CATEGORY:    TECHNICAL

ATTENTION:   ALL DMC DEALERS/SERVICE MANAGERS

SUBJECT:     DOOR LATCH AND LOCK SETTING PROCEDURES.



Attached to this bulletin, are the door latch-lock setting
procedures.

Please inform all personnel concerned.



Sincerely,



Lutz Feuerabendt
Technical Service Manager

LF:dg

attachment(s)




















                   DOOR LATCH CONTROLS SETTING PROCEDURE


 1.   Lower the power window.

 2.   Working through the window opening, pry loose the upper trim panel retaining
      clips.

 3.   Open door and remove upper trim panel.

 4.   Remove screws securing the lower trim panel mounting bracket (upper edge) to
      the door assembly.

 5.   Pry loose the retaining clips securing the lower edge of the trim panel.

 6.   Pull trim panel away from the door to gain access to the door pull handle
      mounting bracket.  Using a long Phillips screwdriver, remove two (2) screws
      securing the door pull handle to its mounting bracket.  Remove the lower
      trim panel.

 7.   When working on the left door, remove the power mirror switch.  When working
      on the right door, remove the close-out plate.

 8.   Remove two screws securing the pull handle mounting bracket.

 9.   Loosen the lock nut on the exterior handle's latch control cable.  Turn the
      cable adjuster to gain enough slack to remove the cable ball from the bell-
      crank assembly.  Disconnect cable from bellcrank assembly.

10.   Working in the lower door area (below armrest support), disconnect the
      interior handle latch control link from the interior handle connection.

11.   Disconnect the rear latch release link from the latch release bellcrank
      assembly.

12.   With the from release link connected, there should now be free play in the
      latch release bellcrank assembly.

13.   Rotate the latch release bellcrank assembly (pulling the front latch release
      link rearward) to remove the free play in the front latch release link.
      Note:  Rotate the bellcrank only enough to remove the free play.  DO NOT
      place any pre-load on the front latch assembly.

14.   While holding the latch release bellcrank assembly in this position (Step 13),
      pull the rear latch release link forward to remove the free play and connect
      the link to the latch release bellcrank assembly.  If the free play cannot
      be removed or a pre-load condition exists, adjust the rear latch release
      link only enough to remove the free play.  DO NOT place any pre-load on the
      link connections.

15.   Reconnect the interior handle's latch control link.  This link is not
      adjustable; therefore, a slight degree of free play or pre-load is acceptable.
                                     -2-



16.   Reconnect the exterior handle's latch control cable to the bellcrank assembly.
      Turn the cable adjuster only enough to remove the slack in the cable.
      Note:  Adjust this cable only enough to remove the slack in the cable.  DO
      NOT place any pre-load on the cable bellcrank connection.

17.   Check both the interior and exterior handles for proper latch release
      operation.  This can be with the door open by:

      a.  Manually close both door latches.
      b.  With pressure applied to one latch (with screwdriver or similar tool)
          slowly open the exterior release handle until the latch is released
          and while holding the exterior release handle in the exact position
          where latch was released, the other latch should release.
      c.  Repeat the above check starting with the opposite latch.
      d.  Repeat the above check, using the interior release handle.
      e.  Open both latches before closing door.

18.   Position and secure pull handle mounting bracket to the pull handle assembly.

19.   Position pull handle assembly into the lower trim panel.

20.   Position lower trim panel on the door and secure with two (2) pull handle
      mounting screws.

21.   Position and secure lower trim panel upper mounting bracket to door assembly.

22.   Position and secure lower trim panel with retaining clips.

23.   Position and secure upper trim panel.


                              DOOR LOCK SETTING PROCEDURES


 1.   Lower the power window.

 2.   Working through the window opening, pry the upper trim panel retaining clips
      loose.

 3.   Open door and remove upper trim panel.

 4.   Remove screws securing the lower trim panel mounting bracket (upper edge)
      to the door assembly.

 5.   Pry loose the retaining clips securing the lower edge of the trim panel.

 6.   Pull trim panel away from the door to gain access to the door pull handle
      mounting bracket.  Using a long Phillips screwdriver, remove two (2) screws
      securing the door pull handle to its mounting bracket.  Remove the lower
      trim panel.

 7.   When working on the left door, remove the power mirror switch.  When working
      on the right door, remove the close-out plate.

 8.   Remove two (2) screws securing the pull handle mounting bracket.

 9.   Disconnect the exterior lock link, the rear lock link and the front lock
      link from the lock bellcrank assembly

10.   Pivot the locking bellcrank assembly back and forth and check that the
      contact wiper arm on the bellcrank makes effective contact to the electrical
      contact points at each limit of travel.  If not, adjust the position of the
      door lock solenoid by loosening the solenoid's attaching screws.  Retighten
      solenoid attaching screws.

11.   Rotate the lock bellcrank to the "unlock" position (solenoid plunger
      retracted).

12.   Pull the front locking link rearward to remove the free play and connect to
      the bellcrank.  Check that the switch's electrical contacts position has not
      changed (Step 11).  If necessary, adjust the "bend" in the front locking link
      to obtain no free play, no pre-load, and good  electrical contact condition.
      Note:  During this lock setting procedure, the door is open and, therefore,
      the latches should be in the "unlock" position.

13.   Pull the rear locking link forward to remove any free play and adjust the
      rear locking link (if necessary) until it matches the established bellcrank
      position.  Connect the rear locking link to bellcrank.

14.   With door lock key installed, pull the exterior lock link forward and connect
      the link to the bellcrank assembly.  Adjust if necessary.

Door Lock Setting Procedures


15.   With the door open, manually close both the front and rear door latch
      assemblies.

16.   Move the interior locking control rocker to the lock position and then
      back to the unlock position.  Check both the mechanical and electrical
      operation of the locking system.  Repeat checking procedure for exterior
      door lock.

17.   With the system in the unlock position and the door open, return the latches
      to the released position.

18.   Position and secure pull handle mounting bracket to the pull handle assembly.

19.   Position pull handle assembly into the lower trim panel.

20.   Position lower trim panel on the door and secure with two (2) pull handle
      mounting screws.

21.   Position and secure lower trim panel upper mounting bracket to door assembly.

22.   Position and secure lower trim panel with retaining clips.

23.   Position and secure upper trim panel.