EXJ_23.PDF

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XJ
BODY
23 - 1
BODY
CONTENTS
page
page
BODY COMPONENT SERVICE . . . . . . . . . . . . . . 17
GENERAL SERVICE INFORMATION . . . . . . . . . . . 1
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL SERVICE INFORMATION
GENERAL INFORMATION
SAFETY PRECAUTIONS AND WARNINGS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
USE A OSHA APPROVED BREATHING FILTER
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL – BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND 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 an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use
when welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels 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 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 being
removed. 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.
23 - 2
BODY
XJ
PAINT
INDEX
page
GENERAL INFORMATION
BASE COAT/CLEAR COAT FINISH . . . . . . . . . . . . 2
PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PAINTED SURFACE TOUCH-UP . . . . . . . . . . . . . 2
page
WET SANDING, BUFFING, AND POLISHING . . . . 2
SPECIFICATIONS
AFTERMARKET PAINT REPAIR PRODUCTS . . . . 3
GENERAL INFORMATION
PAINT CODE
Exterior vehicle body colors are identified on the
Body Code plate. The plate is located on the left side
of the dash panel in the engine compartment. Refer
to the Introduction section at the front of this man-
ual for body code plate description. The paint code is
also identified on the Vehicle Safety Certification
Label which is located on the drivers door shut face.
The color names provided in the Paint and Trim
Code Description chart are the color names used on
most repair product containers.
PAINTED SURFACE TOUCH-UP
When a painted metal surface has been scratched
or chipped, it should be touched-up as soon as possi-
ble to avoid corrosion. For best results, use Mopar
Scratch 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 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 sur-
face 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 wet sanded (1500 grit) and pol-
ished 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.
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 ultraviolet light and provides a dura-
ble high-gloss finish.
WET SANDING, BUFFING, AND POLISHING
Minor acid etching, orange peel, or smudging in
clear coat or single-stage finishes can be reduced
with light wet sanding, hand buffing, and polishing.
If the finish has been wet sanded in the past, it
cannot be repeated. Wet sanding operation
should be performed by a trained automotive
paint technician.
CAUTION: Do not remove clear coat finish, if
equipped. Base coat paint must retain clear coat for
durability.
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BODY
23 - 3
SPECIFICATIONS
AFTERMARKET PAINT REPAIR PRODUCTS
EXTERIOR COLOR
EXTERIOR
COLOR
Flame Red Clear
Coat
Chili Pepper Red
Medium Fern
Pearl Coat
Forest Green
Pearl Coat
Intense Blue Pearl
Coat
Desert Sand
Deep Amethyst
Pearl Coat
Black Clear Coat
Gunmetal Pearl
Coat
Stone White Clear
Coat
CHRY
CODE
*
PR4
VEA
RJP
SG8
VB3
WTD
TCN
DX8
TQ7
SW1
S-W**
M-S**
46916
54470
50270
51062
54468
56153
52026
34858
52952
51539
AKZO
NOBEL
SIKKENS
CHA93:PR4
CHA98:VEA
CHA99:RJP
CHA95:SG8
CHA98:VB3
CHA99:WTD
CHA97:TCN
CHA85:DX8
CHA97:TQ7
CHA96:SW1
PPG
4679
5361
4969
5065
5357
5474
5246
9700
5248
83542
DuPONT
B9326
B9823
B9524
B9609
B9822
B9884
B9736
99
B9735
B9622
ICI**
2NN6B
HMT3B
7CD6B
7MR8B
HMR9B
KGC7B
FNE4B
TC60B
ERA9B
8KY5B
INTERIOR COLOR
INTERIOR
COLOR
Agate
Camel / Dark
Green
CHRY
CODE*
AZ
KG
S-W**
M-S**
45994
N/A
AKZO
NOBEL
SIKKENS
CHALAZI
N/A
PPG
9856 /
2-1461
N/A
DuPONT
C9208
N/A
ICI**
7WC8
K5/G8
NOTE: *Herberts Standox, Spies Hecker, and BASF
use the Chrysler paint code as listed on the Body
Code Plate and the Vehicle Safety Certification
label. ** S-W = Sherwin-Williams, M-S = Martin
Senour, ICI = ICI Autocolor.
23 - 4
BODY
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STATIONARY GLASS
INDEX
page
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 4
REMOVAL AND INSTALLATION
LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . . . . 9
page
REAR DOOR STATIONARY WINDOW GLASS . . . 7
REAR QUARTER WINDOW GLASS . . . . . . . . . . . 8
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
CHRYSLER DOES NOT RECOMMEND GLASS
ADHESIVE BY BRAND. TECHNICIANS SHOULD
REVIEW PRODUCT LABELS AND TECHNICAL DATA
SHEETS, AND USE ONLY ADHESIVES THAT THEIR
MANUFACTURES WARRANT WILL RESTORE A
VEHICLE TO THE REQUIREMENTS OF FMVSS 212.
TECHNICIANS SHOULD ALSO INSURE THAT PRIM-
ERS AND CLEANERS ARE COMPATIBLE WITH THE
PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER’S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
structural 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 moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.
REMOVAL AND INSTALLATION
WINDSHIELD
The windshield is positioned in the reveal molding
and is bonded to the windshield frame with urethane
adhesive.
Depending on the circumstances, either one of two
windshield glass installation methods can be used:
•
The short method.
•
The extended method.
The short method is used when the windshield
glass is removed intact, and the body opening and
the pinchweld flanges do not require repair.
The extended method must be used when the body
opening or a flange is damaged. The extended
method must also be used when urethane no longer
adheres to either the windshield glass or the pinch-
weld flanges.
REMOVAL
(1) Cover the interior and exterior body surface
areas with a protective covering.
(2) Remove the windshield wiper arms and the
rearview mirror.
(3) Using a razor knife, slide the blade between
the windshield glass and the inboard edge of the
reveal molding.
(4) Cut around the interior perimeter of the reveal
molding and sever the cap of the reveal molding.
XJ
REMOVAL AND INSTALLATION (Continued)
(5) Using a cold knife, cut the urethane around the
perimeter of the windshield (Fig. 1).
(6) Remove the windshield glass from the frame.
BODY
23 - 5
(6) Adjust windshield glass position until it is
aligned with the flanges and adhesive.
(7) Using a grease pencil or equivalent, make
alignment marks on the glass and body.
(8) Remove replacement windshield from wind-
shield opening.
(9) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 2).
CAUTION: Avoid spilling or dripping primer on
painted surfaces. Clean spills or drips immediately.
The primer will damage the paint if it remains on
the surface for any length of time.
(10) If the replacement windshield glass does not
have blackout primer:
•
Attach a 25 mm (1 in) wide masking tape band
around the interior side of the glass 16 mm (5/8 in)
from the edge of the glass (Fig. 3).
•
Do not attach tape along the bottom of the glass
and
attach it only to the inside of the glass.
•
Clean the 16-mm (5/8-in) wide surface area
around the glass with isopropyl alcohol.
•
Thoroughly mix and apply glass blackout primer
to the 16 mm (5/8 in) surface area around the inte-
rior side of the glass (Fig. 4).
•
Allow the primer to dry for at least 10-12 min-
utes.
(11) Apply a small amount of adhesive to the bot-
tom support spacers and attach the support spacers
to the bottom of the windshield, 170 mm inboard
from the outer windshield edge (Fig. 5).
(12) Cut the urethane adhesive applicator nozzle
(Fig. 6).
CAUTION: Be prepared to install the glass immedi-
ately after applying the adhesive, as the adhesive
will begin to cure in less than 10 minutes.
(13) Apply a continuous, 6-mm (1/4-in) diameter
bead of urethane adhesive to the surface area.
(14) Align the glass with the reference marks and
position the glass on the pinchweld flanges. Ensure
that the windshield glass is correctly seated on the
support spacers.
(15) Force the windshield glass inward just enough
to wet-out and set the urethane. Use care to avoid
excessive squeeze-out of adhesive.
(16) Water test the windshield with a water spray
after installation. Do not direct high pressure
streams of water directly at urethane. If any leaks
are detected, apply urethane as necessary.
(17) If used, remove the masking tape from the
inner surface of the glass.
(18) Install all components and clean the vehicle.
Fig. 1 Cutting Urethane Around Windshield—Typical
INSTALLATION—SHORT METHOD
WARNING: REVIEW ALL WARNINGS AND CAU-
TIONS IN THIS GROUP BEFORE PRECEDING WITH
INSTALLATION.
(1) Trim the urethane from the pinchweld flanges.
Leave a 3 mm (0.1 in.) level base of urethane on the
pinchweld flanges.
WARNING:
CLEANER
APPLYING
ADHESION
DO NOT USE SOLVENT BASED GLASS
TO CLEAN WINDSHIELD BEFORE
GLASS PREP AND PRIMER. POOR
CAN RESULT.
(2) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.
(3) Prime outer perimeter of interior side of glass
16 mm (5/8 inch) from edge. Use a wipe-off type ure-
thane primer and wipe glass dry after primer appli-
cation.
NOTE: The reveal molding has an adhesive applied
to the windshield contact surface to help secure the
molding to the windshield during the installation
procedure.
(4) Apply the molding to the windshield:
•
With the molding at room temperature, press
the molding onto the windshield corners.
•
From corner to corner, work the molding to the
center of each side. (Some stretching of the molding
may be required during this procedure.)
(5) Place the glass on the pinchweld flanges and
inspect for gaps in the urethane. Gaps in excess of 3
mm (1/8 inch) must be filled with urethane.

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