ECU CHEVROLET DYNASTY 1993 Owners Manual

(3) Fabricate and fasten test probe (Fig. 5) securely
to convenient dust shield bolt hole. Make certain
torque converter is cleared by test probe. Tool must
be clean and dry.
(4) Run engine at approximately 2,500 rpm with
transaxle in neutral, for about 2 minutes. Transaxle
must be at operating temperature. (5) Stop engine and carefully remove tool.
(6) If upper surface of test probe is dry, there is no
torque converter leak. A path of fluid across probe
indicates a torque converter leak. Oil leaking under
the probe is coming from the transaxle pump area. (7) Remove transaxle and torque converter assem-
bly from vehicle for further investigation.The fluid
should be drained from the transaxle. Reinstall oil
pan (with MOPAR tAdhesive Sealant) at specified
torque. Possible sources of transaxle torque converter area
fluid leakage are: (1) Torque converter hub seal.(a) Seal lip cut, check torque converter hub fin-
ish. (b) Bushing moved and/or worn.
(c) Oil return hole in pump housing plugged or
omitted. (d) Seal worn out (high-mileage vehicles).
(2) Fluid leakage at the outside diameter from
pump housing O-ring. (3) Fluid leakage at the pump to case bolts. Check
condition of washers on bolts and use new bolts if
necessary. (4) Fluid leakage due to case or pump housing po-
rosity.
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
² Torque converter weld leaks at the outside diame-
ter (peripheral) weld.
² Torque converter hub weld.
² Torque converter impeller shell cracked adjacent
to hub.
² At drive lug welds. Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter.
AIR PRESSURE TEST OF TRANSAXLE
Fabricate equipment needed for test as shown in
figures 6 and 7.
The transaxle should be prepared for pressure test as
follows after removal of the torque converter: (1) Install a dipstick bore plug and plug oil cooler
line fitting (lower fitting). (2) With rotary motion, install converter hub seal
cup over input shaft. It must go through the converter
hub seal until the cup bottoms against the pump gear
lugs. Before use, inspect hub seal cup (Fig. 6) for nicks
or burrs that could damage seal. Secure with cup
retainer strap (Fig. 7) using starter upper hole and
opposite bracket hole. (3) Attach and clamp hose from nozzle of Tool C-4080
to the upper cooler line fitting position in case.
CAUTION: Do not, under any circumstances, pressur-
ize a transaxle to more than 10 psi. (4) Pressurize the transaxle using Tool C-4080 until
the pressure gauge reads 8 psi. Position transaxle
Fig. 5 Leak Locating Test Probe Tool
Fig. 6 Torque Converter Hub Seal Cup
Fig. 7 Hub Seal Cup Retaining Strap
Ä TRANSAXLE 21 - 45

BAND ADJUSTMENT
KICKDOWN BAND (FRONT)
The kickdown band adjusting screw is located on
left side (top front) of the transaxle case. (1) Loosen locknut and back off nut approximately
five turns. Test adjusting screw for free turning in
the transaxle case. (2) Using wrench, Tool C-3880-A with adapter Tool
C-3705, tighten band adjusting screw to 5 N Im (47 to
50 in. lbs.). If adapter C-3705 is not used, tighten ad-
justing screw to 8 N Im (72 in. lbs.) which is the true
torque. (3) Back off adjusting screw the number of turns
listed in Specifications . Hold adjusting screw in this
position and tighten locknut to 47 N Im (35 ft. lbs.)
LOW/REVERSE BAND-REAR
To adjust low-reverse band, proceed as follows:
(1) Loosen and back off locknut approximately 5
turns. (2) Using an inch-pound torque wrench, tighten
adjusting screw to 5 N Im (41 in. lbs.) true torque.
(3) Back off adjusting screw the number of turns
listed under Specifications in the rear of the Tran-
saxle Section in this service manual. (4) Tighten locknut to 14 N Im (10 ft. lbs.).
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
LINE PRESSURE
An incorrect throttle pressure setting will cause in-
correct line pressure readings even though line pres-
sure adjustment is correct. Always inspect and
correct throttle pressure adjustment before adjusting
the line pressure. The approximate adjustment for line pressure is
1-5/16 inches, measured from valve body to inner
edge of adjusting nut. However, due to manufactur-
ing tolerances, the adjustment can be varied to ob-
tain specified line pressure. The adjusting screw may be turned with an Allen
wrench. One complete turn of adjusting screw
changes closed throttle line pressure approximately
1-2/3 psi. Turning adjusting screw counterclockwise
increases pressure, and clockwise decreases pressure.
THROTTLE PRESSURE
Throttle pressures cannot be tested accurately;
therefore, the adjustment should be measured if a
malfunction is evident. (1) Insert gauge pin of Tool C-3763 between the
throttle lever cam and kickdown valve. (2) By pushing in on tool, compress kickdown
valve against its spring so throttle valve is com-
pletely bottomed inside the valve body. (3) While compressing spring, turn throttle lever
stop screw with adapter C-4553. Turn until head of screw touches throttle lever tang, with throttle lever
cam touching tool and throttle valve bottomed. Be sure
adjustment is made with spring fully compressed and
valve bottomed in the valve body.
VEHICLE SPEED SENSOR PINION GEAR
When the speed sensor is removed for any reason, a
NEW O-ring must be installed on its outside diameter.
REMOVAL AND INSTALLATION
(1) Remove speedometer cable (if so equipped).
(2) Remove harness connector from sensor. Make
sure weatherseal stays on harness connector. (3) Remove bolt securing the distance sensor in the
extension housing. (4) Carefully pull sensor and pinion gear assembly
out of extension housing. (5) Remove pinion gear from sensor.
(6) To install, reverse the above procedure. Make
sure extension housing and sensor flange are clean
prior to installation. Always use a NEW sensor O-ring. (7) Tighten securing bolt to 7 N Im (60 in. lbs.).
Tighten speedometer cable to 4 N Im (35 in. lbs.).
PARK/NEUTRAL POSITION AND BACK-UP LAMP
SWITCH
REPLACEMENT AND TEST
The Park/Neutral switch is the center terminal of the
3 terminal switch. It provides ground for the starter
solenoid circuit through the selector lever in only Park
and Neutral positions. (1) To test switch, remove wiring connector from
switch and test for continuity between center pin of
switch and transaxle case. Continuity should exist only
when transaxle is in Park or Neutral. (2) Check gearshift cable adjustment before replac-
ing a switch which tests bad. (3) Unscrew switch from transaxle case allowing
fluid to drain into a container. Move selector lever to
Park and then to Neutral positions. Inspect to see that
the switch operating lever fingers are centered in
switch opening in the case. (4) Screw the switch with a new seal into transaxle
case and tighten to 33 N Im (24 ft. lbs.). Retest switch
with the test lamp. (5) Add fluid to transaxle to bring up to proper level.
(6) The back-up lamp switch circuit is through the
two outside terminals of the 3 terminal switch. (7) To test switch, remove wiring connector from
switch and test for continuity between the two outside
pins. (8) Continuity should exist only with transaxle in
Reverse position. (9) No continuity should exist from either pin to the
case.
Ä TRANSAXLE 21 - 47

first separator plate and watch carefully for the pis-
ton to move forward. The piston should return to its
original position after the air pressure is removed.
UNDERDRIVE CLUTCH
Because this clutch piston cannot be seen, its oper-
ation is checked by function. Air pressure is applied
to the low/reverse and the 2/4 clutches. This locks
the output shaft. Use a piece of rubber hose wrapped
around the input shaft and a pair of clamp-on pliers
to turn the input shaft. Next apply air pressure to
the underdrive clutch. The input shaft should not ro-
tate with hand torque. Release the air pressure and
confirm that the input shaft will rotate.
FLUID LEAKAGE-TORQUE CONVERTER HOUSING
AREA
(1) Check for source of leakage.
Since fluid leakage at or around the torque con-
verter area may originate from an engine oil leak,
the area should be examined closely. Factory fill
fluid is dyed red and, therefore, can be distinguished
from engine oil. (2) Prior to removing the transaxle, perform the
following checks: When leakage is determined to originate from the
transaxle, check fluid level prior to removal of the
transaxle and torque converter. High oil level can result in oil leakage out the vent
in the manual shaft. If the fluid level is high, adjust
to proper level. After performing this operation, inspect for leak-
age. If a leak persists, perform the following opera-
tion on the vehicle to determine if it is the torque
converter or transaxle that is leaking.
LEAKAGE TEST PROBE
(1) Remove torque converter housing dust shield.
(2) Clean the inside of torque converter housing
(lower area) as dry as possible. A solvent spray fol-
lowed by compressed air drying is preferable. (3) Fabricate and fasten test probe (Fig. 4) securely
to convenient dust shield bolt hole. Make certain
torque converter is cleared by test probe. Tool must be
clean and dry. (4) Run engine at approximately 2,500 rpm with
transaxle in neutral, for about 2 minutes. Transaxle
must be at operating temperature. (5) Stop engine and carefully remove tool.
(6) If upper surface of test probe is dry, there is no
torque converter leak. A path of fluid across probe
indicates a torque converter leak. Oil leaking under the
probe is coming from the transaxle torque converter
area. (7) Remove transaxle and torque converter assembly
from vehicle for further investigation. The fluid should
be drained from the transaxle. Re install oil pan (with
MOPAR tAdhesive Sealant) at specified torque.
Possible sources of transaxle torque converter area
fluid leakage are: (1) Torque converter hub seal.
² Seal lip cut, check torque converter hub finish.
² Bushing moved and/or worn.
² Oil return hole in pump housing plugged or omitted.
² Seal worn out (high-mileage vehicles).
(2) Fluid leakage at the outside diameter from pump
housing O-ring. (3) Fluid leakage at the front pump to case bolts.
Check condition of washers on bolts and use new bolts,
if necessary. (4) Fluid leakage due to case or front pump housing
porosity.
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
² Torque converter weld leaks at the out side (periph-
eral) weld.
² Torque converter hub weld.
Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter. If the torque converter must be replaced, refer
to Torque Converter Clutch Break-in Procedure
in this section. This procedure will reset the
transmission control module break-in status.
Failure to perform this procedure may cause
transaxle shutter.
AIR PRESSURE TEST OF TRANSAXLE
Fabricate equipment needed for test as shown in
Figures 5 and 6. The transaxle should be prepared for pressure test as
follows after removal of the torque converter: (1) Plug dipstick tube and plug oil cooler line fitting.
Remove vent from manual shaft and in stall a 1/8 inch
pipe plug.Fig. 4 Leak Locating Test Probe Tool
Ä TRANSAXLE 21 - 97

CAUTION: Prevent manual shaft rotation during in-
stallation and removal. (2) With rotary motion, install converter hub seal
cup over input shaft. It must go through the con-
verter hub seal until the cup bottoms against the
pump gear lugs. Secure with cup retainer strap using
starter upper hole and opposite bracket hole. (3) Attach and clamp hose from nozzle of Tool
C-4080 to the upper cooler line fitting position in
case.
CAUTION: Do not, under any circumstances, pres-
surize a transaxle to more than 10 psi.
(4) Pressurize the transaxle using Tool C-4080 un-
til the pressure gauge reads 8 psi. Position transaxle
so that pump housing and case front may be covered
with soapy solution of water. Leaks are sometimes
caused by porosity in the case or pump housing. If a leak source is located, that part and all associ-
ated seals, O-rings, and gaskets should be replaced
with new parts.
GEARSHIFT LINKAGE ADJUSTMENT
Normal operation of the transmission range switch
(PRNDL) and park/neutral position switch provides a
quick check to confirm proper manual linkage adjust-
ment. Move the selector level slowly upward until it
clicks into the ``P'' Park notch in the selector gate. If
the starter will operate the ``P'' position is correct. After checking ``P'' position, move selector toward
``N'' Neutral position until lever drops in the ``N''
stop. If the starter will also operate at this point the
gearshift linkage is properly adjusted.
CAUTION:When it is necessary to disassemble link-
age cable from levers, which use plastic grommets
as retainers, the grommets should be replaced with
new grommets. Use a prying tool to force rod from
grommet in lever, then cut away old grommet. Use
pliers to snap new grommet into lever and rod into
grommet.
(1) Set parking brake.
(2) Place gearshift lever in P(PARK) position.
(3) Loosen clamp bolt on gearshift cable bracket.
(4) Column shift: Insure that preload adjustment
spring engages fork on transaxle bracket. (5) Pull the shift lever by hand to the front detent
position (PARK) and tighten lock screw to 11 N Im
(100 in. lbs.). Gearshift linkage should now be prop-
erly adjusted. (6) Check adjustment as follows:(a) Detent position for neutral and drive should
be within limits of hand lever gate stops. (b) Key start must occur only when shift lever is
in park or neutral positions.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum tran-
saxle case and valve body can be repaired by the use
of Heli-Coils, or equivalent. This repair consists of
drilling out the worn-out damaged threads. Then tap
the hole with a special Heli-Coil tap, or equivalent,
and installing a Heli-Coil insert, or equivalent, into
the hole. This brings the hole back to its original
thread size. Heli-Coil, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
COOLERS AND TUBES REVERSE FLUSHING
When a transaxle failure has contaminated the
fluid, the oil cooler(s) must be flushed and the cooler
bypass valve in the transaxle must be replaced. The
torque converter must also be replaced with an ex-
change unit. This will insure that metal particles or
sludged oil are not later transferred back into the re-
conditioned (or replaced) transaxle.
Fig. 5 Torque Converter Hub Seal Cup
Fig. 6 Hub Seal Cup Retaining Strap
21 - 98 TRANSAXLE Ä

(11) Remove front engine mount insulator and
bracket (Fig. 5). (12) On vehicles equipped with D.I.S. ignition sys-
tem, remove crankshaft position sensor from bell
housing. For installation procedure refer to section
8D of this service manual.
CAUTION: Failure to remove the crankshaft position
sensor from the bell housing could damage the
sensor or torque converter drive plate during trans-
mission removal or installation.
(13) Remove starter bolts and set starter aside. Do
not allow the starter to hang from battery cable (Fig.
6). (14) Position transmission jack securely under
transaxle (Fig. 7). (15) With transmission jack in position, remove
the left transmission mount (Fig. 8). (17) Carefully lower the transaxle assembly from
vehicle (Fig. 9). When installing transaxle, reverse the above proce-
dure.
Fig. 2 Remove Left Splash Shield
Fig. 3 Remove Torque Converter Dust Shield
Fig. 4 Disconnect transmission range switch and Park/Neutral Position Switch
Fig. 5 Remove Front Engine Mount
21 - 100 TRANSAXLE Ä

BODY
CONTENTS
page page
AA-VEHICLE BODY COMPONENT SERVICE . . . 11
AC-VEHICLE BODY COMPONENT SERVICE . . . 37
AG-VEHICLE BODY COMPONENT SERVICE . . . 52
AJ-VEHICLE BODY COMPONENT SERVICE . . . 71
AJ/27-VEHICLE CONVERTIBLE BODYCOMPONENT SERVICE ................. 86
AP-VEHICLE BODY COMPONENT SERVICE . . . 97
AP/17-VEHICLE CONVERTIBLE BODY COMPONENT SERVICE ................. 117 AY-VEHICLE BODY COMPONENT SERVICE . . 133
BODY DIAGNOSTIC PROCEDURES .......... 2
GENERAL SERVICE INFORMATION .......... 1
PAINT ................................. 4
POWER SUNROOF ....................... 6
WINDSHIELD ........................... 9
GENERAL SERVICE INFORMATION
VEHICLE IDENTIFICATION
Throughout this group, references to the Chrysler
Corporation vehicle family identification code is used
when describing a procedure that is unique to that
vehicle. Refer to Introduction Group of this manual for
detailed information on vehicle identification. If a
procedure is common to all vehicles covered in this
manual, no reference will be made to a vehicle family
code.
SAFETY PRECAUTIONS AND WARNINGS
WARNING: WHEN SERVICING A VEHICLE EQUIPPED
WITH AIRBAG RESTRAINT SYSTEM, REVIEW ALL
PRECAUTIONS IN GROUP 8M, RESTRAINT SYS-
TEMS. PERSONAL INJURY CAN RESULT. EYE PROTECTION SHOULD BE USED WHEN SER-
VICING GLASS COMPONENTS. PERSONAL INJURY
CAN RESULT. USE A BREATHING FILTER WHEN SPRAYING
PAINT OR SOLVENTS IN A CONFINED AREA. PER-
SONAL INJURY CAN RESULT. AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL BASED CLEANING SOLVENTS.
PERSONAL INJURY CAN RESULT. DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched in
a inner body panel, verify depth of space to the outer
body panel, electrical wiring, or other components.
Damage to vehicle can result. Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result. Do not use harsh alkaline based cleaning solvents
on painted or upholstered surfaces. Damage to finish
or color can result. Do not hammer or pound on plastic trim panel
attaching fasteners when servicing interior trim. Plas-
tic panel can break.
Chrysler Corporation uses many different types of
push-in fasteners to secure the interior and exterior
trim to the body . Most of these fasteners can be reused
to assemble the trim during various repair procedures.
At times a push-in fastener cannot be removed without
damaging the fastener or the component it is holding.
If it is not possible to remove a fastener without
damaging a component or body, cut or brake the
fastener and use a new one when installing the com-
ponent. Never pry or pound on a plastic or press-board
trim component. Using a suitable fork-type prying
device, pry the fastener from the retaining hole behind
the component being removed. When installing, verify
that fastener is aligned with the retaining hole, by
hand, push directly on or over the fastener until it
seats. Apply a low force pull to the panel to verify that
it is secure. When it is necessary to remove components to service
another, it should not be necessary to apply excessive
force or bend a component to remove it. Before damag-
ing a component to be reused, verify there is no hidden
fasteners or captured edges holding the component in.
Often a fastener is hidden by carpeting nap or trim
plugs.
Ä BODY 23 - 1

POWER SUNROOF INDEX
page page
Adjustment Bracket ........................ 7
Drain Channel ............................ 7
Drive Cable Locators ....................... 7
Drive Cables ............................. 8
General Information ........................ 6
Glass Panel ............................. 7 Glass Vertical Height Adjustment
.............. 6
Guide Assembly .......................... 8
Motor and Drive Gears ..................... 7
Sunshade ............................... 8
Wind Deflector ........................... 6
GENERAL INFORMATION
All sunroofs are equipped with drain tubes that are
located in the A, B or C-pillars. The drain tubes
must be kept open to prevent water from entering
the passenger compartment.
LUBRICATION
(1) Lubricate cables with Lubriplate or equivalent
when cables are replaced. (2) Periodically clean dirt from guide rail covers.
DRAIN TUBES
² Inspect the drain holes, located in the trough
around the sunroof opening to verify they are clear.
Inspection should be performed at least once a year
or when problems are suspected. If drain hose or
tubes are plugged, use compressed air or blunt flexi-
ble wire to clear them. If tubes cannot be cleared,
they must be repaired.
² The lower ends of the rear drain tubes are located
in the rear quarter panel drop wells. To clear rear
drain tubes, use compressed air or blunt flexible wire
from the lower ends of the tubes.
GLASS VERTICAL HEIGHT ADJUSTMENT
GLASS VERTICAL ADJUSTMENT (FIG. 1)
(1) Open glass to vent position.
(2) Slide upper half of mechanism covers rearward
until clips disengage and separate covers from vehi-
cle. (3) Close glass panel, separately loosen adjusting
bolts and individually adjust the corners of glass. (4) Adjust front of glass panel to 1.0 mm (0.040 in.)
below top surface of roof panel. (5) Adjust rear of glass to 1.0 mm (0.040 in.) above
top surface of roof panel. (6) Secure adjustment bolts and install cover.
WIND DEFLECTOR
WIND DEFLECTOR REMOVAL (FIG. 2)
(1) Open sun roof glass panel.
(2) Remove screws holding wind deflector to sun
roof unit side rail. (3) Separate wind deflector from vehicle.
WIND DEFLECTOR INSTALLATION
Reverse the preceding operation.
WIND DEFLECTOR ADJUSTMENT (FIG. 2)
(1) Open sunroof.
Fig. 1 Glass Adjustment
Fig. 2 Deflector Assembly
23 - 6 BODY Ä

(2) position wind deflector so 19 mm (0.75 in.)
above top surface of roof panel and 1 mm (0.040 in.)
rearward of roof panel forward edge. (3) Secure wind deflector to sunroof unit.
GLASS PANEL
GLASS PANEL REMOVAL
(1) Remove wind deflector mechanism covers (Fig.
1). (2) Position glass to vent position.
(3) Position sunshade full rearward.
(4) Loosen nuts holding glass panel to side adjust-
ment brackets. (5) Slide glass panel rearward 12 mm (0.5 in.) and
separate glass from sunroof unit.
GLASS PANEL INSTALLATION
(1) Position glass panel in opening with logo rear-
ward and slide panel forward 12 mm (0.5 in.). (2) Verify that attaching nuts are below top sur-
face of glass adjustment brackets. (3) Close sunroof to center glass panel in roof open-
ing. (4) Tighten center screws to hold adjustment.
(5) Open glass to vent position and tighten nuts to
8N Im (70.8 in-lbs.).
(6) Close glass and check alignment.
(7) Install the mechanism covers.
(8) Adjust wind deflector, if necessary.
ADJUSTMENT BRACKET
ADJUSTMENT BRACKET REMOVAL (FIG. 3)
(1) Remove wind deflector, mechanism covers and
glass panel. (2) Move glass carriage to vent position and re-
move rearward adjustment bolt from adjustment
bracket. (3) Lift rear of adjustment bracket to highest ver-
tical position and disengage front of bracket from
unit.
ADJUSTMENT BRACKET INSTALLATION
Reverse the preceding operation. Adjust glass, and
wind deflector as necessary.
DRAIN CHANNEL
DRAIN CHANNEL REMOVAL
(1) Remove wind deflector mechanism covers and
glass panel. (2) Locate glass carriage to vent position and drain
channel in full forward position. (3) Remove screws holding drain channel to sup-
port frame.
DRAIN CHANNEL INSTALLATION
Reverse the preceding operation.
DRIVE CABLE LOCATORS
DRIVE CABLE LOCATORS REMOVAL (FIG. 4)
(1) Position glass 19 mm (0.75 in.) until rearward
until cable locator is visible. (2) Remove screws holding drive cable locator to
unit. (3) Remove travel limiting micro switch grommet
and disconnect wire connector. (4) Insert a small screwdriver under rear edge of
locator and pry locator from track.
DRIVE CABLE LOCATORS INSTALLATION
Reverse the preceding operation. The small out-
board lip underneath cable locator slips under bottom
slot on guide track. After locator is seated install
screws.
MOTOR AND DRIVE GEARS
MOTOR AND DRIVE GEAR REMOVAL (FIG. 5)
(1) Open sunroof to vent position.
(2) Remove head lining.
Fig. 3 Glass Height Vertical Adjustment
Fig. 4 Removing Cable Drive Locator
Ä BODY 23 - 7

GUIDE ASSEMBLY INSTALLATION
(1) Install guide cable into rear of guide assembly.
(2) Install guide assembly at an angle so the rear
portion slips under finger clips at rear of module
housing. (3) Place cable in groove of cable holder.
(4) Install screws in track assembly.
(5) Install locators.
(6) Reverse removal operation.
WINDSHIELD
SAFETY PRECAUTIONS AND WARNINGS
WARNING: DO NOT OPERATE VEHICLE FOR AT
LEAST 24 HOURS AFTER WINDSHIELD INSTALLA-
TION. WINDSHIELD MAY NOT PERFORM PROPERLY
IN THE EVENT OF A COLLISION IF URETHANE AD-
HESIVE IS NOT SUFFICIENTLY CURED. REFER TO
MANUFACTURER OF URETHANE BEING USED FOR
CURING TIME SPECIFICATIONS. WHEN INSTALLING GLASS, DO NOT USE URE-
THANE ADHESIVE AFTER DATE ON PRODUCT HAS
EXPIRED. SAFETY AND QUALITY OF REPAIR
WOULD BE QUESTIONABLE. DO NOT USE URETHANE ADHESIVE OR PRIMER IN
CLOSED WORK AREA, PERSONAL INJURY CAN RE-
SULT. PROTECT SKIN FROM COMING IN CONTACT WITH
URETHANE, PERSONAL INJURY CAN RESULT. WEAR EYE AND HAND PROTECTION WHEN
WORKING WITH GLASS, PERSONAL INJURY CAN
RESULT.
CAUTION: Protect all painted or trimmed surfaces
from coming in contact with urethane or primers,
damage will result. Do not damage painted surfaces when removing
mouldings or cutting urethane around windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the struc-
tural support for the roof. The urethane bonding used
to secure the windshield to the fence is difficult to cut
or clean from any surface. If the mouldings are set in
urethane, it would also be unlikely they could be
salvaged. Before removing the windshield, check the
availability of the windshield and mouldings from the
parts supplier.
WINDSHIELD REMOVAL
(1) Remove inside rear view mirror.
(2) Remove cowl cover.
(3) Remove windshield mouldings using a suitable
hook tool and trim stick (Fig. 1). (4) Cut urethane bonding from around windshield
using a suitable sharp cold knife. A pneumatic cutting
device can be used if available (Fig. 2). (5) Separate windshield from vehicle.
WINDSHIELD INSTALLATION
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment if a door or the trunk lid is
slammed before urethane bonding is cured. Water
leaks can result.
Fig. 8 Guide Assembly
Fig. 1 Windshield Mouldings
Fig. 2 Cut Urethane Around Windshield
Ä BODY 23 - 9

AA-VEHICLE BODY COMPONENT SERVICE INDEX
page page
A-Pillar and Roof Rail Mouldings ............. 25
B-Pillar Trim Panel ....................... 25
Body Side Moulding and Applique ............ 24
Cowl Cover ............................. 13
Cowl Panel Trim and Scuff Plates ............ 25
Door Opening Weatherstrips ................ 24
Floor Carpet ............................ 30
Front Center Console ..................... 29
Front Door and Hinge ..................... 15
Front Door Belt Moulding and Weatherstrip ..... 17
Front Door Glass ........................ 17
Front Door Glass Channel and Run Weatherstrip . 18
Front Door Glass Run Lower Channel ......... 18
Front Door Latch ......................... 16
Front Door Side View Mirror ................ 17
Front Door Silencer and Water Shield ......... 15
Front Door Trim Panel .................... 14
Front Door Window Regulator/Manual ......... 18
Front Door Window Regulator/Power .......... 19
Front End Splash Shields .................. 13
Front Fender ............................ 14
Front Power Door Lock Actuator ............. 19
Front Seat Belts ......................... 27
Front Seats ............................. 28
Fuel Fill Door ........................... 36
Grille .................................. 11
Head Lining ............................. 30
Hood and Hinges ........................ 11
Hood Latch and Release Cable .............. 12
Outside Front Door Latch Release Handle ..... 16
Outside Rear Door Latch Release Handle ...... 21 Overhead Console
........................ 30
Quarter Extension Trim Panel ............... 27
Quarter Trim Panel ....................... 27
Rear Deck Filler Panel .................... 31
Rear Door and Hinge ..................... 20
Rear Door Belt Moulding and Weatherstrip ..... 22
Rear Door Glass ......................... 22
Rear Door Glass Run Weatherstrip ........... 22
Rear Door Glass Stationary Glass Module ..... 23
Rear Door Latch ......................... 21
Rear Door Silencer and Water Shield ......... 20
Rear Door Trim Panel ..................... 20
Rear Door Window Regulator/Manual ......... 23
Rear Door Window Regulator/Power .......... 23
Rear Power Door Lock Actuator ............. 22
Rear Seat Belts .......................... 28
Rear Seats ............................. 28
Rear Shelf Trim Panel ..................... 27
Rear Window Glass ...................... 32
Sun Roof Air Deflector .................... 31
Sun Roof Drain Tubes .................... 31
Sun Roof Weatherstrip .................... 31
Trunk Lid .............................. 33
Trunk Lid Hinge ......................... 34
Trunk Lid Latch .......................... 34
Trunk Lid Lock .......................... 34
Trunk Lid Luggage Rack ................... 35
Trunk Lid Torsion Bar ..................... 34
Trunk Lining ............................ 35
Trunk Opening Weatherstrip ................ 35
Vinyl Roof Bonnet ........................ 31
GRILLE
REMOVAL (FIG. 1)
(1) Raise hood to full up position.
(2) Remove hood safety catch release rod retainer
and separate rod from grille. (3) Remove grille end reinforcement attaching
bolts. (4) Remove nuts holding grille to hood.
(5) Separate grille from hood.
INSTALLATION
Reverse the preceding operation.
HOOD AND HINGES
HOOD REMOVAL (FIG. 2)
(1) Raise hood to full up position.
(2) Lift front edge of cowl cover on the right side of
the windshield washer bottle and disconnect the un-
der hood lamp wire connector. (3) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation. When install- ing hood, align all marks and secure bolts. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers. (4) Remove the top hood to hinge attaching bolts
and loosen the bottom bolts until they can be re-
moved by hand.
Fig. 1 Grille Assembly
Ä AA-BODY 23 - 11