

and regulator installation point is visible through the service hole.

(2) Install the door glass to the power window regulator

and temporarily tighten the nuts. (3) Loosely tighten nuts A. (4) After making the adjustment of the door glass tilt,

tighten nuts A.

23-70

Door glass stabilizer (outer)

a

;z:

BODY

Door outer t3anel I

- _____~~~

.-.

- Front Door Glass and Regulator

8. INSTALLATION OF DOOR GLASS STABILIZER (OUTER) / 7. DOOR GLASS STABILIZER (INNER)

Install the door glass stabilizers to the door panel at the s:

positions shown in the illustration.

~~-~e

Ek.

B!-=

wsy

gIc+: s

E:

\

Door glass stabilizer

(inner)

stabil;er (inner)

1 RY491

I

2. APPLICATION OF SEALANT TO WATERPROOF FILM Apply the sp~ecfied sealant at the position shown in the

illustration, and then attach the waterproof film.

Specified Sealant: MOPAR Rope Caulk Sealer 3/16 x

80” roll Part No. 4026044 or equivalent.

BODY - Front Door Handle and Latch

23-71

FRONT DOOR HANDLE AND LATCH

REMOVAL AND INSTALLATION

N23MDAM

Removal steps (II)

4*

l * l + IO. Reed switch

1. Door trim

I)+ 2. Waterproof film

3. Rod snap

4. Rod snap

5. Door inside handle

6. Inside lock rod

7. Inside handle rod

8. Rod snap

9. Door outside handle

11. Lock cylinder retainer l * 12. Key cylinder l * 13. Door latch (with door lock switch) I)* 14. Rod snap l + 15. Door lock actuator

NOTE (1) Reverse the removal procedures to reinstall. (2) +I): Refer to “Service Points of Removal”. (3) I)*: Refer to “Service Points of Installation”. (4) q : Non-reusable parts

23-72

BODY

- Front Door Handle and Latch

SERVICE POINTS OF REMOVAL

I. REMOVAL OF DOOR TRIM

Refer to P.2364.

5. REMOVAL OF DOOR INSIDE HANDLE Remove the inside handle mounting screws, and then

disconnect the .inside lock rod and the inside handle rod ii from the inside handle.

16Y265:

-

10. REMOVAL OF REED SWITCH

(1) Disconnect the reed switch connector from lhe door ;_

harness.:~ :

(2) Remove Ihe reed switch from the key cylinder.

INSPECTION

DOOR LOCK ACTUATOR (1) Remove the’door lock actuator from the. door panel.

(2) The actuatoflswitch circuit is functioning properly if con- -

tinuity exists between actuator connector terminals (2) and _;

(4) while the actuator plunger is out (while the -door lock actuator switch is OFF), -and c-eases to exist &hen the ~1 plunger goes in (when the door lock actuator switch -_ becomes ON).

(3) Connect the battery source to the actuator terminals (1) and -2

(3). and check the shaft for operation. If the shaft moves in . opposite direction when the connectlon polarity IS changed,

the actuator should be consrdered to be in normal condition. .z

Mitsubishi Starion 1988 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual