rear view mirror CHRYSLER CARAVAN 2003 User Guide

INSTALLATION
SHORT WHEELBASE
(1) Position the air exhauster to the hole in the
lower aperture panel (Fig. 19).
(2) Using hand pressure, press the air exhauster
into the opening in the lower aperture panel until
the snap features are fully engaged.
(3) Reinstall the rear fascia onto the body. (Refer
to 13 - FRAMES & BUMPERS/BUMPERS/REAR
FASCIA - INSTALLATION).
LONG WHEELBASE
NOTE: Models with the optional rear heater and air
conditioner do not have an air exhauster on the
right side of the vehicle, but have a plastic plug
installed in the right lower aperture panel. This plug
is installed using the same procedure used to
install the air exhauster onto the short wheelbase
model. Refer to SHORT WHEELBASE.
(1) Position the air exhauster to the hole in the
lower aperture panel (Fig. 20).
(2) Using hand pressure, press the air exhauster
into the opening in the lower aperture panel until
the snap features are fully engaged.
(3) Reinstall the quarter trim panel onto the inside
of the left or right quarter inner panel. (Refer to 23 -
BODY/INTERIOR/RIGHT QUARTER TRIM PANEL
- INSTALLATION) or (Refer to 23 - BODY/INTERI-
OR/LEFT QUARTER TRIM PANEL - INSTALLA-
TION).
ROOF JOINT MOLDING
REMOVAL
The RAP molding is set with body side molding
tape. The temperature in the work area and the vehi-
cle should be at least 21É C (70É F) to avoid damag-
ing the RAP moldings.
(1) Warm the affected stick-on molding and body
metal to approximately 38É C (100É F) using a suit-
able heat lamp or heat gun.
(2) Pull stick-on molding from painted surface.
(3) Remove adhesive tape residue from painted
surface of vehicle. Use a 3M Scotch-BriteŸ Molding
Adhesive and Stripe Removal Discs, or equivalent, to
clean adhesive residue from painted surfaces. The
adhesive removal discs are available from automotive
paint suppliers. Refer to instructions supplied with
the discs for proper usage.
INSTALLATION
The RAP molding is set with body side molding
tape. The temperature in the work area and the vehi-
cle should be at least 21É C (70É F) to avoid damag-
ing the RAP moldings.
(1) If molding is to be reused;
(a) Remove tape residue from molding.
(b) Clean back of molding with MopartSuper
Kleen solvent, or equivalent.
(c) Wipe molding dry with lint free cloth.
(d) Apply new body side molding (two sided
adhesive) tape to back of molding.
(2) Clean body surface with MopartSuper Kleen
solvent, or equivalent. Wipe surface dry with lint free
cloth.
(3) Remove protective cover from tape on back of
molding.
(4) Apply molding to body from front of vehicle to
rear.
(5) Using a roller tool, roll molding onto body
panel with enough force to assure adhesion and not
bend roof panels.
SIDE VIEW MIRROR
REMOVAL
(1) Using a trim stick C-4755 or equivalent, lift up
the end of the instrument panel top pad enough to
gain access to the mirror electrical connector, if
equipped. (Refer to 23 - BODY/INSTRUMENT PAN-
EL/INSTRUMENT PANEL TOP COVER -
REMOVAL)
(2) Disconnect the electrical connector, if equipped.
(3) Using a trim stick or equivalent, remove the
trim cover (Fig. 21).
(4) Remove the bolts.
(5) Remove the mirror from the pillar.
INSTALLATION
(1) Route the mirror wire harness, if equipped,
through the a-pillar and place side view mirror in
position on vehicle (Fig. 21).
(2) Install the bolts and tighten to 10 N´m (85 in.
lbs.).
(3) Install the mirror trim cover.
(4) Connect the electrical connector, if equipped.
(5) Install the instrument panel top cover, if
equipped with the electric mirror. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION)
RSEXTERIOR23-57
REAR QUARTER PANEL/FENDER AIR EXHAUSTER (Continued)
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INTERIOR
TABLE OF CONTENTS
page page
A-PILLAR LOWER EXTENSION TRIM
REMOVAL.............................73
INSTALLATION.........................73
A-PILLAR TRIM
REMOVAL.............................73
INSTALLATION.........................73
ASSIST HANDLE
REMOVAL.............................73
INSTALLATION.........................73
B-PILLAR LOWER TRIM
REMOVAL.............................73
INSTALLATION.........................74
B-PILLAR UPPER TRIM
REMOVAL.............................74
INSTALLATION.........................74
CARPETS AND FLOOR MATS
REMOVAL.............................74
INSTALLATION.........................75
COWL TRIM
REMOVAL.............................75
INSTALLATION.........................75
C-PILLAR TRIM
REMOVAL.............................75
INSTALLATION.........................76
DOOR SILL TRIM PLATE
REMOVAL.............................76
INSTALLATION.........................76
HEADLINER
REMOVAL.............................76
INSTALLATION.........................76
LEFT D-PILLAR TRIM PANEL
REMOVAL.............................77
INSTALLATION.........................77
LIFTGATE SILL PLATE
REMOVAL.............................77
INSTALLATION.........................77
QUARTER TRIM BOLSTER
REMOVAL.............................77INSTALLATION.........................77
RIGHT QUARTER TRIM PANEL
REMOVAL.............................78
INSTALLATION.........................78
LEFT QUARTER TRIM PANEL
REMOVAL.............................78
INSTALLATION.........................78
REAR HEADER TRIM
REMOVAL.............................79
INSTALLATION.........................79
REAR HVAC LOUVER
REMOVAL.............................79
INSTALLATION.........................79
REAR VIEW MIRROR
REMOVAL.............................79
INSTALLATION.........................80
RIGHT D-PILLAR TRIM PANEL
REMOVAL.............................80
INSTALLATION.........................80
SLIDING DOOR SILL PLATE
REMOVAL.............................80
INSTALLATION.........................80
SUN VISOR
REMOVAL.............................81
INSTALLATION.........................81
SUN VISOR SUPPORT
REMOVAL.............................81
INSTALLATION.........................81
FLOOR CONSOLE TRAY
REMOVAL.............................81
INSTALLATION.........................81
FLOOR CONSOLE TRAY - BRACKET
ASSEMBLY
REMOVAL.............................82
INSTALLATION.........................82
23 - 72 INTERIORRS
ProCarManuals.com

(6) Position quarter trim panel on inner quarter
panel.
(7) Install screws attaching rear edge of quarter
trim to attaching bracket or inner quarter panel.
(8) Install screws attaching quarter trim to inner
quarter panel in bolster area.
(9) Install second row seat belts anchor on long
wheel base vehicle. Tighten all seat belt bolts to 39
N´m (28 in. lbs.) torque.
(10) Install first row seat belt anchor.
(11) Install left D-pillar trim panel.
(12) Install C-pillar trim panel.
(13) Install upper left B-pillar trim on three door
vehicle.
(14) Install left quarter trim bolster.
(15) Install front door sill plate on three door vehi-
cle.
(16) Install sliding door sill plate on four door
vehicle.
(17) Install second row seat, if equipped.
(18) Install first row seat.
(19) Connect the battery negative cable.
REAR HEADER TRIM
REMOVAL
(1) Disengage hidden clips holding trim to rear
header (Fig. 10).
(2) Separate rear header trim from vehicle.
INSTALLATION
(1) Place rear header trim in position on vehicle.
(2) Align guide pins on trim to holes in header.
(3) Engage hidden clips to hold trim to rear
header.
(4) Engage interlock tabs at D-pillar trim.
REAR HVAC LOUVER
REMOVAL
(1) Using a trim stick (C-4755), pry edge of louver
from bezel.
(2) Remove HVAC louver from bezel.
(3) Using a trim stick, pry lower edge of HVAC
bezel away from headlining (Fig. 11).
(4) Remove louver from vehicle.
INSTALLATION
(1) Place bezel in position in HVAC duct opening.
(2) Push inward on bezel until clips snap in place.
Verify that all four clips have been engaged to the
bezel and that the bezel is flush to the headlining
(3) Position HVAC louver to bezel.
(4) Snap both ends of the louver into HVAC bezel.
REAR VIEW MIRROR
REMOVAL
(1) If equipped, disconnect mirror harness connec-
tor (Fig. 12).
(2) Loosen the mirror base set screw (Fig. 13).
(3) Slide the mirror base upward and off the
bracket.
Fig. 10 REAR HEADER TRIM
1 - REAR HEADER
2 - GUIDE PINS
3 - CLIPS
Fig. 11 REAR HVAC LOUVER
1 - HEVAC DUCT
2 - REAR HEVAC LOUVER
3 - HEADLINING
4 - CLIP
RSINTERIOR23-79
LEFT QUARTER TRIM PANEL (Continued)
ProCarManuals.com

INSTALLATION
(1) Position the mirror base at the bracket and
slide it downward onto the support bracket.
(2) Tighten the setscrew 1 N´m (15 in. lbs.) torque.
(3) If equipped, connect mirror harness connector.
RIGHT D-PILLAR TRIM PANEL
REMOVAL
(1) Remove rear header trim cover.
(2) Remove liftgate sill plate.
(3) Remove second row seat belt turning loop on
long wheel base vehicle.
(4) Remove bolt attaching second row seat belt,
anchor to quarter on short wheel base vehicle.
(5) Disengage hidden clips attaching trim to D-pil-
lar.
(6) Remove D-pillar trim panel from D-pillar.
(7) Disconnect speaker wire connector, if equipped.(8) Pass second row seat belt, if equipped, through
slot in trim panel on short wheel base vehicle.
(9) Remove D-pillar trim from vehicle.
INSTALLATION
(1) Position D-pillar trim on vehicle.
(2) Pass second row seat belt, if equipped, through
slot in trim panel on short wheel base vehicle.
(3) Connect speaker wire connector to speaker, if
equipped.
(4) Align locating pins on backside of trim panel to
mating holes in D-pillar.
(5) Engage hidden clips attaching trim to D-pillar.
(6) Install screws attaching trim panel to attach-
ing bracket on short wheel base vehicle.
(7) Install quarter trim bolster on short wheel base
vehicle.
(8) Install bolt to attach second row seat belt, if
equipped, anchor to quarter on short wheel base
vehicle. Tighten all seat belt bolts to 39 N´m (29 ft.
lbs.) torque.
(9) Install second row seat belt turning loop on
long wheel base vehicle.
(10) Install liftgate sill plate.
(11) Install rear header trim cover.
SLIDING DOOR SILL PLATE
REMOVAL
(1) Disengage hidden clips holding sill plate to
sliding door opening sill.
(2) Disengage hooks holding outside edge of sill
plate to door sill (Fig. 14).
(3) Remove sill plate from vehicle.
INSTALLATION
(1) Place sill plate in position on vehicle.
Fig. 12 REAR VIEW MIRROR ASSEMBLY
1 - HEADLINER
2 - WIRE COVER
3 - MIRROR
4 - MIRROR ASSEMBLY
5 - WIRE CONNECTOR
6 - WINDSHIELD
Fig. 13 REAR VIEW MIRROR
1 - MIRROR
2 - WINDSHIELD
Fig. 14 SLIDING DOOR SILL PLATE
1 - HOOKS
2 - SILL PLATE
3 - CLIPS
4 - SLIDING DOOR SILL
5 - CLIPS
23 - 80 INTERIORRS
REAR VIEW MIRROR (Continued)
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STATIONARY GLASS
TABLE OF CONTENTS
page page
WINDSHIELD
DESCRIPTION........................105
WARNING
WINDSHIELD SAFETY PRECAUTIONS....105
REMOVAL............................105
INSTALLATION........................106
SLIDING DOOR GLASS
REMOVAL............................107INSTALLATION........................107
QUARTER WINDOW
REMOVAL............................108
INSTALLATION........................108
REAR DOOR GLASS
REMOVAL............................108
INSTALLATION........................108
WINDSHIELD
DESCRIPTION
The windshield is attached to the window frame
with urethane adhesive. The urethane adhesive is
applied cold and seals the surface area between the
window opening and the glass. The primer adheres
the urethane adhesive to the windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
structural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficult
to cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.
WARNING
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVESTHAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
REMOVAL
WINDSHIELD REMOVAL ± EXTERIOR METHOD
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 wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
(1) Remove inside rear view mirror.
(2) Remove windshield wiper arms.
(3) Remove cowl cover.
RSSTATIONARY GLASS23 - 105
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(4) Remove A-pillar trim panels.
(5) Place protective covers over instrument panel
and hood.
(6) Remove windshield molding. Using pliers, pull
outward on molding at the bottom of A-pillars.
(7) Using a sharp cold knife, cut urethane adhe-
sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 1). A power
cutting device can be used if available.
(8) Remove windshield from vehicle.
WINDSHIELD REMOVAL ± INTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Remove instrument panel top cover. Refer to
Group 8E, Instrument Panel and Systems.
(3) Remove A-pillar trim covers.
(4) Place protective covers over instrument panel
and hood.
(5) 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 equip-
ment being used.
(6) Remove windshield from vehicle.
INSTALLATION
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 wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment. If a door is slammed before
urethane bonding is cured, water leaks can result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.To avoid stressing the replacement windshield, the
urethane bonding material on the windshield fence
should be smooth and consistent to the shape of
the replacement windshield. The support spacers
should be cleaned and properly installed on weld
studs or repair screws at bottom of windshield
opening.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing 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 wind-
shield 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 par-
allel 75 cm (2.5 ft.) apart (Fig. 2).
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.
(7) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of windshield and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.
(8) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying time.
(9) Using a razor knife, remove as much original
urethane as possible. Do not damage paint on wind-
shield 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 (Fig. 3).
(12) Apply a 10 mm (0.4 in.) bead of urethane on
center line of windshield fence.
(13) With the aid of a helper, position the wind-
shield 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 (Fig. 3).
(15) Clean access urethane from exterior with
MopartSuper Kleen or equivalent.
Fig. 1 CUT URETHANE AROUND WINDSHIELD
1 - COLD KNIFE
2 - WINDSHIELD
23 - 106 STATIONARY GLASSRS
WINDSHIELD (Continued)
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(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.
(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.SLIDING DOOR GLASS
REMOVAL
The temperature of the vehicle should be at least
21É C (70É F) before removing the stationary quarter/
sliding door glass. Butyl sealer becomes more pliable
at high temperatures.
(1) Remove interior trim as necessary to gain
access attaching locations on back of glass.
(2) Remove nuts holding stationary glass to fence.
(3) Using razor knife, cut butyl sealer holding
glass to fence from between the mounting studs (Fig.
4).
(4) Push glass from opening.
INSTALLATION
The temperature of the vehicle should be at least
21É C (70É F) before removing the stationary quarter/
sliding door glass. Butyl sealer becomes more pliable
at high temperatures.
The stationary glass fence should be cleaned of all
old butyl sealer.
(1) Applya6mm(0.25 in.) butyl tape around
perimeter of glass assembly encapsulation track.
Ensure that the butyl tape is wrapped around the
mounting studs.
(2) Place the glass into the opening and insert
mounting studs through holes in fence.
(3) Install nuts to hold stationary glass to fence.
CAUTION: Tighten nuts to 3.4 N´m (30 in. lbs.)
torque in the sequence indicated. Do not over
torque, or glass breakage may result (Fig. 4).
(4) Install interior trim. (Refer to 23 - BODY/
DOORS - SLIDING/TRIM PANEL - INSTALLATION)
(5) Verify alignment and flushness.
Fig. 2 WORK SURFACE SET UP AND MOLDING
INSTALLATION
1 - WINDSHIELD AND MOLDINGS
2 - BLOCKS
Fig. 3 LOWER WINDSHIELD INTO POSITION
1 - WINDSHIELD
2 - COMPRESSION SPACERS
Fig. 4 SLIDING DOOR STATIONARY GLASS
1 - NUMBERS INDICATE THE TIGHTENING SEQUENCE
2-6mmBEAD OF BUTYL TAPE
3 - BODY SIDE/SLIDING DOOR GLASS
RSSTATIONARY GLASS23 - 107
WINDSHIELD (Continued)
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WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL............................110
INSTALLATION........................110
FRONT DOOR OUTER BELT MOLDING
REMOVAL............................110
INSTALLATION........................110
FRONT DOOR WEATHERSTRIP
REMOVAL............................111INSTALLATION........................111
SLIDING DOOR WEATHERSTRIP
REMOVAL............................112
INSTALLATION........................112
FRONT DOOR INNER BELT MOLDING
REMOVAL............................112
INSTALLATION........................112
FRONT DOOR GLASS RUN
WEATHERSTRIP
REMOVAL
(1) Remove door frame closeout moldings.
(2) Pull weatherstrip from glass run channel at
rear of door frame, working from the bottom to the
top.
(3) Disengage clip attaching weatherstrip to door
frame.
(4) Pull weatherstrip from lip along top of door
frame (Fig. 1).
(5) Remove door trim panel.
(6) Remove door speaker, if equipped.
(7) Remove watershed as necessary to gain access
to screw attaching front lower corner of glass run
weatherstrip to inner door panel.
(8) Remove screw attaching glass run weatherstrip
to inner door panel.
(9) Remove inner belt weatherstrip.
(10) Pull weatherstrip from front glass run chan-
nel.
(11) Remove glass run weatherstrip from vehicle.
INSTALLATION
(1) Position glass run weatherstrip on vehicle (Fig.
1).
(2) Push weatherstrip into front glass run channel.
(3) Install screw attaching glass run weatherstrip
to inner door panel.
(4) Install inner belt weatherstrip.
(5) Install watershed.
(6) Push weatherstrip groove onto lip along top of
door frame.(7) Engage clip into slot in door frame.
(8) Push weatherstrip into channel at rear of door
frame, working from the top to bottom.
(9) Install door frame closeout moldings.
(10) Install door speaker, if equipped.
(11) Install door trim panel.
FRONT DOOR OUTER BELT
MOLDING
REMOVAL
(1) Remove the side view mirror. (Refer to 23 -
BODY/EXTERIOR/SIDE VIEW MIRROR -
REMOVAL)
(2) Remove door trim panel.
(3) Roll door glass down.
(4) Using a hook tool, disengage interlocking lip at
the base of the inward edge of the belt molding (Fig.
1).
(5) Remove belt molding from door.
INSTALLATION
(1) Place belt molding in position on door (Fig. 1).
NOTE: Make sure end of applique is against outer
belt.
(2) Engage interlocking lip at the base of the
inward edge of the belt molding on door panel.
(3) Install door trim panel.
23 - 110 WEATHERSTRIP/SEALSRS
ProCarManuals.com

fort temperature. For instance, on sunny summer
days the air flow will probably be cooler than the
comfort temperature; on cold or cloudy days and at
night it will probably be slightly warmer. Infrared
Three-Zone Temperature Control provides side-to-
side and front-to-rear variation in comfort tempera-
ture settings. The Infrared Three-Zone Automatic
Temperature Control fan provides a continuously
variable air flow rate to meet occupant comfort
requirements.
FRONT CONTROL PANEL
²AUTO HI/LO± This system features two sets of
automatic control logic that allow either a rapid cool-
down rate or a somewhat slower cool-down rate with
less fan noise. HI-AUTO controls the system to reach
its assigned temperature quickly with a higher fan
speed. LO-AUTO controls the system to reach its
assigned temperature somewhat slower with less fan
noise. Both modes will automatically engage auto
recirculation.
²DE-FROST± The de-frost function is active
when the rear window defogger function is active or
when the defog/defrost mode is selected.
²RECIRC± The RECIRC button will close the
air inlet door. If the system is in auto recirc (indica-
tor being displayed automatically), pressing the man-
ual recirc button will disable the auto recirc function
until one of the auto keys are pressed or the ignition
is cycled. If Auto HI/LO is pressed while manual
recirc is active, manual recirc will be deactivated.
²REAR WINDOW DEFOGGER± Pushing the
button sends a PCI bus message to the Intelligent
Power Module which controls the Rear Window
Defogger and side view mirror (if equipped) circuitry.
The defogger function will be active for 10 minutes
and can be turned off by a switch press. The defogger
will function while the control is in the ON mode.
²FAN/MODE± The Fan and Mode knobs have
17 manual selectable positions. Manually changing
either of the rotary knobs for mode or fan speed set-
tings makes control of that function alone manual for
as long as the ignition is on. If only one is changed
manually, the other remains under automatic control.
Pressing the HI-AUTO/LO-AUTO rocker switch
restores full automatic control.
²REAR CONTROL± When the Rear System
control knob is moved to the OFF position, there will
be a delay of approximately 1 second before the sys-
tem actually turns off. This delay is to prevent an
undesired blower dropout if the knob is moved
through OFF to the other selections.
²BLOWER DELAY TIMER± The word DELAY
is displayed at start-up to signify that the system is
waiting so that cold air will not be blowing. This tells
the operator that it is unnecessary to turn the sys-tem off, raise the temperature setting or turn the fan
speed setting down to prevent cold air from blowing.
A countdown in minutes and seconds until the engine
is warm enough to begin delivering heat to the pas-
sengers alternates with the DELAY message at 25
second intervals. This countdown is based on actual
measurement of the rate of engine coolant tempera-
ture change. During the delay time, Defrost mode is
selected and the fan operates at a low speed to keep
the windshield fog free.
REAR CONTROL PANEL
Primary control of the rear compartment unit is in
the instrument panel center stack. The rear unit con-
trol knob there allows the driver to turn the rear
unit off, allow control by the intermediate seat occu-
pants by switching to the REAR position, or provide
fully automatic control based on the temperature set-
ting shown on the front control display.
²REAR CONTROL± Selecting automatic control
of the rear unit at the instrument panel, illuminates
a Locked Padlock in the rear control panel display.
Selecting REAR activates the rear control panel and
the Padlock then appears unlocked.
²FAN KNOB± The rear fan control has Off and
AUTO positions and a range of manual speed set-
tings that override the AUTO setting.
²MODE KNOB± The mode control allows inter-
mediate seat occupants to manually override the
automatic mode and select any balance of air flow
between overhead and floor outlets from full over-
head to full floor.
²SET TEMP± The rear set temp control will
operate identical to the front controls. If the front
control rear set temp button is pressed simulta-
neously with the rear control head, then the front
control head press events shall have priority, i.e. if
the front user presses Rear Set Temp down and the
rear user presses Set Temp up, then the rear set
temp will decrease.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C COOL DOWN
TEST
The heater-A/C control module can perform an A/C
cool down test, which is a test performed during the
manufacturing process to confirm that the air condi-
tioning system is performing satisfactorily. This test
can also provide a quick confirmation of air condi-
tioning system performance to the service technician.
If the test is completed satisfactorily, no further ser-
vice is required. If the test is failed, proceed to the
A/C Performance Test to confirm the a/c system is
operating properly, or use a DRBIIItscan tool to
24 - 4 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)
ProCarManuals.com

FRONT SUSPENSION, SPECIAL TOOLS.....2-3
FRONT WASHER PUMP MOTOR -
INSTALLATION.......................8R-8
FRONT WASHER PUMP MOTOR -
REMOVAL...........................8R-8
FRONT WHEEL SPEED SENSOR -
INSTALLATION........................5-80
FRONT WHEEL SPEED SENSOR -
REMOVAL...........................5-79
FRONT WHEELHOUSE SPLASH SHIELD -
INSTALLATION.......................23-54
FRONT WHEELHOUSE SPLASH SHIELD -
REMOVAL..........................23-54
FRONT WIPER ARM ALIGNMENT -
STANDARD PROCEDURE...............8R-8
FRONT WIPER ARMS - INSTALLATION....8R-9
FRONT WIPER ARMS - REMOVAL........8R-9
FRONT WIPER MOTOR - INSTALLATION . . . 8R-9
FRONT WIPER MOTOR - REMOVAL.......8R-9
FRONT WIPER SYSTEM - DIAGNOSIS
AND TESTING........................8R-2
FRONT WIPER/WASHER SWITCH -
DIAGNOSIS AND TESTING..............8R-2
FRONT/QUAD SEAT CUSHION -
INSTALLATION.......................23-92
FRONT/QUAD SEAT CUSHION -
REMOVAL..........................23-92
FRONT-WHEEL-DRIVE - INSTALLATION....2-36
FRONT-WHEEL-DRIVE - REMOVAL........2-35
FUEL CORRECTION OR ADAPTIVE
MEMORIES, OPERATION...............14-20
FUEL DELIVERY SYSTEM - DIAGNOSIS
AND TESTING........................14-2
FUEL DOSING PUMP - DESCRIPTION....24-108
FUEL DOSING PUMP - INSTALLATION . . . 24-108
FUEL DOSING PUMP - OPERATION.....24-108
FUEL DOSING PUMP - REMOVAL.......24-108
FUEL ENGINE OIL - DESCRIPTION,
FLEXIBLE.............................0-3
FUEL FILL DOOR - INSTALLATION.......23-51
FUEL FILL DOOR - REMOVAL...........23-51
FUEL FILL DOOR BLOCKER LATCH -
INSTALLATION.......................23-52
FUEL FILL DOOR BLOCKER LATCH -
REMOVAL..........................23-52
FUEL FILL DOOR BLOCKER LATCH
STRIKER - INSTALLATION..............23-52
FUEL FILL DOOR BLOCKER LATCH
STRIKER - REMOVAL.................23-52
FUEL FILL DOOR BLOCKER LOCKOUT
LINK - INSTALLATION.................23-53
FUEL FILL DOOR BLOCKER LOCKOUT
LINK - REMOVAL.....................23-52
FUEL FILLER CAP - DESCRIPTION.......25-12
FUEL FILLER CAP - OPERATION.........25-12
FUEL FILTER - INSTALLATION............14-4
FUEL FILTER - REMOVAL...............14-4
FUEL INJECTOR - DESCRIPTION.........14-26
FUEL INJECTOR - OPERATION..........14-26
FUEL LEVEL SENDING UNIT / SENSOR -
DESCRIPTION........................14-4
FUEL LEVEL SENDING UNIT / SENSOR -
INSTALLATION........................14-5
FUEL LEVEL SENDING UNIT / SENSOR -
OPERATION..........................14-5
FUEL LEVEL SENDING UNIT / SENSOR -
REMOVAL...........................14-5
FUEL LINE - INSTALLATION...........24-110
FUEL LINE - REMOVAL...............24-109
FUEL LINES/HOSES AND CLAMPS -
DESCRIPTION........................14-6
FUEL PRESSURE REGULATOR -
INSTALLATION........................14-7
FUEL PRESSURE REGULATOR -
OPERATION..........................14-7
FUEL PRESSURE REGULATOR -
REMOVAL...........................14-7
FUEL PUMP - DESCRIPTION.............14-7
FUEL PUMP - OPERATION..............14-7
FUEL PUMP MODULE - DESCRIPTION.....14-8
FUEL PUMP MODULE - INSTALLATION....14-9
FUEL PUMP MODULE - OPERATION.......14-8
FUEL PUMP MODULE - REMOVAL
........14-8
FUEL PUMP RELAY - DESCRIPTION
......14-28
FUEL PUMP RELAY - OPERATION
........14-28
FUEL REQUIREMENTS - DESCRIPTION
......0-4
FUEL REQUIREMENTS - DIESEL ENGINE
- DESCRIPTION
........................0-6FUEL, SPECIAL TOOLS............14-23,14-3
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE - STANDARD
PROCEDURE.........................14-2
FUEL SYSTEM PRESSURE,
SPECIFICATIONS......................14-3
FUEL TANK - DESCRIPTION............14-10
FUEL TANK - INSTALLATION............14-11
FUEL TANK - OPERATION..............14-10
FUEL TANK - REMOVAL...............14-11
FUEL TANK - STANDARD PROCEDURE,
DRAINING...........................14-2
FUEL TANK FILLER TUBE -
INSTALLATION.......................14-12
FUEL TANK FILLER TUBE - REMOVAL....14-12
FULL OPEN SWITCH - DESCRIPTION....8N-12,
8N-31
FULL OPEN SWITCH - INSTALLATION....8N-13
FULL OPEN SWITCH - OPERATION . 8N-12,8N-31
FULL OPEN SWITCH - REMOVAL........8N-13
FUNCTIONS - DESCRIPTION, CIRCUIT . . 8W-01-6
FUSE - DESCRIPTION, IOD...........8W-97-4
FUSE - INSTALLATION, IOD..........8W-97-5
FUSE - OPERATION, IOD.............8W-97-5
FUSE - REMOVAL, IOD..............8W-97-5
FUSES POWERING SEVERAL LOADS -
STANDARD PROCEDURE, TESTING
FOR A SHORT TO GROUND ON......8W-01-10
FWD - INSTALLATION..............2-41,2-44
FWD - INSTALLATION, REAR WHEEL
SPEED SENSOR.......................5-81
FWD - REMOVAL..................2-40,2-44
FWD - REMOVAL, REAR WHEEL SPEED
SENSOR............................5-81
GALLERY PLUGS - STANDARD
PROCEDURE, ENGINE CORE AND OIL . 9-10,9-86
GAP - STANDARD PROCEDURE,
COMPRESSOR CLUTCH AIR............24-17
GAP AND FLUSH MEASUREMENTS -
SPECIFICATIONS....................23-121
GAP, SPECIFICATIONS - WHEEL SPEED
SENSOR AIR.........................5-79
GAS - INSTALLATION, MODULAR
CLUTCH ASSY - 2.4L..................6-11
GAS - REMOVAL, MODULAR CLUTCH
ASSY - 2.4L..........................6-11
GASKET - DIAGNOSIS AND TESTING,
CYLINDER HEAD..................9-24,9-99
GASKET SURFACE PREPARATION -
STANDARD PROCEDURE, ENGINE....9-11,9-85
GASKETS AND SEALERS - STANDARD
PROCEDURE, FORM-IN-PLACE.......9-11,9-84
GEAR - DESCRIPTION.................19-26
GEAR - INSTALLATION, LHD............19-32
GEAR - INSTALLATION, RHD............19-33
GEAR & LINK ROD - DESCRIPTION, LIFT . 8N-16
GEAR & LINK ROD - INSTALLATION,
LIFT...............................8N-16
GEAR & LINK ROD - OPERATION, LIFT . . . 8N-16
GEAR & LINK ROD - REMOVAL, LIFT.....8N-16
GEAR - OPERATION...................19-27
GEAR - REMOVAL, LHD...............19-27
GEAR - REMOVAL, RHD...............19-31
GEAR END PLAY - ADJUSTMENT,
DIFFERENTIAL SIDE..................21-70
GEAR SHIFT CABLE - INSTALLATION....21-205
GEAR SHIFT CABLE - REMOVAL........21-204
GEAR SHIFT LEVER - INSTALLATION.....19-21
GEAR SHIFT LEVER - REMOVAL.........19-21
GEAR, SPECIAL TOOLS - POWER
STEERING..........................19-34
GEARSHIFT BOOT - INSTALLATION......21-73
GEARSHIFT BOOT - REMOVAL..........21-72
GEARSHIFT CABLE - CROSSOVER -
INSTALLATION.......................21-76
GEARSHIFT CABLE - CROSSOVER -
REMOVAL..........................21-73
GEARSHIFT CABLE - SELECTOR -
INSTALLATION.......................21-84
GEARSHIFT CABLE - SELECTOR -
REMOVAL..........................21-81
GEARSHIFT CABLE ADJUSTMENT,
ADJUSTMENTS
.....................21-206
GEARSHIFT KNOB - INSTALLATION
......21-87
GEARSHIFT KNOB - REMOVAL
..........21-87
GEARSHIFT MECHANISM -
INSTALLATION
.......................21-89
GEARSHIFT MECHANISM - REMOVAL
....21-87GEARTRAIN - DESCRIPTION,
PLANETARY........................21-232
GEARTRAIN - OPERATION, PLANETARY . . 21-232
GENERAL - WARNINGS.............8W-01-7
GENERAL DIAGNOSIS - DIAGNOSIS AND
TESTING, 41TE TRANSAXLE...........21-119
GENERATOR - DESCRIPTION...........8F-23
GENERATOR - OPERATION.............8F-23
GENERATOR DECOUPLER PULLEY -
DESCRIPTION.......................8F-25
GENERATOR DECOUPLER PULLEY -
DIAGNOSIS AND TESTING..............8F-25
GENERATOR DECOUPLER PULLEY -
INSTALLATION.......................8F-26
GENERATOR DECOUPLER PULLEY -
OPERATION.........................8F-25
GENERATOR DECOUPLER PULLEY -
REMOVAL..........................8F-26
GENERATOR, SPECIFICATIONS..........8F-22
GLASS - DESCRIPTION, HEATED.........8G-1
GLASS - INSTALLATION, DOOR.........23-17
GLASS - INSTALLATION, REAR DOOR . . . 23-108
GLASS - INSTALLATION, SIDE VIEW
MIRROR...........................23-58
GLASS - INSTALLATION, SLIDING DOOR . 23-107
GLASS - OPERATION, HEATED...........8G-1
GLASS - REMOVAL, DOOR.............23-17
GLASS - REMOVAL, REAR DOOR.......23-108
GLASS - REMOVAL, SIDE VIEW MIRROR . . 23-58
GLASS - REMOVAL, SLIDING DOOR.....23-107
GLASS INTEGRAL ANTENNA - EXPORT -
DESCRIPTION, QUARTER...............8A-9
GLASS INTEGRAL ANTENNA - EXPORT -
DIAGNOSIS AND TESTING, QUARTER.....8A-9
GLASS INTEGRAL ANTENNA - EXPORT -
OPERATION, QUARTER.................8A-9
GLASS PANEL - INSTALLATION........23-117
GLASS PANEL - REMOVAL............23-117
GLASS PANEL ADJUSTMENT,
ADJUSTMENTS - SUNROOF...........23-117
GLASS RUN WEATHERSTRIP -
INSTALLATION, FRONT DOOR..........23-110
GLASS RUN WEATHERSTRIP -
REMOVAL, FRONT DOOR.............23-110
GLOVE BOX - INSTALLATION...........23-63
GLOVE BOX - REMOVAL...............23-63
GLOVE BOX LAMP SWITCH -
INSTALLATION.......................8L-26
GLOVE BOX LAMP SWITCH - REMOVAL . . 8L-26
GLOVE BOX LATCH - INSTALLATION.....23-63
GLOVE BOX LATCH - REMOVAL.........23-63
GLOVE BOX LATCH STRIKER -
INSTALLATION.......................23-64
GLOVE BOX LATCH STRIKER - REMOVAL . 23-64
GRID LINE AND TERMINAL REPAIR -
STANDARD PROCEDURE...............8G-3
GRID LINE REPAIR REAR - STANDARD
PROCEDURE.........................8G-2
GRILLE - INSTALLATION, COWL.........23-50
GRILLE - REMOVAL, COWL............23-49
GRILLE OPENING REINFORCEMENT -
INSTALLATION
.......................23-53
GRILLE OPENING REINFORCEMENT -
REMOVAL
..........................23-53
GROCERY BAG RETAINER -
INSTALLATION, PLASTIC
..............23-103
GROCERY BAG RETAINER - REMOVAL,
PLASTIC
..........................23-103
GROMMET REPLACEMENT - STANDARD
PROCEDURE, PUSH-PIN
...............8N-28
GROUND - OPERATION, PCM
...........8E-15
GROUND - STANDARD PROCEDURE,
TESTING FOR A SHORT TO
..........8W-01-9
GROUND AND SPLICE INFORMATION -
DESCRIPTION, CONNECTOR
..........8W-01-7
GROUND ON FUSES POWERING
SEVERAL LOADS - STANDARD
PROCEDURE, TESTING FOR A SHORT
TO
.............................8W-01-10
GUIDE - INSTALLATION, UNDER SEAT
STORAGE BIN
......................23-104
GUIDE - REMOVAL, UNDER SEAT
STORAGE BIN
......................23-104
GUIDE PIN BUSHINGS (DISC/DISC
BRAKES) - ASSEMBLY, CALIPER
..........5-25
GUIDE PIN BUSHINGS (DISC/DISC
BRAKES) - DISASSEMBLY, CALIPER
.......5-24
14 INDEXRS
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