WINDSHIELD REMOVAL - INTERIOR METHOD Chrysler Pacifica CS

WINDSHIELD REMOVAL - INTERIOR METHOD

1. Remove inside rear view mirror.
2. Remove instrument panel top cover. «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL TOP COVER - REMOVAL)»(ref-245423-S38495119682006110200000) .
3. Remove A-pillar trim covers.
4. Remove A-pillar exterior molding.
5. Place protective covers over instrument panel and hood.
6. Using a reciprocating or oscillating power knife, cut urethane adhesive holding the windshield to the A-pillars, roof header and cowl pinch weld fences. Refer to instructions provided with the equipment being used.
7. Remove windshield from vehicle.

Refer to the Safety Precautions in this section for description of tools and adhesive systems that are recommended for use in this procedure. (Refer to BODY/STATIONARY GLASS - WARNING) .

The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended.

1. Place replacement windshield into windshield opening and position glass in the center of the opening against the compression spacers.
2. Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement windshield. If not, the pinch weld fence must be formed to the shape of the new glass.
3. Remove replacement windshield from windshield opening.
4. 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 parallel 75 cm (2.5 ft.) apart. see scheme 294 WARNING: DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN WINDSHIELD BEFORE APPLYING GLASS PREP AND PRIMER. POOR ADHESION CAN RESULT.
5. Clean inside of windshield with ammonia based glass cleaner and lint-free cloth.
6. Install molding to perimeter of windshield. (Scheme 371)
7. Apply Glass Prep adhesion promoter 15 mm (0.6 in.) wide around perimeter of windshield and wipe with clean/dry lint-free cloth until no streaks are visible.
8. Apply Glass Primer 15 mm (0.6 in.) wide around perimeter of windshield. Allow at least three minutes drying time. (Scheme 372)
9. Using a razor knife, remove as much original urethane as possible. Do not damage paint on windshield fence.
10. Apply pinch weld primer 19 mm (0.75 in.) wide around the windshield fence. Allow at least three minutes drying time.
11. If a low viscosity urethane adhesive is used, install compression spacers on the fence around the windshield opening. (Scheme 373)
12. Apply a 9.5 mm (0.4 in.) bead of urethane on center line of windshield fence.
13. With the aid of a helper, position the windshield over the windshield opening.
14. Slowly lower windshield glass to windshield opening fence. Guide the molding into proper position as necessary. Push windshield inward until molding is flush to roof line and A-pillars.
15. Clean access urethane from exterior with Mopar(R) Super Kleen or equivalent.
16. Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures.
17. Install A-pillar trim panels and side moldings. «(Refer to BODY/EXTERIOR/MOLDING - INSTALLATION)»(ref-245423-S17378948692006110200000).
18. Install cowl cover and wipers.
19. Install inside rear view mirror.
20. After urethane has cured, remove tape strips and water test windshield to verify repair.

Scheme 371

Scheme 372

Scheme 373

1. Position the switch against the overhead console and push the switch to seat properly in retaining clip.
2. Install the overhead console.
3. Connect the negative battery cable.

1. Remove the sunroof «(Refer to BODY/SUNROOF/MODULE ASSEMBLY - REMOVAL)»(ref-245423-S17061270562006110200000).
2. Remove the sunroof motor retaining bolts and remove motor. see scheme 298

1. Assure proper sunroof motor timing before installation «(Refer to BODY/SUNROOF/DRIVE MOTOR - ADJUSTMENTS)»(ref-245423-S41788540582006110200000).
2. Position the sunroof motor to the sunroof assembly and install the retaining bolts. see scheme 298 Tighten sunroof motor retaining bolts to 4.2 N.m (40 lbs. in.) torque.
3. Connect the timed sunroof assembly to a power source and assure proper operation before installing the sunroof assembly into the vehicle.

1. Move the glass panel to the vent position.
2. Slide sunshade rearward to the open position.
3. Remove the glass panel screws. see scheme 298
4. Lift off glass panel and remove from vehicle.

1. Position glass panel on to mechanism lift arms.
2. Start the attaching screws, and hand tighten. see scheme 298
3. Adjust sunroof glass to fit flush with roof line «(Refer to BODY/SUNROOF/GLASS PANEL - ADJUSTMENTS)»(ref-245423-S09790188672006110200000).
4. Verify sunroof operation and alignment.

1. Move glass panel to the fully closed position.
2. Disconnect battery negative cable.
3. Remove headliner «(Refer to BODY/INTERIOR/HEADLINER - REMOVAL)»(ref-245423-S08364243672006110200000).
4. Disconnect the four drain tubes from sunroof housing. «(Refer to BODY/SUNROOF/DRAIN TUBE - REMOVAL)»(ref-245423-S14835114872006110200000).
5. Disconnect sunroof wire connector. (Scheme 374)
6. Loosen fasteners attaching sunroof assembly. (Scheme 375)
7. With the aid of a helper, support the sunroof and remove the fasteners attaching sunroof assembly to roof panel.
8. Remove sunroof from vehicle.

Scheme 374

Scheme 375

1. Ensure that u-nuts are in position in the roof bow #2. (Scheme 376)
2. Raise sunroof module assembly and guide it carefully into position. (Scheme 375)
3. While supporting the sunroof assembly start the attaching screws. Tighten the attaching screws in sequence to 6 N.m (53 in. lbs.) torque. (Scheme 377)
4. Connect sunroof wire connector. (Scheme 374)
5. Connect the drain tubes to the sunroof «(Refer to BODY/SUNROOF/DRAIN TUBE - INSTALLATION)»(ref-245423-S01475045822006110200000).
6. Connect battery negative cable.
7. Test sunroof operation, adjust as necessary «(Refer to BODY/SUNROOF/GLASS PANEL - ADJUSTMENTS)»(ref-245423-S09790188672006110200000).
8. Install headliner «(Refer to BODY/INTERIOR/HEADLINER - INSTALLATION)»(ref-245423-S31913720812006110200000).

Scheme 376

Scheme 377

1. Place the sunroof glass panel in the vent position.
2. Remove glass panel «(Refer to BODY/SUNROOF/GLASS PANEL - REMOVAL)»(ref-245423-S15293051772006110200000).
3. Remove water channel. see scheme 298
4. Cycle sunroof motor to the open position.
5. Move sunshade towards the closed position stopping three to four inches from the closed position.
6. Depress the spring feet clips on one side of the sun shade.
7. Remove sunshade.

1. Place one side of the sunshade spring feet clips into the top track U-frame.
2. Depress the both releasing clips on the other side to allow them to go into the top track U-frame.
3. Move sunshade to the open position.
4. Install water channel. see scheme 298
5. Verify that the sunshade move back and forth properly.
6. Cycle sunroof towards the closed position.
7. Install glass panel «(Refer to BODY/SUNROOF/GLASS PANEL - INSTALLATION)»(ref-245423-S13571932622006110200000).

1. Remove glass panel «(Refer to BODY/SUNROOF/GLASS PANEL - REMOVAL)»(ref-245423-S15293051772006110200000).
2. Remove the retaining screws. see scheme 298
3. Carefully slide water channel forward to release tabs from U-frame and remove from vehicle.

1. Carefully place water channel onto U-frame and slide it rearward to lock tabs. see scheme 298
2. Install the water channel attaching screws. see scheme 298
3. Position glass panel on to mechanism lift arms.
4. Start the glass attaching screws, and hand tighten.
5. Adjust sunroof glass «(Refer to BODY/SUNROOF/GLASS PANEL - ADJUSTMENTS)»(ref-245423-S09790188672006110200000).
6. Verify sunroof operation and alignment.

Scheme 378

1. Fully open sunroof glass panel.
2. Disconnect negative battery cable.
3. Remove sunroof assembly «(Refer to BODY/SUNROOF/MODULE ASSEMBLY - REMOVAL)»(ref-245423-S17061270562006110200000).
4. Depress the front deflector retaining tabs. (Scheme 378)1 - Sun Roof 2 - Retaining Clip 3 - Sun Roof Assembly Trim
5. Remove wind deflector.

1. Place wind deflector arms in upward position engage the wind deflector blade into the U-frame. (Scheme 378)
2. Engage the retaining clips. see scheme 298
3. Verify wind deflector operation.
4. Install the sun roof assembly «(Refer to BODY/SUNROOF/MODULE ASSEMBLY - INSTALLATION)»(ref-245423-S40222160312006110200000).

Scheme 379

1. Open door.
2. Using a trim stick C-4755 or equivalent, disengage the push pins attaching door trim inner seal to door sill. (Scheme 380)
3. Remove door trim inner seal from vehicle.

Scheme 380

1. Place door trim inner seal into position.
2. Press on door inner seal and push pins to engage into door sill. (Scheme 380)
3. Close door.

1. Open front door.
2. Using a trim stick C-4755 or equivalent, disengage the plastic pins attaching front door header weatherstrip to door frame. (Scheme 381)
3. Remove weatherstrip from door.

Scheme 381

1. Place weatherstrip into position.
2. Press on attaching plastic pins to engage front door header weatherstrip to door frame. (Scheme 381)
3. Close front door.

1. Open front door.
2. Remove front door sill scuff plate.
3. Pull front door weatherstrip from door opening fence. (Scheme 379)and (Scheme 382).
4. Remove door opening weatherstrip from vehicle.

Scheme 382

1. Place front door opening weatherstrip into position starting at the upper rear corner of the B-pillar. (Scheme 379)and (Scheme 382).
2. Work the weatherstrip down the B-pillar to the floor pan. Leave slack to ensure completion of the weatherstrip throughout the entire opening.
3. Starting at B-pillar going along the under side of the header and down the A-pillar leaving slack to ensure proper installation of the bottom portion of the weatherstrip.
4. Joint the two end of the weatherstrip together and ensure complete seating of weatherstrip.
5. Install front door sill scuff plate.
6. Close front door.

1. Lower window completely.
2. Remove door trim panel. «(Refer to BODY/DOOR - FRONT/TRIM PANEL - REMOVAL)»(ref-245423-S16680146352006110200000).
3. Remove front inner molding weatherstrip. «(Refer to BODY/WEATHERSTRIP/SEALS/FRONT DOOR INNER BELT WEATHERSTRIP - REMOVAL)»(ref-245423-S17179806402006110200000).
4. Remove frame closeout molding. «(Refer to BODY/DOOR - FRONT/FRAME CLOSEOUT MOLDING - REMOVAL)»(ref-245423-S41492845872006110200000).
5. Remove foam stuffer in mirror flag area.
6. Remove side view mirror. «(Refer to BODY/EXTERIOR/SIDE VIEW MIRROR - REMOVAL)»(ref-245423-S33378214792006110200000).
7. Remove screw attaching outer belt molding, one at the inside of the front door shut face at the B-pillar.
8. Insert special tool #9093 between belt molding and glass at rear and then slide tool forward approximately 14 cm (5.5 in.). (Scheme 383)and see scheme 318.
9. Push down on outer belt molding and rotate upper part of tool outward from vehicle approximately 6 - 8 cm (2.5 - 3 in.) then lift up on molding to disengage from locking tab.
10. Repeat step 3 and 4 at as necessary till outer belt molding is free.
11. Remove outer belt molding weatherstrip.

Scheme 383

1. Place outer belt molding weatherstrip into position. (Scheme 383)
2. Press down or tap lightly on outer belt molding until fully seated.
3. Install screw attaching outer belt molding, one at the inside of the front door shut face at the B-pillar.
4. Install side view mirror. «(Refer to BODY/EXTERIOR/SIDE VIEW MIRROR - INSTALLATION)»(ref-245423-S38251814172006110200000).
5. Install foam stuffer in mirror flag area.
6. Install frame closeout molding. «(Refer to BODY/DOOR - FRONT/FRAME CLOSEOUT MOLDING - INSTALLATION)»(ref-245423-S19319953482006110200000).
7. Install front inner molding weatherstrip. «(Refer to BODY/WEATHERSTRIP/SEALS/FRONT DOOR INNER BELT WEATHERSTRIP - INSTALLATION)»(ref-245423-S20233725182006110200000).
8. Install door trim panel. «(Refer to BODY/DOOR - FRONT/DOOR TRIM PANEL - INSTALLATION)»(ref-245423-S26865939162006110200000).
9. Close window.

1. Open front door.
2. Using a trim stick C-4755 or equivalent, disengage the push pins attaching front door mounted weatherstrip to door frame. (Scheme 384)
3. Remove weatherstrip from door frame.

Scheme 384

1. Place front door mounted weatherstrip into position. (Scheme 384)
2. Press on attaching push pins fasteners to attach weatherstrip to lower door and engage upper front door mounted weatherstrip to door frame.
3. Close front door.

1. Remove the door trim panel. «(Refer to BODY/DOOR - FRONT/TRIM PANEL - REMOVAL)»(ref-245423-S16680146352006110200000).
2. Rotate the inner belt molding outboard while pulling up to disengage the retention tabs. (Scheme 385)
3. Remove inner belt molding from door.

Scheme 385

1. Place inner belt molding into position.
2. Press down on inner belt molding to engage the retention tabs. (Scheme 385)
3. Install the door trim panel. «(Refer to BODY/DOOR - FRONT/TRIM PANEL - INSTALLATION)»(ref-245423-S26865939162006110200000).

1. Open liftgate door.
2. Remove liftgate sill scuff plate.
3. Pull Liftgate door weatherstrip from liftgate opening fence. (Scheme 386)
4. Remove liftgate opening weatherstrip from vehicle.

Scheme 386

1. Place liftgate opening weatherstrip into position locate non plug end of weatherstrip to bottom of liftgate opening at left of center. Align end of weatherstrip to second slot left of striker hole. (Scheme 386)
2. Secure weatherstrip to liftgate opening in a counterclockwise direction around left side of opening including the left lower and upper corners of the fence flange.
3. Align the paint dot on the inner side of weatherstrip with right side upper corner of liftgate opening. Be sure to leave slack in the weatherstrip between the two upper corners of opening.
4. Secure weatherstrip down the right side of opening including the upper and lower right side corners.
5. Secure weatherstrip to upper portion of liftgate opening between the left and right upper corners.
6. Joint the two end of the weatherstrip together and ensure complete seating of weatherstrip.
7. Install liftgate sill scuff plate.
8. Close liftgate door.

1. Warm the affected stick on upper secondary weatherstrip and body metal to approximately 27° C (80° F) using a suitable heat lamp or heat gun.
2. Pull stick on weatherstrip from painted surface.
3. Remove adhesive tape residue from painted surface of vehicle.
4. Use a 3M Scotch-Brite(tm) Molding Adhesive and Stripe Removal Disc, or equivalent, to clean adhesive residue from painted surfaces. These products are available from automotive paint suppliers. Refer to instructions supplied with the specific product for proper usage.

1. If upper secondary weatherstrip is to be reused, Remove tape residue from molding. Clean back of molding with Mopar(R) Super Kleen, or equivalent. Wipe molding dry with lint free cloth. Apply a single coat of Mopar(R) TPO Molding Prep to tape side of molding and allow to dry thoroughly. Apply new body side molding (two sided adhesive) tape to back of weatherstrip.
2. Clean liftgate surface with Mopar(R) Super Kleen, or equivalent. Wipe surface dry with lint free cloth.
3. Remove protective cover from tape on back of upper secondary weatherstrip.
4. Apply weatherstrip to liftgate between liftgate hinges. There is less than 1/8 in. clearance between the hinges.
5. Using a roller tool, roll weatherstrip onto liftgate with enough force to assure adhesion. Do not apply excessive force, or damage to weatherstrip may result.

1. Open rear door.
2. Using a trim stick C-4755 or equivalent, disengage the push pins attaching rear door header weatherstrip to door frame. (Scheme 387)
3. Remove weatherstrip from door.

Scheme 387

1. Place weatherstrip into position.
2. Press on weatherstrip push pins to engage rear door header weatherstrip to door frame. (Scheme 387)
3. Close rear door.

1. Remove the door trim panel. «(Refer to BODY/DOORS - REAR/TRIM PANEL - REMOVAL)»(ref-245423-S10651588582006110200000).
2. Rotate the inner belt molding outboard while pulling up to disengage the retention tabs. (Scheme 388)
3. Remove inner belt molding from door.

Scheme 388

1. Place inner belt molding into position.
2. Press down on inner belt molding to engage the retention tabs. (Scheme 388)
3. Install the door trim panel. «(Refer to BODY/DOORS - REAR/TRIM PANEL - INSTALLATION)»(ref-245423-S19646409282006110200000).

1. Open front door.
2. Using a trim stick C-4755 or equivalent, disengage the push pins attaching rear door mounted weatherstrip to door frame. (Scheme 389)
3. Remove weatherstrip from door frame.

Scheme 389

1. Place rear door mounted weatherstrip into position. (Scheme 389)
2. Press on attaching push pins fasteners to attach weatherstrip to lower door and engage upper rear door mounted weatherstrip to door frame.
3. Close front door.

1. Lower window completely.
2. Remove rear inner molding weatherstrip. «(Refer to BODY/WEATHERSTRIP/SEALS/REAR DOOR INNER BELT MOLDING - REMOVAL)»(ref-245423-S41274856122006110200000).
3. Remove fixed glass run channel. «(Refer to BODY/DOORS - REAR/REAR DOOR FIXED GLASS RUN CHANNEL - REMOVAL)»(ref-245423-S30548015622006110200000).
4. Remove fixed glass run channel.
5. Remove screws attaching outer belt molding, one at the inside of the rear door shut face at the B-pillar and one at the inside of the rear door shut face at the C-pillar.
6. Insert special tool #9093 between belt molding and glass at rear and then slide tool forward approximately 14 cm (5.5 in.). (Scheme 390)and see scheme 326.
7. Push down on outer belt molding and rotate upper part of tool outward from vehicle approximately 6 - 8 cm (2.5 - 3 in.) then lift up on molding to disengage from locking tab.
8. Repeat step 3 and 4 at as necessary till outer belt molding is free.
9. Remove outer belt molding weatherstrip.

Scheme 390

1. Place outer belt molding weatherstrip into position. (Scheme 390)
2. Press down or tap lightly on outer belt molding until fully seated.
3. Install screws attaching outer belt molding, one at the inside of the rear door shut face at the B-pillar and one at the inside of the rear door shut face at the C-pillar.
4. Install fixed glass run channel.
5. Install rear inner molding weatherstrip. «(Refer to BODY/WEATHERSTRIP/SEALS/REAR DOOR INNER BELT MOLDING - INSTALLATION)»(ref-245423-S03229999492006110200000).
6. Install door trim panel. «(Refer to BODY/DOORS - REAR/TRIM PANEL - INSTALLATION)»(ref-245423-S19646409282006110200000).
7. Close window.

1. Open front door.
2. Remove rear door sill scuff plate.
3. Pull rear door weatherstrip from door opening fence. (Scheme 391)
4. Remove door opening weatherstrip from vehicle.

Scheme 391

1. Place rear door opening weatherstrip into position starting at the upper rear corner of the C-pillar. (Scheme 382)
2. Work the weatherstrip down the C-pillar to the floor pan. Leave slack to ensure completion of the weatherstrip throughout the entire opening.
3. Starting at B-pillar going along the under side of the header and down the B-pillar leaving slack to ensure proper installation of the bottom portion of the weatherstrip.
4. Joint the two end of the weatherstrip together and ensure complete seating of weatherstrip.
5. Install rear door sill scuff plate.
6. Close front door.