BODY
TAB LE O F CO NTE NTS
page page
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 1
DIAGNOSIS AND TESTING - WIND NOISE . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR ........................3
STANDARD PROCEDURE - BUZZ, SQUEAK
& RATTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS .......................11
DOOR - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DOORS - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DOORS - SLIDING . . . . . . . . . . . . . . . . . . . . . . . . 35
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . 55
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . 84
WEATHERSTRIP/SEALS . . . . . . . . . . . . . . . . . . . 90
BODY STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . 91
BODY
WA RNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE AN OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED 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
electrical 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.
DI AGN OSI S AN D T EST I N G
DIAGNOSIS AND TESTING - WATER LEAKS
Water lea ks ca n be ca used by poor sealing,
improper body com pon ent a lignment, body seam
por osity, missing plugs, or blocked drain holes. Cen-
trifuga l an d gravita tion al for ce can cause wat er to
dr ip from a loca tion awa y from t he actual leak point,
makin g lea k det ection difficult. All body sealing
points should be water tigh t in nor mal wet-driving
conditions. Wat er flowin g downwa rd fr om th e front of
the veh icle shou ld not enter the passenger or luggage
compart ment . Moving sea lin g su rfaces will n ot
alwa ys seal wa ter tight under all con dition s. At
times, side glass or door seals will allow wa ter t o
enter th e passen ger com pa rtmen t during high pres-
su re washing or ha rd driving ra in (severe) condi-
tions. Overcompensating on door or glass
adju st ment s to st op a water lea k that occur s under
severe condition s can cause pr emat ure seal wea r an d
excessive closing or latching effort . After completing
a repa ir, water test vehicle to verify leak ha s st opped
before r etur ning veh icle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor a nd body plugs a re in place, body
dr ains are clear, and body components are properly
VA BODY 23 - 1
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