At this point:
"Next installed are the door latches, window seals, window regulators, and the glass. Before any upholstery is installed, every car passes through a water leak test booth, which is the length of three cars. Highly-pressured water is directed at the top, bottom, and sides of the car as it travels through the dark booth. An inspector riding inside the car looks for leaks, using a flashlight, and notes any problems on a heavy paper inspection form."
E Body Assembly Sequence
ASSEMBLY SEQUENCE:
(some variation with different body types)
(from bare painted body shell)
Spray radiator saddle blackout
Rocker panel pinchweld blackout (if applicable)
Front frame rail side blackout (if applicable)
1. trunk weatherstrip
2. body rubber bumpers
3. trunk latch mechanism
4. hood latches & release mechanisms
5. main body brake & fuel tubing
6. fuel tank & fuel hose connections
7. emissions tubes & hose connections (if applicable)
8. inner cowl insulation pad
9. firewall insulation pad
10. swing pedal(s)
11. brake booster (if applicable)
12. master cylinder
13. defroster duct
14. kick panel insulation pads
15. LH vent box (if applicable)
16. E-brake pedal assembly & front cable
17. wiper mechanism
18. wiper motor
19. heater box assembly
20. cowl vent screens (if applicable)
21. accelerator pedal & cable
22. dash assembly (completely assembled outside
of car including instrument cluster, dash pad, glove
box liner, radio, speaker, wiring, etc.)
23. Vent pull cables, defroster & vent cables
24. proportioning valve & metering block (if applicable)
25. firewall brake tubing
26. starter relay
27. forward lamp harness
28. engine harness
29. starter wiring
30. washer bottle & hoses
31. ballast resistor
32. voltage regulator
33. horn relay (Bbody cars)
34. horns
35. heater hoses
36. headlights
37. fender inner splash shields (front & rear of wheel)
38. rear suspension stop bumpers
39. rear seat belts (some bolt tips get undercoating)
40. rear shocks bolted in at top only & compressed
41. grille & headlight doors
42. front bumper
43. front valance (if applicable) with directionals
44. front & rear side marker lamps
45. rear bumper
46. radio antenna
47. fender emblems (if applicable)
48. rear of fender splash shields
49. undercoat wheelwells
50. exterior emblems
51. windshield & backlite stainless trim
52. windshield wiper arms & blades
53. other exterior trim
54. taillights
55. mid body/rear lamp wiring harness
56. dome lamp wiring harness
57. shoulder harness clips (if applicable)
58. rear grip strips (Bbody)
59. headliner
60. roofrail c-channels
61. roofrail weatherstrips
62. windshield & backlite moulding clips
63. windshield & backlite
64. upper control arms on body
65. fuel hose clamped on body side fuel tubing
with keystone crimp clamp
66. install rear leaf springs front only
67. position rear end housing on springs
68. loosely fasten u-bolts
69. lift rear axle into position and install shackles
70. connect e-brake cables
71. connect brake line tubing & hose
72. DRIVETRAIN SUBASSEMBLE
a. K-member
b. engine
c. carb(s)
d. starter
e. alternator
f. fan & fan clutch
g. power steering pump (if applicable)
h. belts
i. motor mounts
j. trans & related hardware
k. lower control arms
l. strut rods
m. center link, idler arm, tie rods
n. steering box & pitman arm
o. fuel pump and tubing
p. fan blade
q. radiator hoses
73. drop body onto drivetrain subassembly
74. connect heater hoses
75. install trans crossmember
76. install driveshaft
77. connect shift linkages
78. install z-bar (if applicable)
79. connect clutch linkage (if applicable)
80. plug in electrical connections to engine
81. position fan shroud over fan blade
82. install radiator & connect hoses
83. connect trans cooler (if applicable)
84. bolt up fan shroud
85. install torsion bars
86. install exhaust system
87. install rear valance (if applicable)
88. set car on the ground
89. install & align door and quarter glass
90. install steering column
91. install carpeting
92. install seat belts
93. install quarter interior trim panels
94. install rear seat
95. install console (if applicable)
96. install front seat(s)
97. install trunk mat
98. install spare tire
99. install bumper jack
There are many different sequences of assembly possible.
Sometimes I'll jump from one area to another depending on parts available or other road blocks.
There are cases where the wrong order will give you headaches though!
