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Frame and Bumpers: Removal & Installation Dodge Dart PF

Frames, Subframes & Crossmembers 14 illustrations ~1922 words

INSTALLATION

  1. With the help of an assistant, position the fascia to the vehicle.
  2. Align and hand tap the fascia sides (4, 5) to engage the fascia retaining tabs. Repeat on the opposite side.
  3. Install the fascia to upper radiator fasteners (2, 3, 6). Tighten the fasteners securely.
  4. Install the four fascia to upper radiator support push pins (1).
  5. Align the upper fascia closeout panel (1).
  6. Install the eight push pin fasteners (2) into the upper fascia closeout panel (1).
  7. Raise the vehicle.
  8. Install the fender to fascia fastener (1). Tighten the fastener securely. Repeat for the opposite side.
  9. If equipped, connect the fog lamps.
  10. Accessing from under the vehicle, connect the active grille shutter wire harness.
  11. Position the fascia lower closeout panel (1), install the thirteen fasteners (2) securing the fascia lower close out panel. Tighten the fasteners securely.
  12. Install the front splash shield. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION»(ref-646233-S24910490662014072800000) .
  13. Lower the vehicle.
  14. Connect the negative battery cable.
  15. Close the hood.

REMOVAL

  1. Disconnect the negative battery cable.
  2. Raise and support the vehicle.
  3. Remove the front splash shield. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL»(ref-646233-S05943217422014072800000) .
  4. Remove the thirteen fasteners (2) securing the fascia lower closeout panel (1).
  5. Remove the fascia lower closeout panel (1).
  1. If equipped, connect the fog lamps.
  2. Position the fascia lower closeout panel (1), install the thirteen fasteners (2) securing the fascia lower close out panel. Tighten the fasteners securely.
  3. Install the front splash shield. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION»(ref-646233-S24910490662014072800000) .
  4. Lower the vehicle.

Scheme 17

Scheme 17: REMOVAL
Scheme 17: REMOVAL

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20
  1. Open the vehicle decklid.
  2. Disconnect the negative battery cable.
  3. Raise and support the vehicle.
  4. Remove the wheelhouse splash shields. Refer to «SHIELD, SPLASH, REAR WHEELHOUSE, REMOVAL»(ref-646233-S11862273022014072800000) .
  5. Remove the push-pin retainer (1) that secures the side underbody splash shield (2) to the rear fascia assembly.
  6. Remove the fasteners (3, 4) that secure the side underbody splash shield (2) to the rear fascia assembly.
  7. Remove the side underbody splash shield (2).
  8. Repeat the removal steps on the opposite side.
  9. Remove the fasteners (3, 4) that secures the center underbody splash shield (1) to the underbody and rear fascia assembly.
  10. Remove the fasteners (2) that secures the rear fascia assembly to the underbody.
  11. Remove the center underbody splash shield (1).
  12. Accessing from the wheelhouse, remove the fender to fascia fastener (1). Repeat for the opposite side.
  13. Lower the vehicle slightly.
  14. Remove the lower rear trunk trim panel. Refer to «PANEL, TRUNK TRIM, REMOVAL»(ref-646233-S39675619732014072800000) .
  15. Pull out on the fascia (1) at the wheel house opening to disengage the fascia from the retaining bracket. Repeat on the opposite side.
  16. With the help of an assistant, pull rearward to disengage the fascia (1) from the rear retaining bracket. Do not completely remove at this time.
  17. Disconnect the vehicle wiring harness (2).
  18. Remove the fascia (1) from vehicle.
  1. With the help of an assistant, position the fascia (1) to the vehicle.
  2. Connect the vehicle wiring harness (2).
  3. With the help of an assistant and using firm pressure, align and push forward to engage the fascia (1) to the rear retaining bracket.
  4. Align the fascia (1) with the retaining brackets at the tail lamp and wheelhouse openings. Using firm pressure push in to engage. Repeat on the opposite side.
  5. Install the lower rear trunk trim panel. Refer to «PANEL, TRUNK TRIM, INSTALLATION»(ref-646233-S11107010512014072800000) .
  6. Raise and support the vehicle.
  7. Accessing from the wheelhouse, install the fastener (1) that secures the rear fascia assembly to the rear quarter. Tighten the fastener securely. Repeat for opposite side.
  8. Install the fasteners (2) that secures the rear fascia assembly to the underbody.
  9. Align and position the center underbody splash shield (1).
  10. Install the fasteners (3, 4) that secures the center underbody splash shield (1) to the underbody and rear fascia assembly. Tighten the fasteners securely.
  11. Align and position the side underbody splash shield (2).
  12. Install the fasteners (3, 4) that secure the side underbody splash shield (2) to the rear fascia assembly. Tighten the fasteners securely.
  13. Install the push-pin retainer (1) that secures the side underbody splash shield (2) to the rear fascia assembly.
  14. Install the wheelhouse splash shields. Refer to «SHIELD, SPLASH, REAR WHEELHOUSE, INSTALLATION»(ref-646233-S21019795112014072800000) .
  15. Repeat the installation steps on the opposite side.
  16. Lower the vehicle.
  17. Connect the negative battery cable.
  18. Close the vehicle decklid.

Scheme 21

Scheme 21: UPPER REINFORCEMENT
Scheme 21: UPPER REINFORCEMENT
  1. Remove front fascia. Refer to «FASCIA, FRONT, REMOVAL»(ref-646214-S35831020322014072800000) .
  2. Remove the fasteners (2) securing the upper bumper reinforcement (1) to the frame/front end module. Repeat on the opposite side and remove the upper bumper reinforcement (1).

Scheme 22

Scheme 22: LOWER REINFORCEMENT
Scheme 22: LOWER REINFORCEMENT
  1. Remove front fascia. Refer to «FASCIA, FRONT, REMOVAL»(ref-646214-S35831020322014072800000) .
  2. Remove the fasteners (2) securing the lower bumper reinforcement (1) to the frame/front end module. Remove the lower bumper reinforcement (2).
  3. If necessary, repeat steps for the opposite side.
  1. Position rear bumper reinforcement (1) on vehicle.
  2. Install nuts (2) attaching the bumper reinforcement to frame rail. Use the reference marks to properly position bumper reinforcement (1).
  3. Tighten nuts (2) to 28 N.m (21 ft. lbs.).
  4. Install rear fascia. Refer to «FASCIA, REAR, INSTALLATION»(ref-646214-S21494098532014072800000) .
  1. Slowly raise the crossmember (2) into mounted position using the transmission jack matching the crossmember to the marked locations on the body made during removal.
  2. Install four mounting bolts (1, 3) and tighten to 189 N.m (139 ft. lbs.).
  3. Install the upper mounting bolt (1) on each side of the crossmember and tighten to 120 N.m (86 ft. lbs.).
  4. Connect the steering harness connector (1) to the body harness connector at the bottom of the dash panel.
  5. Install the tie strap (2) to the crossmember.
  6. Connect the harness connectors (2) at the steering gear module (1).
  7. Install the rear engine mount. Refer to «INSULATOR, ENGINE MOUNT, LEFT, INSTALLATION»(ref-646215-S15249086532014072800000) for 1.4L, «INSULATOR, ENGINE MOUNT, REAR, INSTALLATION»(ref-646215-S32115423112014072800000) for 1.4L, «INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION»(ref-646215-S02011565972014072800000) for 1.4L, «INSULATOR, ENGINE MOUNT, LEFT, INSTALLATION»(ref-646216-S38752139742014072800000) for 2.0L, «INSULATOR, ENGINE MOUNT, REAR, INSTALLATION»(ref-646216-S06092366102014072800000) for 2.0L, «INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION»(ref-646216-S27557929332014072800000) for 2.0L, «INSULATOR, ENGINE MOUNT, LEFT, INSTALLATION»(ref-646217-S28607551492014072800000) for 2.4L, «INSULATOR, ENGINE MOUNT, REAR, INSTALLATION»(ref-646217-S11710778622014072800000) for 2.4L, «INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION»(ref-646217-S05475237812014072800000) for 2.4L.
  8. Install the exhaust extension pipe.
  9. Connect the downstream oxygen sensor harness connector.
  10. Install the front fascia beams (1).
  11. Install the fasteners (2) securing the lower bumper reinforcement (1) to the frame/front end module. Tighten the fasteners to 45 N.m (33 ft. lbs.).
  12. Install the crossmember to fascia support beam bracket and install the four retaining bolts (1) and tighten to 95 N.m (70 ft. lbs.).
  13. Insert the lower ball joint into the knuckle and install a NEW pinch bolt and NEW nut (3) and tighten to 70 N.m (52 ft. lbs.).
  14. Install the outer tie rod end (1) into the knuckle and install the retaining nut (2) and tighten to 25 N.m Plus 80° (18 ft. lbs. Plus 80°).
  15. Install the stabilizer link stud into the strut and install the nut (1).
  16. Hold the stabilizer link stud stationary and tighten the nut to 63 N.m (46 ft. lbs.).
  17. If equipped, install the engine belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
  18. Install the tire and wheel assembly. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000) .
  19. Lower the vehicle.
  20. Install the intermediate shaft (2) to the steering gear pinion shaft (4).
  21. Install a NEW pinch bolt (3) and tighten to 55 N.m (40 ft. lbs.).
  22. Remove the steering wheel holder.
  23. Connect the battery negative cable.

Scheme 23

Scheme 23: REMOVAL
Scheme 23: REMOVAL

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27
  1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
  2. Remove both rear wheels.
  3. On each side of the vehicle, hold the stabilizer link upper stud stationary, remove the upper nut (1) from the stabilizer link and separate the link from the stabilizer bar.
  4. Remove the lower transversal link (2) to crossmember bolt (3).
  5. Mark the location of the lower transversal link to lower control arm bolt (1) and remove the bolt.
  6. Remove the lower shock to lower transversal link bolt and remove the lower transversal link (2) from the vehicle.
  7. Remove the upper transversal link (2) retaining nut (1) and bolt (3).
  8. Remove the upper transversal link to crossmember mounting bolt (2) and remove the upper transversal link (1) from the vehicle.
  9. Remove the exhaust from the vehicle. Refer to «MUFFLER, EXHAUST, REMOVAL»(ref-646259-S39337395252014072800000) .
  10. Remove the rear crossmember mounting bolts (1, 3) and remove the rear crossmember (2) from the vehicle.
  1. Install the rear crossmember (2) to the body and install the mounting bolts (1, 3) and tighten to 130 N.m (96 ft. lbs.).
  2. Install the exhaust to the vehicle. Refer to «MUFFLER, EXHAUST, INSTALLATION»(ref-646259-S13636980092014072800000) .
  3. Install the upper transversal link (1) into the crossmember and install the retaining bolt. Do not tighten to specification at this time.
  4. Position the upper transversal link (2) to the lower control arm.
  5. Install the retaining bolt (3) and nut (1). Do not tighten to specification at this time.
  6. Install the lower transversal link (2) to the crossmember and install the retaining bolt (3).
  7. Install the lower transversal link bolt (1) through the lower control arm.
  8. Rotate the bolt until it matches the marks that were made during disassembly and securely tighten the bolt. Do not tighten the bolt to specifications at this time.
  9. Install the upper stud of the stabilizer link (2) to the stabilizer bar.
  10. While holding the stabilizer link stud stationary, tighten the upper nut (1) to 55 N.m (41 ft. lbs.).
  11. Lower the vehicle and tighten the following fasteners with the vehicle at normal ride height: Lower transversal link to rear crossmember: 90 N.m (66 ft. lbs.) Plus 45°. Upper transversal link to rear crossmember: 90 N.m (66 ft. lbs.) Plus 45°. Upper transversal link to lower control arm: 80 N.m (59 ft. lbs.) Plus 45°.
  12. Perform a wheel alignment. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-646210-S39626530632014072800000) then tighten the lower transversal link to lower control arm bolt to 130 N.m (96 ft. lbs.).

Scheme 28

Scheme 28
Scheme 28
  1. Raise and support the vehicle.
  2. Remove the fasteners (2) that secure the front fascia lower closeout panel (1) to the underside of the vehicle.
  3. Remove the front fascia lower closeout panel (1).
  4. Remove the fasteners (2) securing the engine belly pan (1).
  5. Remove the engine belly pan (1) from the underside of the vehicle.
  1. Position the engine belly pan (1) to the underside of the vehicle.
  2. Install the fasteners (2) securing the engine belly pan (1). Tighten the fasteners securely.
  3. Position the front fascia lower closeout panel (1) to the fascia and engine belly pan.
  4. Install the fasteners (2) that secure the front fascia lower closeout panel (1) to the underside of the vehicle. Tighten the fasteners securely.
  5. Lower the vehicle.

Scheme 29

Scheme 29: RIGHT SIDE SHIELD
Scheme 29: RIGHT SIDE SHIELD
  1. Raise and support the vehicle, refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
  2. Remove the fasteners (2) that secures the right side shield (1) to the underbody.
  3. Lower the right side shield (1) from the vehicle.
  4. Lower the vehicle.

Scheme 30

Scheme 30: LEFT SIDE SHIELD
Scheme 30: LEFT SIDE SHIELD
  1. Raise and support the vehicle, refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
  2. Remove the fasteners (2) that secures the left side shield (1) to the underbody.
  3. Lower the left side shield (1) from the vehicle.
  4. Lower the vehicle.
  1. Raise and support the vehicle, refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
  2. Remove the fasteners (3, 4) that secures the center underbody splash shield (1) to the underbody and rear fascia assembly.
  3. Remove the center underbody splash shield (1).
  4. Lower the vehicle.
  1. Raise and support the vehicle, refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
  2. Align and position the center underbody splash shield (1).
  3. Install the fasteners (3, 4) that secure the side underbody splash shield (2) to the rear fascia assembly. Tighten the fasteners securely.
  4. Lower the vehicle.

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