Service Procedure
A. Inspect Left Front Door Flange:1. Open the left front door and fully open the window.
2. Push up on the upper door frame where it turns downward near the upper A-pillar (Figure 1)
3. < If movement is seen between the inner and outer panels at the upper hem flange, the door must be repaired. Continue with Section B - Reseal Left Front Door Flange.
> If there is NO movement between the inner and outer panels at the upper flange, the door adhesive was properly applied. No further action is necessary. Return the vehicle to the customer.
B. Reseal Left Front Door Flange:
1. Remove the three (3) screws from the left front door trim panel (Figure 2).
2. Lift the trim panel up off the lock rod and attachment hooks and slightly separate the trim panel from the door (Figure 2).
IMPORTANT:
The trim panel is attached to the door with hooks that are molded into the panel. Do not pull the trim panel straight off or damage to the panel and/or power switch assembly may occur.
3. Disconnect the inside handle actuator rod (Figure 2).
4. Disconnect the electrical connectors from the trim panel switches (Figure 2).
5 Remove the power window switch module from the door trim panel and then set the trim panel aside.
6. Pull the watershield from the rear half of the inner door panel and door latch linkages (Figure 3).
CAUTION:
Do not allow the watershield or adhesive to become contaminated with dirt or other foreign substances. Do not damage the watershield during removal and installation.
7. Remove the inner belt weatherstrip.
8. Remove the upper window seal.
9. Cover the door to prevent metal chips from falling inside of the door.
10 Using a 9/32" drill bit, drill two holes in the upper door frame under the surface where the window seal sits (Figure 4). The first hole should be just above the first spot weld forward of the door B-post radius. The second hole should be outward of the first weld down from the door B-post radius.
NOTE:
The holes will not be visible when the window seal is reinstalled.
IMPORTANT:
Use a drill bit stop to keep the drill bit from penetrating the sheet metal more than 9/32" or damage to the outer sheet metal can occur.
11. Countersink the edges of the 9/32" holes so that the foam will cover the edge of the holes.
12. Stuff a paper towel or shop towel into the bottom of the upper door frame at the belt line above the door latch (Figure 4). This will keep foam runoff from dripping on the latch mechanism.
IMPORTANT:
Use a screwdriver to pack the towel into the rear corner of the opening or foam will be able to drip past it.
13 Dispense 50% of the rigid foam into the upper door frame through the hole in the underside of the window frame (Figure 4). After dispensing, cover the hole with masking tape to keep the foam inside during the curing process.
14. Dispense the remainder of the rigid foam into the upper side door frame through the hole in the side of the upper door frame (Figure 4). After dispensing, cover the hole with masking tape to keep the foam inside during the curing process.
15. Connect the power window switch module to the door electrical connectors and then raise the window to about 6" below the upper door frame.
16. Clean the area between the inner and outer door panels inside the door cavity where the adhesive will be applied with Mopar Brake Parts Cleaner (P/N 04897150AB or equivalent) (Figure 4).
17 Apply the Mopar/Fusor adhesive into the gap between the inner and outer door panels inside the door cavity, from 6" above the door latch to 6" above the bottom of the inner door (Figure 4).
18. Using a body filler applicator, squeegee or similar tool, push the adhesive into the gap.
19. Apply a final bead of adhesive into the gap area for extra support.
20. Lower the window and then disconnect the power switch module.
21. Remove the masking tape from the door frame holes.
22. Remove the paper towel or shop towel from inside the door near the bottom of the upper door frame.
23. Clean any foam or adhesive residue from the door.
24. Install the upper window seal.
25. Install the inner belt weatherstrip.
26. Position the wire harness and latch actuator rods through the holes in the watershield.
27. Secure the watershield to the inner door panel (Figure 3).
28. Install the power window switch module into the door trim panel.
29. Position the door trim panel onto the door.
30. Connect electrical connectors to the trim panel switches (Figure 2).
31. Connect the inside door handle actuator rod (Figure 2).
32. Lift the trim panel up and onto the lock rod and attachment hooks.
33. Install the three (3) trim panel screws (Figure 2). Tighten the screws securely.