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.

BODY

23 - 1

BODY DIAGNOSTIC PROCEDURES

INDEX

page

Water Leaks

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Wind Noise

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

WATER LEAKS

Water leaks can be caused by poor sealing, improper

body component alignment, body seam porosity, miss-
ing plugs, or blocked drain holes. Centrifugal and
gravitational force can cause water to drip from an
area somewhat distant from the actual leak point,
making leak detection difficult. All body sealing points
should be water tight in normal wet driving conditions.
Water flowing downward from the front of the vehicle
should not enter the passenger or luggage compart-
ment. Moving sealing surfaces will not always seal
water tight under all conditions. At times, side glass,
door, or convertible top seals will allow water to enter
the passenger compartment during high pressure
washing or hard driving rain (severe) conditions. Over
compensating on door, glass, or top adjustments to stop
a water leak that occurs under severe conditions, can
cause premature seal wear and excessive closing or
latching effort. After a repair procedure has been
performed, water test vehicle to verify leak has stopped
before returning vehicle to use.

VISUAL INSPECTION BEFORE WATER LEAK
TESTS

Verify that floor and body plugs are in place, body

drains are clear and body components are aligned and
sealed. If component alignment or sealing is necessary,
refer to the appropriate section of this group for proper
procedures.

WATER LEAK TESTS

WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA, PERSONAL IN-
JURY CAN RESULT.

When a determination has been made on the condi-

tions that a water leak occurs, simulate the conditions
as closely as possible.
• If a leak occurs when the car is parked in a steady
light rain, flood the leak area with a open ended garden
hose.
• If a leak occurs at highway speeds in a steady rain,
test the leak area with a stream or fan spray of water
from a garden hose with an adjustable nozzle. Direct
the spray in the direction comparable to actual condi-
tions.

• If a leak seems to occur only when the vehicle is
parked on an incline, hoist the end or side of the vehicle
to simulate this condition before water testing. This
method can also be used when the leak occurs when the
vehicle accelerates, stops, or turns. If the leak occurs
on acceleration, hoist the front of the vehicle. If the
leak occurs when braking, hoist the back of the vehicle.
If the leak occurs on left turns, hoist the left side of the
vehicle. If the leak occurs on right turns, hoist the right
side of the vehicle. For hoisting recommendations refer
to Group 0, Lubrication and Maintenance, General
Information section.

WATER LEAK DETECTION

To detect a water leak point of entry, perform a water

test and watch for water tracks or droplets forming on
the inside if the vehicle. If necessary remove interior
trim covers or panels to gain visual access to the leak
area. If the hose can not be positioned without being
held, have someone help perform the water test.

Some water leaks must be tested for a considerable

length of time to become apparent. When a leak ap-
pears, determine the highest point of the water track or
drop. The highest point usually will indicate the point
of entry. After leak point has been determined, repair
the leak and water test to verify that leak has stopped.

Locating the entry point of water that is leaking into

a cavity between panels can be difficult. The trapped
water splashes or runs from the cavity it is dammed up
in, often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on a incline.

MIRROR INSPECTION METHOD

When a leak point area is visually obstructed, use a

suitable mirror to gain visual access. A mirror can also
be used to deflect light to a limited access area to assist
in locating a leak point.

BRIGHT LIGHT LEAK TEST METHOD

Some water leaks in the luggage compartment can be

detected without water testing. Position the vehicle in
a brightly light area. From inside the darkened lug-
gage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the lug-

23 - 2

BODY

gage compartment. If light is visible through a nor-
mally sealed location, water could enter through the
opening.

PRESSURIZED LEAK TEST METHOD

When a water leak into the passenger compartment

can not be detected by water testing, pressurize the
passenger compartment and soap test exterior of the
vehicle. To pressurize the passenger compartment,
close all doors and windows, start engine, and set
heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to assure adequate voltage to the blower. With
interior pressurized, apply dish detergent solution to
suspected leak area on the exterior of the vehicle.
Apply detergent solution with spray device or soft
bristle brush. If soap bubbles occur at a body seam,
joint, seal or gasket the leak entry point could be at
that location.

WIND NOISE

Wind noise is the result of most air leaks. Air leaks

can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be air tight in normal
driving conditions. Moving sealing surfaces will not
always seal air tight under all conditions. At times,
side glass, door, or convertible top seals will allow wind
noise to be noticed in the passenger compartment
during high cross-winds. Over compensating on door,
glass, or top adjustments to stop wind noise that occurs
under severe conditions, can cause premature seal
wear and excessive closing or latching effort. After a

repair procedure has been performed, test vehicle to
verify leak has stopped before returning vehicle to use.

Wind noise can also be caused by improperly fitted

exterior mouldings or body ornamentation. Loose
mouldings can flutter, creating a buzzing or chattering
noise. An open cavity or protruding edge can create
whistling or howling noise. Inspect the exterior of the
vehicle to verify that these conditions do not exist.

VISUAL INSPECTION BEFORE TESTS

Verify that floor and body plugs are in place, body

drains are clear and body components are aligned and
sealed. If component alignment or sealing is necessary,
refer to the appropriate section of this group for proper
procedures.

ROAD TESTING WIND NOISE

(1) Drive the vehicle to verify the general location of

the wind noise.

(2) Apply 50 mm (2 in.) masking tape in 150 mm (6

in.) lengths along weatherstrips, weld seams or moul-
dings. After each length is applied drive vehicle. If
noise goes away after a piece of tape is applied, remove
tape, locate and repair defect.

POSSIBLE CAUSE OF WIND NOISE
• Mouldings standing away from body surface can
catch wind and whistle.
• Gaps in sealed areas behind overhanging body
flanges can cause wind rushing sounds.
• Misaligned movable components.

• Missing or improperly installed plugs in pillars.

• Weld burn through holes.

BODY

23 - 3

PAINT

INTRODUCTION

A paint code is provided on the body code plate

located in the engine compartment. Refer to the Intro-
duction section at the front of this manual for body code
plate description. The color names provided in the
Paint and Trim Code Description chart are the color
names used on most repair product containers. The
color names in the new vehicle ordering guides vary
depending on car line but use the same color code.

BASE COAT/CLEAR COAT FINISH

On most vehicles a two part paint application (base

coat/clear coat) is used. Color paint that is applied to
primer is called base coat. The clear coat protects the
base coat from ultra violet light and provides a durable
high gloss finish.

WET SANDING,BUFFING AND POLISHING

Minor acid etching, orange peel or smudging in clear

coat can be reduced with light wet sanding, hand
buffing and polishing. If the finish has been wet sanded
in the past, it can not be repeated. Wet sanding
operation should be performed by a trained automotive
painter.

CAUTION: Do not remove clear coat finish, if
equipped. Base coat paint must retain clear coat to
shine.

PAINTED SURFACE TOUCH-UP

When a painted metal surface has been scratched or

chipped, it should be touched-up as soon as possible to

avoid corrosion. For best results, use Mopar

tScratch

Filler/Primer, Touch-Up Paints and Clear Top Coat.
Refer to Introduction group of this manual for Body
Code Plate information.

TOUCH-UP PROCEDURE

(1) Scrape loose paint and corrosion from inside

scratch or chip.

(2) Clean affected area with Mopar

t Tar/Road Oil

Remover and allow to dry.

(3) Fill the inside of the scratch or chip with a coat of

filler/primer. Do not overlap primer onto good surface
finish. The applicator brush should be wet enough to
puddle fill the defect without running. Do not stroke
brush applicator on body surface. Allow the filler/
primer to dry hard.

(4) Cover the filler/primer with color touch-up paint.

Do not overlap touch-up color onto the original color
coat around the scratch or chip. Butt the new color to
the original color if possible. Do not stroke applicator
brush on body surface. Allow touch-up paint to dry
hard.

(5) On vehicles without clear coat, the touch-up color

can be lightly (600 grit) wet sanded and polished with
rubbing compound.

(6) On vehicles with clear coat, Apply clear top coat

to touch-up paint with the same technique as described
in step 4. Allow clear top coat to dry hard. If desired,
step 5 can be performed on clear top coat.

23 - 4

BODY

Content .. 146 147 148 149 ..