tailgate DODGE TOWN AND COUNTRY 2001 Service Manual

INSTALLATION
(1) Position arm on pivot.
(2) Pull up on arm and release lock
(3) Allow wiper arm to rest on rear window.
REAR WIPER MOTOR
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove rear wiper arm. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL) in this section.
(3) Open liftgate.
(4) Remove liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL).
(5) Disconnect wire connector from rear wiper
motor.
(6) Remove screws holding rear wiper motor to lift-
gate (Fig. 9).
(7) Remove wiper motor from liftgate.
INSTALLATION
(1) Position the wiper motor in the liftgate.
(2) Install the retaining screws.
(3) Connect the wire harness connector.
(4) Install the liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - INSTALLATION).
(5) Disconnect wire connector from rear wiper
motor.
(6) Remove screws holding rear wiper motor to lift-
gate (Fig. 9).(7) Remove wiper motor from liftgate (Fig. 9).
(8) Close the liftgate.
(9) Install the wiper arm. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS - INSTAL-
LATION) in this section.
(10) Connect the battery negative cable.
REAR WIPER/WASHER
SWITCH
DESCRIPTION
The rear window wiper/washer switches are
located on the center bezel with the hazard and
heated seat switches (Fig. 10). They are not service-
able seperately from the hazard and heated seat
switches. If defective, the entire switch assembly
must be replaced.
OPERATION
Refer to the vehicle Owner's Manual for operating
instructions for the rear window wiper and washer.
WASHER HOSES
REMOVAL
(1) Remove rear window wiper motor. (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/REAR WIPER
MOTOR - REMOVAL).
(2) Peel wiper pivot seal grommet from rear glass.
(3) Remove grommets from vehicle (Fig. 11).
Fig. 9 REAR WINDOW WIPER MOTOR
1 - REAR WINDOW
2 - REAR WIPER MOTOR
3 - CHMSL
4 - WELL NUTS
Fig. 10 HVAC CONTROL PANEL
1 - TRIM BEZEL
2 - ACT SENSOR
3 - A/C REQUEST SWITCH
4 - REAR WINDOW DEFOGGER/HEATED MIRRORS SWITCH
COMBO
5 - FRONT WINDOW DEFROSTER MODE SELECTOR
RSWIPERS/WASHERS8R-7
REAR WIPER ARM (Continued)
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BODY
TABLE OF CONTENTS
page page
BODY
DESCRIPTION............................1
WARNING...............................2
DIAGNOSIS AND TESTING..................2
WATER LEAKS..........................2
WIND NOISE...........................3
STANDARD PROCEDURE...................4
PLASTIC BODY PANEL REPAIR.............4
HEAT STAKING.........................8
SPECIFICATIONS.........................9
SPECIAL TOOLS........................151DOOR - FRONT.........................152
DOORS - SLIDING.......................162
DECKLID/HATCH/LIFTGATE/TAILGATE.......180
EXTERIOR.............................184
HOOD................................199
INSTRUMENT PANEL....................202
INTERIOR.............................208
PAINT................................220
SEATS................................222
STATIONARY GLASS.....................243
WEATHERSTRIP/SEALS..................248
BODY
DESCRIPTION - LOCK CYLINDERS
Ignition, door, deck lid, and rear hatch lock cylin-
ders are all codable to the key. Lock barrels, tum-
blers, and tumbler springs are available to allow the
technician to change replacement locks cylinders to
match the customer's original key set. See the appro-
priate section in this manual for lock cylinder
removal. See the Moparž catalogue for part numbers
and lock coding procedures.
DESCRIPTION - VEHICLE IDENTIFICATION
Throughout this group, references to the
DaimlerChrysler Corporation vehicle family identifi-
cation code are 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.
DESCRIPTION - PUSH-IN FASTENERS
DaimlerChrysler 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 com-
ponent it is holding. If it is not possible to remove a
fastener without damaging a component or body, cut
or break the fastener and use a new one when
installing the component. Never pry or pound on a
plastic or pressed-board trim component. Using a
suitable fork-type prying device, pry the fastener
from the retaining hole behind the component beingremoved. When installing, verify fastener alignment
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 ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges holding the component in
place.
DESCRIPTION
PAINT
The original equipment finish is a multi-step pro-
cess that involves cleaning, electrodeposition (e-coat),
base coat, and clear coat steps. Additionally, selected
areas of the vehicle may be coated with an anti-chip
finish.
On most vehicles a two-stage paint application
(base coat/clear coat) is used. Color that is applied to
primer is called base coat. The clear coat protects the
base coat from ultraviolet light and provides a dura-
ble high-gloss finish.
STATIONARY GLASS
Windshields are made of two pieces of glass with a
plastic inner layer. Windshields and selected station-
ary glass are structural members of the vehicle. The
windshield glass is bonded to the windshield frame
with urethane adhesive.
Windshields and other stationary glass protect the
occupants from the effects of the elements. Wind-
shields are also used to retain some airbags in posi-
tion during deployment. Urethane bonded glass is
difficult to salvage during removal. The urethane
bonding is difficult to cut or clean from any surface.
RSBODY23-1
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DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL.............................180
INSTALLATION..........................180
HINGE
REMOVAL.............................180
INSTALLATION..........................181
LATCH
REMOVAL.............................181
INSTALLATION..........................181
LATCH STRIKER
REMOVAL.............................181
INSTALLATION..........................181
LIFTGATE
REMOVAL.............................181INSTALLATION..........................182
LIFTGATE SPOILER
REMOVAL.............................182
INSTALLATION..........................182
LOCK CYLINDER
REMOVAL.............................182
INSTALLATION..........................182
SUPPORT CYLINDER
REMOVAL.............................183
INSTALLATION..........................183
TRIM PANEL
REMOVAL.............................183
INSTALLATION..........................183
EXTERIOR HANDLE
REMOVAL
(1) Remove liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the exterior handle electrical con-
nectors.
(3) Remove the two outer screws and the two inner
screws.
(4) Remove the exterior handle/license plate light
assembly.
INSTALLATION
(1) Route the exterior handle electrical connector
through the door and position handle.
(2) Install the two inner bolts and tighten to 40
N´m (30 ft. lbs.).
(3) Install the two out screws and tighten to 20
N´m (15 ft. lbs.).
(4) Connect the electrical connector.
(5) Install the trim panel. (Refer to 23 - BODY/
DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM
PANEL - INSTALLATION)
HINGE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device in
the full open position.(3) Apply several layers of duct tape on the outside
of to roof across the gap to the lift gate to hold the
liftgate in position.
(4) Remove bolts attaching liftgate hinge to roof
header.
(5) Disconnect VTSS switch from the body har-
ness.
(6) Remove bolts attaching hinge to liftgate (Fig.
1).
(7) Remove hinge from vehicle.
Fig. 1 Liftgate Hinge
1 - LIFTGATE
2 - HINGE
3 - REAR ROOF HEADER
23 - 180 DECKLID/HATCH/LIFTGATE/TAILGATERS
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INSTALLATION
(1) If necessary, paint replacement hinge before
installation.
(2) Place hinge in position on vehicle.
(3) Align hinge to marks on liftgate.
(4) Install bolts attaching hinge to liftgate (Fig. 1)
. Tighten bolts to 33 N´m (24 ft. lbs.) torque.
(5) Align hinge to marks on roof header.
(6) Install bolts attaching liftgate hinge to roof
header. Tighten outer two bolts to 33 N´m (24 ft. lbs.)
torque. The sheet medal screw at center 12 N´m (105
in. lbs.)
(7) Remove duct tape from roof and liftgate.
(8) Verify liftgate alignment. Refer to Liftgate
Remove and Installation for proper gap measure-
ments.
LATCH
REMOVAL
(1) Remove liftgate trim panel.
(2) Disengage outside handle link from clip on
latch.
(3) Disconnect wire connector from liftgate latch
(Fig. 2).
(4) Remove screws attaching latch to liftgate.
(5) Remove latch from vehicle.
INSTALLATION
(1) Engage like and place latch in position on vehi-
cle.
(2) Install screws attaching latch to liftgate.
Tighten to 10 N´m (95 lb.in.) torque.
(3) Connect wire connector to liftgate latch.
(4) Verify liftgate fit and operation. Adjust as nec-
essary.
(5) Install liftgate trim panel.
LATCH STRIKER
REMOVAL
(1) Open liftgate.
(2) Mark outline of striker on sill to aid installa-
tion.
(3) Remove screws attaching striker to sill (Fig. 3)
.
(4) Remove striker from vehicle.
INSTALLATION
(1) Place striker in position on vehicle.
(2) Align striker to outline mark on sill.
(3) Install screws attaching striker to sill. Tighten
screws to 28 N´m (21 ft. lbs.) torque.
(4) Verify liftgate alignment and operation.
LIFTGATE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Remove screws attaching liftgate wire connec-
tor to rear header.
Fig. 2 Liftgate Latch
1 - ELECTRICAL CONNECTOR
2 - LIFTGATE LATCH
3 - SCREW
4 - LIFTGATE
5 - LIFTGATE LOCK CYLINDER
Fig. 3 Liftgate Latch Striker
1 - LIFTGATE SILL
2 - LIFTGATE STRIKER
RSDECKLID/HATCH/LIFTGATE/TAILGATE23 - 181
HINGE (Continued)
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(3) Disconnect liftgate wire harness from body
wire harness.
(4) Remove liftgate upper frame molding.
(5) Disconnect rear window washer hose from
spray nozzle.
(6) Support liftgate on a suitable lifting device.
(7) Remove screws attaching support cylinders to
liftgate.
(8) Remove bolts attaching liftgate hinge to roof
header (Fig. 4) .
(9) With assistance, remove liftgate from vehicle.
INSTALLATION
(1) With assistance, place liftgate in position on
vehicle.
(2) Install bolts attaching liftgate hinge to roof
header. Tighten bolts to 33 N´m (24 ft. lbs.) torque.
(3) Install screws attaching support cylinders to
liftgate. Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(4) Remove lifting device from under liftgate.
(5) Connect liftgate wire harness into body wire
harness.
(6) Install screws attaching wire connector to rear
header.
(7) Connect rear window washer hose onto spray
nozzle.
(8) Install liftgate upper frame molding.
(9) Verify liftgate alignment. The liftgate should
have a gap to adjacent panels and fit flush across the
gaps. The gap is;
²7 mm (0.280 in.) to the fascia,
²6 mm (0.240 in.) to the roof,
²4 mm (0.160 in.) to the aperture.
LIFTGATE SPOILER
REMOVAL
(1) Remove nuts (Fig. 5).
(2) Remove spoiler from vehicle.
INSTALLATION
(1)Place liftgate spoiler in position and install nuts.
(2) Tighten nuts to 9 N´m (80 in. lbs.) torque.
LOCK CYLINDER
REMOVAL
(1) Remove the liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the electrical connector.
(3) Disconnect the latch rod.
(4) Rotate plastic lock cylinder nut one quarter
turn and remove nut and spring washer.
(5) Remove the lock cylinder from the liftgate.
INSTALLATION
(1) Install lock cylinder into liftgate.
(2) Install the plastic lock cylinder lock nut, spring
washer and rotate one quarter turn.
(3) Connect the electrical connector.
(4) Connect the latch rod.
(5) Install the trim panel. (Refer to 23 - BODY/
DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM
PANEL - INSTALLATION)
(6) Verify lock cylinder operation.
Fig. 4 Liftgate
1 - HINGE
2 - ROOF
3 - NET HOLE OR SLOT
Fig. 5 Liftgate Spoiler
1 - RETAINER SEALER WASHER
2 - LIFT GATE SPOILER
23 - 182 DECKLID/HATCH/LIFTGATE/TAILGATERS
LIFTGATE (Continued)
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SUPPORT CYLINDER
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device in
the full open position.
(3) Pull liftgate opening weatherstrip from D-pillar
flange next to prop assembly end pivot.
(4) Remove bolt attaching end pivot to D-pillar
(Fig. 6) .
(5)
Remove bolt attaching prop assembly to liftgate.
(6) Remove prop assembly from vehicle.
INSTALLATION
Ensure that the cylinder end is attached to the
D-pillar and the shaft end is attached to the liftgate.
(1) Place prop assembly in position.
(2) Install bolt attaching prop assembly to liftgate.
(3) Install bolt attaching end pivot to D-pillar.
Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(4) Install liftgate opening weatherstrip to D-pillar
flange next to prop assembly end pivot.
(5) Close liftgate. Check liftgate operation.
TRIM PANEL
REMOVAL
(1) Remove the bolt attaching the lift motor link, if
equipped (Fig. 7).
(2) Remove liftgate upper frame molding (Fig. 8).
(3) Remove assist handle screws.
(4) Disengage hidden clips holding trim panel to
liftgate from around perimeter or liftgate (Fig. 8).(5) Disconnect wire connector from lamps.
(6) Remove liftgate trim panel from vehicle.
INSTALLATION
(1) Place liftgate trim panel in position on vehicle.
(2)
Engage hidden clips to hold trim panel to liftgate
and fasteners around perimeter of liftgate (Fig. 8).
(3) Connect wire connector into lamp.
(4) Install courtesy lamps into liftgate trim.
(5) Install screws to hold assist handle to liftgate.
(6) Install upper frame side moldings.
(7) Install liftgate upper frame molding.
(8) Install the bolt attaching the lifgate motor link
and tighten to 28 N´m (21 ft. lbs.)
Fig. 6 Liftgate Prop Assembly
1 - LIFTGATE
2 - PROP ASSEMBLY
Fig. 7 LIFTGATE MOTOR
1 - LIFTGATE MOTOR LINK BOLT
2 - LIFTGATE MOTOR
3 - LIFTGATE
Fig. 8 LIFTGATE TRIM
1 - LIFTGATE
2 - LOWER TRIM PANEL
3 - ASSIST HANDLE SCREWS
4 - UPPER TRIM
5 - UPPER TRIM CLIPS
RSDECKLID/HATCH/LIFTGATE/TAILGATE23 - 183
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