Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Doors

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REMOVAL & INSTALLATION



Except Premier
1981-90 MODELS

All vehicles covered by this information are equipped with doors with hinges welded to both the door panel and the door pillar. Doors are removed and installed by disconnecting them at the hinges.

To perform this procedure, you'll need a hinge alignment tool C-4741 and a removal tool C-4614 or C-4716 (depending on the size of the hinge), or equivalent. It will also be helpful to have a grinding wheel.

  1. Disconnect the negative battery cable. If there is any kind of wiring harness to the door, remove the door panel as described later in this section. Then, label all electrical connectors. Unplug each connector. Route the harness through the grommet in the edge of the door, coil it and tape it in a spot where it will be kept away from the area of the door hinges.
  2.  
  3. Open the door and, using a padded device of some kind, support it securely from underneath near the outer end.
  4.  
  5. Use the hinge removal tool to remove the lower hinge pin. Then, immediately install the hinge alignment tool in place of the hinge pin.
  6.  
  7. Make sure the door is steadied against falling over. Use the appropriate sized hinge removal tool to remove the upper hinge pin. Then, remove the alignment tool and remove the door from the vehicle.
  8.  

To install:
  1. Grind a chamfer on the lower end of both hinge pins to ease installation.
  2.  
  3. Position the door so as to fit its hinge-halves into the hinge-halves welded to the body. Align the door precisely and install the 2 hinge alignment tools.
  4.  
  5. Position the upper hinge pin under the upper hinge and use a small hammer to tap it upward and through the hinge. Install the lower hinge pin from the upper side of the lower hinge in a similar manner. Remove the 2 alignment tools.
  6.  
  7. Route the wiring harness through the door, connecting all connectors to their original locations. Install the door panel as described later in this section.
  8.  

1991-95 MODELS

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: One half of the hinges are bolted to the door pillar, the other is welded to the door itself

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the door trim panel, silencer pad and water shield.
  4.  
  5. Unplug all wire connectors and wire harness hold-downs inside the door. Push the wiring harness through the access hole in the front of the door into the hinge pillar opening.
  6.  
  7. Open the door and support the door on a suitable lifting device (floor jack).
  8.  
  9. Drive the bottom hinge pin upward and remove the pin from the hinge.
  10.  
  11. Drive the top hinge pin downward and remove the pin from the hinge.
  12.  

To install:
  1. Using the floor jack, position the door so that the hinges line up.
  2.  
  3. Line the top hinge holes up, then insert the pin into the holes from the bottom until flush.
  4.  
  5. Insert the lower hinge pin into the lower hinge from the top.
  6.  
  7. Route the wiring harness through the door and attach all electrical connectors.
  8.  
  9. Install the water shield, silencer pad and door trim panel.
  10.  
  11. Remove the floor jack.
  12.  
  13. Connect the negative battery cable.
  14.  

Premier

See Figure 2

Click image to see an enlarged view

Fig. Fig. 2: The door check bolts must be removed before attempting to remove the door from the hinges

  1. With the door wide open, place a floor jack with a block of wood on it under the door for support.
  2.  
  3. Remove the door trim panel.
  4.  
  5. On vehicles with electrical wiring in the doors, disconnect and remove the wiring from the door assembly.
  6.  
  7. Loosen the door hinge set screws.
  8.  
  9. Remove the bolts attaching the door check assembly to the A-pillar.
  10.  
  11. Lift the door straight up and off of the hinge pins.
  12.  

To install:
  1. Place the door (supported by a padded jack) in position on the hinge pins.
  2.  
  3. Install the bolts attaching the door check assembly to the A-pillar.
  4.  
  5. Tighten the set screws.
  6.  
  7. If applicable, install the wiring in the door and attach it to the components.
  8.  
  9. Perform the door aligning procedure (if required) and install the trim panel.
  10.  

ADJUSTMENT



Except Premier
1981-90 MODELS

The door hinges are welded to both the door panels and door pillars. Because of this fact, adjustments can be performed only through the use of a special door hinge adjusting tool (C-4736), which bends the hinges in a controlled way.

Before adjusting either hinge, check these items:



The alignment of the striker plate. Is it correct-
 
The fit and condition of the hinge roll pins. If there is looseness, they must be replaced.
 
The installation of the door seal. Sealing problems which may seem to be door misalignment may actually be due to irregular/incorrect positioning of the seal on the body.
 

  1. If it is necessary to adjust the striker plate:
    1. Scribe around the striker plate to mark its location against the door jamb. Then, loosen the mounting screws just slightly.
    2.  
    3. Open and close the door slowly to watch engagement of the door with the striker. The door should not rise or fall as it is closed. Reposition the striker vertically to ensure that this requirement is met.
    4.  
    5. Close the door and inspect its outer surface to see if it is flush with adjacent sheet metal. If not, adjust the striker inward or outward until the door rests in a flush position.
    6.  
    7. Tighten the striker adjustments securely.
    8.  

  2.  
  3. If these other checks fail to resolve door alignment problems, it is necessary to bend the hinges. Keep in mind that this process must be done gradually to fine tune the door position. First, determine the exact angle/area of misalignment.
  4.  
  5. Slip the hinge bending tool completely over the hinge to be bent. Then, slowly and gradually apply pressure so the change in door position can be monitored accurately. Stop the process and check the point of misalignment frequently.
  6.  

1991-95 MODELS

If the hinges are not removed from the pillar the door should not need adjusting. If, however, the hinges were removed or the door does need adjusting, perform the following:

  1. Scribe around the striker plate to mark its location against the door jamb. Then, loosen the mounting screws just slightly.
  2.  
  3. Open and close the door slowly to watch engagement of the door with the striker. The door should not rise or fall as it is closed. Reposition the striker vertically to ensure that this requirement is met.
  4.  
  5. Close the door and inspect its outer surface to see if it is flush with adjacent sheet metal. If not, adjust the striker inward or outward until the door rests in a flush position.
  6.  
  7. Close the door and inspect the gap around the door. The gap should be approximately 1 / 4 in. (6mm) wide and even all the way around the door. Adjust the hinges up or down, or install shims to the hinges, to adjust the gap.
  8.  
  9. After the door is correctly adjusted, tighten the striker adjustments securely.
  10.  

Premier

Refer to the previous adjusting procedure for 1991-95 non-Premier vehicles.

LATCH ADJUSTMENT



The latch adjustment affects both the smoothness of door latch operation and the door handle-to-skin position.

  1. Insert a 5 / 32 in. (4mm) Allen wrench through the access hole in the end of the door and engage it with the Allen screw in the latch mechanism. Slide the screw up or down in the slot to adjust the latch position and then tighten the Allen screw to 30 inch lbs. (4 Nm). Remove the wrench.
  2.  
  3. Close the door and check the operation of the latch, as well as the door handle position.
  4.  
  5. Readjust as described in Steps 1 and 2 until the door closes smoothly and the door handle is flush.
  6.  

 
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