wiring CHRYSLER CARAVAN 2003 Service Manual

WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
UTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) If the vehicle is equipped with the memory sys-
tem and the driver side power seat exhibits a inter-
rupted or jerky motion, there is a possibility that the
wires leading from the memory seat module to the
memory seat motor are mis-wired. To check the con-
cern, obtain a DRBIIItscan tool and energize each
axis one at a time. If any axis stops in approximately
2 seconds (without hitting the end of travel), the
feedback for that axis may have an open, short or be
mis-wired. Check the wiring to that axis (module to
motor). Fix any wiring problems and retry that axis.
(2) If any power seat is not operational in any
direction, check the power seat circuit breaker,
located under the trailing edge of the driver side
power seat. Refer to the Power Distribution section of
this service manual for the circuit breaker diagnosis
and testing procedure.
(3) If the power seat circuit breaker is OK, check
for proper battery and ground connections at the
power seat switch and/or memory seat module. Fix
any wiring problems and retry.
(4) Check the power seat system wire harness con-
nections and pins to ensure proper circuit continuity
and ground paths. For complete circuit diagrams,
refer toWiring Diagrams.
(5) With the dome lamp on, apply the power seat
switch in the direction of the failure. If the dome
lamp dims, the seat may be jamming. Check under
and behind the seat for binding or obstructions. If
the dome lamp does not dim, proceed with testing of
the individual components and circuits in the power
seat system.
DIAGNOSIS AND TESTING - MEMORY SYSTEM
In order to obtain conclusive testing of the memory
system, the Programmable Communications Interface
(PCI) data bus network and all of the electronic mod-
ules that provide inputs to, or receive outputs from
the memory system components must be checked.
The most reliable, efficient, and accurate means to
diagnose the memory system requires the use of a
DRB IIItscan tool and the proper Diagnostic Proce-
dures manual. The DRB IIItscan tool can provideconfirmation that the PCI data bus is functional, that
all of the electronic modules are sending and receiv-
ing the proper messages on the PCI data bus, and
that the memory system is receiving the proper hard
wired inputs and relaying the proper hard wired out-
puts to perform its functions.
(1) If the driver power seat exhibits a interrupted
or jerky motion, there is a possibility that the wires
leading from the memory seat module to the memory
seat motor are mis-wired. To check the concern,
obtain a DRB IIItscan tool and energize each axis
one at a time. If any axis stops in approximately 2
seconds (without hitting the end of travel), the feed-
back for that axis may have an open, short or be mis-
wired. Check the wiring to that axis (module to
motor). Fix any wiring problems and retry that axis.
Refer to Wiring Diagrams for complete circuit sche-
matic or connector pin-out information.
DRIVER SEAT SWITCH
DESCRIPTION
Vehicles equipped with a driver side power seat
utilize an eight-way power seat switch. This eight-
way power seat switch features two knobs ganged
together on the outboard seat cushion side shield
(Fig. 2).
The switch is secured to the back of the seat cush-
ion side shield with two screws. However, the control
Fig. 2 Power Seat Switch Location
1 - Power Seat Switch
2 - Seat Cushion Side Shield
RSPOWER SEAT SYSTEM8N-53
POWER SEAT SYSTEM (Continued)
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REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) On models equipped with the eight-way power
seat, using a push pin remover or another suitable
wide flat-bladed tool, gently pry the power seat and
power recliner switch knobs off of the switch levers
(Fig. 4).
(3) Remove the screws that secure the outboard
seat cushion side shield to the seat cushion frame.
Refer to the Body section of the service manual for
the procedure.
(4) Pull the outboard seat cushion side shield away
from the seat cushion frame far enough to access the
power seat switch wire harness connector.
(5) Disconnect the power seat wire harness connec-
tor from the power seat switch connector receptacle.
(6) Remove the screws that secure the power seat
switch to the inside of the outboard seat cushion side
shield.
(7) Remove the power seat switch from the out-
board seat cushion side shield.
INSTALLATION
(1) Position the power seat switch onto the out-
board seat cushion side shield.
(2) Install and tighten the screws that secure the
power seat switch to the inside of the outboard seat
cushion side shield. Tighten the screws to 1.5 N´m
(14 in. lbs.).
(3) Reconnect the power seat wire harness connec-
tor to the power seat switch connector receptacle.(4) Position the outboard seat cushion side shield
onto the seat cushion frame
(5) Install and tighten the screws that secure the
outboard seat cushion side shield to the seat cushion
frame. Tighten the screws to 1.5 N´m (14 in. lbs.).
(6) Install the switch knobs on the switch control
levers, if equipped.
(7) Reconnect the battery negative cable.
MEMORY SET SWITCH
DESCRIPTION
Vehicles equipped with the memory system have a
memory switch mounted to the driver side front door
trim panel (Fig. 5). This switch is used to set and
recall all of the memory system settings for up to two
drivers. The memory switch is a resistor multiplexed
unit that is hard wired to the Body Control Module
(BCM). The BCM sends out the memory system set
and recall requests to the other electronic modules
over the Programmable Communications Interface
(PCI) data bus.
The memory switch cannot be adjusted or repaired
and, if faulty or damaged, it must be replaced. For
complete circuit diagrams, refer toWiring Dia-
grams.
Fig. 4 Removing Switch Control Knobs - Typical
Fig. 5 Memory Switch Location
1 - Memory Switch
2 - Switch Bezel
RSPOWER SEAT SYSTEM8N-55
DRIVER SEAT SWITCH (Continued)
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(3) Reconnect the power seat wire harness connec-
tor to the power seat switch connector receptacle.
(4) Position the outboard seat cushion side shield
onto the seat cushion frame
(5) Install and tighten the screws that secure the
outboard seat cushion side shield to the seat cushion
frame. Tighten the screws to 1.5 N´m (14 in. lbs.).
(6) Install the switch knobs on the switch control
levers, if equipped.
(7) Reconnect the battery negative cable.
DRIVER POWER SEAT TRACK
DESCRIPTION
The eight-way driver side power seat option
includes a electrically operated power seat track
located under the driver side front seat. The front
power seat track on the driver side of the vehicle also
provides the mounting location for the Memory Seat/
Mirror Module (MSMM). The power seat circuit
breakers are mounted on the rear of the driver side
power seat track, just behind the seat rear trim
panel. The lower half of the power seat track is
secured to the floor panel via four studs and nuts
that must be accessed from the underside of the vehi-
cle. Four bolts secure the bottom of the seat cushion
pan to the upper half of the power seat track unit.
Four additional bolts secure the seat back frame to
the power seat track unit.
The power seat track unit includes four reversible
electric motors that are secured to the upper half of
the track unit. Each motor moves the seat adjuster
through a combination of worm-drive gearboxes and
screw-type drive units. Each of the four power seat
track motors used on models equipped with the
optional memory system incorporates a position
potentiometer integral to the motor assembly, which
electronically monitors the motor position. This
enables the memory system to function by referenc-
ing the motor positions programmed into the memory
seat/mirror module.
The front and rear of the seat are operated by two
separate vertical adjustment motors. These motors
can be operated independently of each other, tilting
the entire seat assembly forward or rearward; or,
they can be operated in unison by selecting the
proper power seat switch functions, which will raise
or lower the entire seat assembly. A third motor is
the horizontal adjustment motor, which moves the
seat track in the forward and rearward directions.
The forth motor is the recliner adjustment motor,
which moves the seat back in the forward and rear-
ward directions.
The power seat track unit cannot be repaired, and
is serviced only as a complete unit. If any componentin this unit is faulty or damaged, the entire power
seat track unit must be replaced.
OPERATION
When the driver side power seat switch control
knob or knobs are actuated, a battery feed and a
ground path are applied through the switch contacts
to the power seat track or recliner adjuster motor.
The selected adjuster motor operates to move the
seat track or recliner through its drive unit in the
selected direction until the switch is released, or
until the travel limit of the adjuster is reached.
When the switch is moved in the opposite direction,
the battery feed and ground path to the motor are
reversed through the switch contacts. This causes the
adjuster motor to run in the opposite direction.
No power seat switch should be held applied in any
direction after the adjuster has reached its travel
limit. The power seat adjuster motors each contain a
self-resetting circuit breaker to protect them from
overload. However, consecutive or frequent resetting
of the circuit breaker must not be allowed to con-
tinue, or the motor may be damaged.
See the owner's manual in the vehicle glove box for
more information on the power seat switch functions
and the seat adjusting procedures.
DIAGNOSIS AND TESTING - DRIVER POWER
SEAT TRACK
WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
UTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
Actuate the driver side power seat switch to move
all three power seat track adjusters in each direction.
The power seat track adjusters should move in each
of the selected directions. If a power seat track
adjuster fails to operate in only one direction, move
the adjuster a short distance in the opposite direction
and test again to be certain that the adjuster is not
at its travel limit. If the power seat track adjuster
still fails to operate in only one direction, refer to
Diagnosis and Testing Power Seat Switchin this
section. If the power seat track adjuster fails to oper-
ate in more than one direction, perform the following
tests. For complete circuit diagrams, refer toWiring
Diagrams.
8N - 58 POWER SEAT SYSTEMRS
PASSENGER SEAT SWITCH (Continued)
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ward and rearward directions. The recliner adjust-
ment motor moves the seat back in the forward and
rearward directions.
The power seat track unit cannot be repaired, and
is serviced only as a complete unit. If any component
in this unit is faulty or damaged, the entire power
seat track unit must be replaced.
OPERATION
When a passenger side power seat switch control
knob or knobs are actuated, a battery feed and a
ground path are applied through the switch contacts
to the power seat track or recliner adjuster motor.
The selected adjuster motor operates to move the
seat track or recliner through its drive unit in the
selected direction until the switch is released, or
until the travel limit of the adjuster is reached.
When the switch is moved in the opposite direction,
the battery feed and ground path to the motor are
reversed through the switch contacts. This causes the
adjuster motor to run in the opposite direction.
No power seat switch should be held applied in any
direction after the adjuster has reached its travel
limit. The power seat adjuster motors each contain a
self-resetting circuit breaker to protect them from
overload. However, consecutive or frequent resetting
of the circuit breaker must not be allowed to con-
tinue, or the motor may be damaged.
See the owner's manual in the vehicle glove box for
more information on the power seat switch functions
and the seat adjusting procedures.
DIAGNOSIS AND TESTING - POWER SEAT
TRACK
WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
UTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO SO COULDRESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
Actuate the passenger side power seat switch to
move the power seat track adjuster in each direction.
The power seat track adjuster should move in each of
the selected directions. If a power seat track adjuster
fails to operate in only one direction, move the
adjuster a short distance in the opposite direction
and test again to be certain that the adjuster is not
at its travel limit. If the power seat track adjuster
still fails to operate in only one direction, refer to
Diagnosis and Testing Power Seat Switchin this
section. If the power seat track adjuster fails to oper-
ate in more than one direction, perform the following
tests. For complete circuit diagrams, refer toWiring
Diagrams.
(1) Check the power seat circuit breaker under the
seat. If OK, go to Step 2. If not OK, replace the
faulty power seat circuit breaker.
(2) Check for battery voltage at the power seat cir-
cuit breaker under the seat. If OK, go to Step 3. If
not OK, repair the open fused B(+) circuit to the fuse
in the Intelligent Power Module as required.
(3) Remove the outboard seat cushion side shield
from the seat. Disconnect the seat wire harness con-
nector from the power seat switch connector recepta-
cle. Check for battery voltage at the fused B(+)
circuit cavity of the power seat wire harness connec-
tor for the power seat switch. If OK, go to Step 4. If
not OK, repair the open fused B(+) circuit to the
power seat circuit breaker under the seat as
required.
(4) Check for continuity between the ground cir-
cuit cavity of the power seat wire harness connector
for the power seat switch and a good ground. There
should be continuity. If OK, go to Step 5. If not OK,
repair the open ground circuit to ground as required.
(5) Test the power seat switch. Refer toDiagnosis
and Testing Power Seat Switchin this section. If
the switch tests OK, test the circuits of the power
seat wire harness between the inoperative power seat
track adjuster motor and the power seat switch for
shorts or opens. If the circuits check OK, replace the
faulty power seat track unit. If the circuits are not
OK, repair the power seat wire harness as required.
8N - 60 POWER SEAT SYSTEMRS
PASSENGER POWER SEAT TRACK (Continued)
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POWER WINDOWS
TABLE OF CONTENTS
page page
POWER WINDOWS
DESCRIPTION.........................62
OPERATION...........................62
DIAGNOSIS AND TESTING - POWER
WINDOWS...........................62
VENT WINDOW MOTOR
DIAGNOSIS AND TESTING - VENT WINDOW
MOTOR .............................63
REMOVAL.............................63INSTALLATION.........................64
WINDOW MOTOR
REMOVAL.............................64
WINDOW SWITCH
DIAGNOSIS AND TESTING - WINDOW
SWITCH............................64
REMOVAL.............................65
INSTALLATION.........................65
POWER WINDOWS
DESCRIPTION
The Power Window System is activated through
switches mounted on the driver and passenger door
panels.
OPERATION
Front door window lift motors use permanent type
magnets. The B+ and ground applied at the motor ter-
minal pins will cause the motor to rotate in one direc-
tion. Reversing current through the motor terminals
will cause the motor to rotate in the opposite direction.
The power window motors ground through the
master switch in the driver door by a black wire
attached to the left cowl panel. Refer to the appropri-
ate wiring information. The wiring information
includes wiring diagrams, proper wire and connector
repair procedures, details of wire harness routing
and retention, connector pin-out information and
location views for the various wire harness connec-
tors, splices and grounds.
The power rear vent windows, if equipped, are
operated by switches mounted in the driver door
switch bezel. A separate switch is used for each win-
dow. Permanent magnet type motors connected to a
crank system are used to open and close the rear
vent windows. A battery positive and negative con-
nection to either of the two motor terminals will
cause the motor to rotate in one direction. Reversing
current through these same two connections will
cause the motor to rotate in the opposite direction.
Refer to the appropriate wiring information. The wir-
ing information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
DIAGNOSIS AND TESTING - POWER
WINDOWS
POWER WINDOW MOTOR TEST
If the power window motor is receiving proper cur-
rent and ground and does not operate, proceed with
motor test. Refer to the appropriate wiring informa-
tion. The wiring information includes wiring dia-
grams, proper wire and connector repair procedures,
details of wire harness routing and retention, connec-
tor pin-out information and location views for the
various wire harness connectors, splices and grounds.
(1) Remove front door trim panel and sound pad as
necessary to gain access to power window motor wire
connector, (Refer to 23 - BODY/DOOR - FRONT/
TRIM PANEL - REMOVAL).
(2) Disconnect power window motor wire connector
from door harness.
(3) Using two jumper wires, connect one to a bat-
tery (+) source and the other to a good ground (-).
(4) Connect the Negative (-) jumper probe to one of
the motor connector terminals.
(5) Momentarily touch the Positive (+) jumper
probe to the other motor connector terminal.
When positive probe is connected the motor should
rotate in one direction to either move window up or
down. If window is all the way up or down the motor
will grunt and the inner door panel will flex when
actuated in that one direction.
(6) Reverse jumper probes at the motor connector
terminals and window should now move in opposite
direction. If window does not move or grunt, replace
the motor.
If window moved completely up or down, reverse
the jumper probes and cycle window to the opposite
position to verify full operation.
If motor grunts and does not move, verify that reg-
ulator is not binding.
8N - 62 POWER WINDOWSRS
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WIRING VOLTAGE TEST
The following wiring test determines whether or
not voltage is continuous through the body harness
to switch.
(1) Remove the power window switch and bezel
assembly from the driver door. (Refer to 8 - ELEC-
TRICAL/POWER WINDOWS/POWER WINDOW
SWITCH - REMOVAL).
(2) Disconnect wire connector from back of power
window switch.
(3) Switch ignition ON position.
(4) Connect the clip end of a 12 volt test light to
Pin 13 in door harness connector at the window
switch. Touch the test light probe to Pin 9 and then
to Pin 11.
²If the test light illuminates, the wiring circuit
between the battery and switch is OK.
²If the lamp does not illuminate, first check the
25 amp circuit breaker attached to the electrical dis-
tribution wiring bracket. If the circuit breaker is OK,
then check the 40 amp fuse (#28) in the Integrated
Power Module (IPM). If both components are OK,
then check for a broken wire.
²Refer to the appropriate wiring information.
The wiring information includes wiring diagrams,
proper wire and connector repair procedures, details
of wire harness routing and retention, connector pin-
out information and location views for the various
wire harness connectors, splices and grounds.
VENT WINDOW MOTOR
DIAGNOSIS AND TESTING - VENT WINDOW
MOTOR
If the power vent window motor is receiving proper
current and ground and does not operate proceed
with motor test. Refer to the appropriate wiring
information. The wiring information includes wiring
diagrams, proper wire and connector repair proce-
dures, details of wire harness routing and retention,
connector pin-out information and location views for
the various wire harness connectors, splices and
grounds.
(1) Remove D-pillar trim panel necessary to gain
access to power vent window motor wire connector,
(Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR
TRIM PANEL - REMOVAL) or (Refer to 23 - BODY/
INTERIOR/RIGHT D-PILLAR TRIM PANEL -
REMOVAL).
(2) Disconnect power vent window motor wire con-
nector from body harness.
(3) Using two jumper wires, connect one to a bat-
tery (+) source and the other to a good ground (-).
(4) Connect the Negative (-) jumper probe to one of
the motor connector terminals.(5) Momentarily touch the Positive (+) jumper
probe to the other motor connector terminal.
When positive probe is connected the motor should
rotate in one direction to either move window open or
closed. If window is all the way open or closed the
motor will grunt and the crank system will flex when
actuated in that one direction.
Reverse jumper probes at the motor connector ter-
minals and window should now move in opposite
direction. If window does not move or grunt, replace
the motor.
If window moved completely open or closed, reverse
the jumper probes and cycle window to the opposite
position to verify full operation.
If motor grunts and does not move, verify that
crank system is not binding.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove D-pillar trim panel. (Refer to 23 -
BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL -
REMOVAL) or (Refer to 23 - BODY/INTERIOR/
RIGHT D-PILLAR TRIM PANEL - REMOVAL).
(3) Disconnect wire connector from power vent
motor.
(4) Using a flat bladed tool, carefully lift the circu-
lar actuator link tab. Remove link from window ball
socket.
(5) Remove bolts holding power vent motor to
D-pillar (Fig. 1).
(6) Remove power vent motor.
Fig. 1 VENT WINDOW MOTOR
1 - VENT WINDOW MOTOR
2 - WIRE HARNESS CONNECTOR
3 - BOLT
4 - VENT WINDOW
RSPOWER WINDOWS8N-63
POWER WINDOWS (Continued)
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CLOCK SPRING
DESCRIPTION
The clock spring is screwed to a plastic mounting
platform on the steering column behind the steering
wheel. The clock spring is used to maintain a contin-
uous electrical circuit between the wiring harness
and the drivers airbag.
OPERATION
This assembly consists of a flat ribbon like electri-
cally conductive tape which winds and unwinds with
the steering wheel rotation. The clock spring cannot
be repaired. If the clock spring is faulty, damaged, or
if the airbag has been deployed, the clock spring
must be replaced.
STANDARD PROCEDURE - CLOCK SPRING
CENTERING
If the rotating tape (wire coil) in the clock spring is
not positioned properly with the steering wheel and
the front wheels, the clock spring may fail. The fol-
lowing procedure MUST BE USED to center the
clock spring if it is not known to be properly posi-
tioned, or if the front wheels were moved from the
straight ahead position.
(1) Position steering wheel and front wheels
straight ahead.
(2) Release hood latch and open hood.
(3) Disconnect and isolate the battery negative
cable.
(4) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(5) Remove driver airbag from steering wheel
(Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER
AIRBAG - REMOVAL).
(6) Disconnect wire connectors from back of driver
airbag.(7) Disconnect the 2±way connector from remote
radio control harness.
(8) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
(9) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(10) Rotate the clock spring rotor clockwise until
the rotor stops. Do not apply excessive force.
(11) From the end of travel, rotate the rotor two
turns counterclockwise until the wires end up at the
top.
(12) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(13) Connect the 4±way harness connector to the
speed control/horn harness to the clock spring.
(14) Connect the 2±way connector to the remote
radio control harness.
(15) Install the driver airbag (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION). Torque the two screws to 10 N´m (90 in.
lbs.).
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
REMOVAL
(1) Position steering wheel and front wheels
straight ahead.
(2) Release hood latch and open hood.
(3) Disconnect and isolate the battery negative
cable.
(4) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(5) Remove driver airbag from steering wheel
(Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER
AIRBAG - REMOVAL).
(6) Disconnect wire connectors from back of driver
airbag.
(7) Disconnect the 2±way connector from remote
radio control harness.
(8) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
(9) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(10) Remove steering column shrouds and discon-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - REMOVAL).
(11) Disconnect 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
Fig. 1 VACUUM HEATER AND A/C OUTLETS -
TYPICAL
8O - 4 RESTRAINTSRS
RESTRAINTS (Continued)
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(12) Remove clock spring from column assembly by
removing the two retaining screws that attach the
clock spring to the column.
INSTALLATION
(1) Install the clock spring on the column.
(2) Connect the 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(3) Install the steering column shrouds and con-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - INSTALLATION).
(4) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(5) Connect the 4±way harness connector to the
speed control/horn harness to the clock spring.
(6) Connect the 2±way connector to the remote
radio control harness.
(7) Install the driver airbag (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION). Torque the two screws to 10 N´m (90 in.
lbs.).
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
DRIVER AIRBAG
DESCRIPTION
The Driver Airbag is located in the center of the
steering wheel. The most visible part of the airbag is
the cover/horn switch. The Driver Airbag and Driver
Airbag Cover/Horn Pad are serviced separately from
each other.
OPERATION
The Driver Airbag cover contains the horn switch,
inflator device, and a fabric bag. The airbag cover/
horn switch is serviced separately from the inflator
and bag components.
When the front airbag system is deployed, the fol-
lowingMUSTbe replaced:
²Complete Steering Column Assembly.
²Lower Steering Column Coupler.
²Steering Wheel.
²Clock Spring.
²Driver Airbag
²Passenger Airbag
²Upper Instrument Panel with Pad.
CARE OF UNDEPLOYED AIRBAGS
Airbags must be stored in their original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag. When carrying or handling an
undeployed airbag, the trim side of the airbag should
be pointing away from the body to minimize possibil-
ity of injury if accidental deployment occurs. Do not
place undeployed airbag face down on a solid surface,
the airbag will propel into the air if accidental
deployment occurs.
REMOVAL
DEPLOYED AIRBAG
(1) Clean powder residue from interior of vehicle
(Fig. 1).
(2) Position steering wheel and front wheels
straight ahead.
(3) Release hood latch and open hood.
(4) Disconnect and isolate the battery negative
cable.
(5) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(6) Remove two screws retaining driver airbag to
steering wheel.
(7) Disconnect wire connectors from back of driver
airbag.
(8) Disconnect the 2±way connector from remote
radio control harness.
(9) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
(10) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(11) Remove steering column shrouds and discon-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - REMOVAL).
(12) Disconnect 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(13) Remove clock spring from column assembly by
removing the two retaining screws that attach the
clock spring to the column.
NOTE: The clock spring, steering wheel, and com-
plete steering column assembly w/lower steering
column coupler must be replaced also in the event
of a driver airbag deployment
UNDEPLOYED AIRBAG
(1) Release hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
RSRESTRAINTS8O-5
CLOCK SPRING (Continued)
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(3) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(4) Remove two screws retaining driver airbag to
steering wheel.
(5) Disconnect wire connectors from back of driver
airbag (Fig. 2).
(6) Disconnect the 2±way connector from remote
radio control harness.
(7) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
INSTALLATION
DEPLOYED AIRBAG
(1) Perform clean up procedure (Refer to 8 - ELEC-
TRICAL/RESTRAINTS - STANDARD PROCEDURE
- SERVICE AFTER AN AIRBAG DEPLOYMENT).
(2) Install a new steering column assembly and
lower steering column coupler (Refer to 19 - STEER-
ING/COLUMN - INSTALLATION).
(3) Install the new clock spring.
(4) Connect the 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(5) Install the steering column shrouds and con-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - INSTALLATION).
(6) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(7) Connect the 4±way harness connector to the
speed control/horn harness to the clock spring.(8) Connect the 2±way connector to the remote
radio control harness.
(9) Install the driver airbag and the two screws
retaining the airbag. Tighten screws to 10 N´m (90
in. lbs.)
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
UNDEPLOYED AIRBAG
(1) Connect the harness connector on the DAB
cover (horn, speed controls) to the clock spring.
(2) Connect the squib connectors to the DAB.
(3) Position a new airbag into the airbag cavity.
(4) Install the two screws retaining the airbag.
Tighten screws to 10 N´m (90 in. lbs.)
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
DRIVER AIRBAG TRIM COVER
REMOVAL
The horn switch is integral to the driver airbag
trim cover. If either component is faulty or damaged,
the entire driver airbag trim cover and horn switch
unit must be replaced.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge.
(2) Remove the driver airbag from the steering
wheel (Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL).
(3) Remove the plastic wire retainer that captures
the horn switch feed pigtail wire between the upper
left inflator stud and the inflator on the back of the
driver airbag housing and disconnect the speed con-
trol switches (if equipped).
(4) Remove the four nuts that secure the trim
cover retainer to the studs on the back of the driver
airbag housing.
(5) Remove the horn switch ground pigtail wire
eyelet terminal from the upper left airbag housing
stud.
(6) Remove the trim cover retainer from the airbag
housing studs.
(7) Disengage the six trim cover locking blocks
from the lip around the outside edge of the driver
airbag housing and remove the housing from the
cover.
Fig. 2 DRIVER AIRBAG WIRE CONNECTIONS
1 - AIRBAG SQUIB CONNECTORS
2 - DRIVER AIRBAG
3 - HORN/SPEED CONTROL CONNECTOR
4 - CLOCK SPRING
8O - 6 RESTRAINTSRS
DRIVER AIRBAG (Continued)
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passenger airbag cushion and the airbag cushion
supporting components.
The passenger airbag includes a magnesium hous-
ing within which the cushion and inflator are
mounted and sealed.
Following a passenger airbag deployment, the pas-
senger airbag and the instrument panel must be
replaced. The passenger airbag cannot be repaired,
and must be replaced if deployed or damaged in any
way.
OPERATION
The passenger airbag is equipped with two infla-
tors, each with three levels of pressure output. The
inflators seal the hole in the airbag cushion so it can
discharge the gas it produces directly into the cush-
ion when supplied with the proper electrical signal.
Following an airbag deployment, the airbag cushion
quickly deflates by venting this gas through the
cushion material towards the instrument panel.
The passenger airbag is secured with screws to the
instrument panel beneath the instrument panel top
pad and above the glove box opening. The instrument
panel top pad above the glove box opening conceals
the airbag door and a predetermined hinge line
beneath its decorative cover. Upon airbag deploy-
ment, the top pad will bend at the hinge line and the
door will fold back out of the way onto the top of the
instrument panel.
When the front airbag system is deployed, the fol-
lowingMUSTbe replaced:
²Complete Steering Column Assembly.
²Lower Steering Column Coupler.
²Steering Wheel.
²Clock Spring.
²Driver Airbag.
²Passenger Airbag.
²Upper Instrument Panel with Pad.
CARE OF UNDEPLOYED AIRBAGS
Airbags must be stored in their original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag. When carrying or handling an
undeployed airbag, the trim side of the airbag should
be pointing away from the body to minimize possibil-
ity of injury if accidental deployment occurs. Do not
place undeployed airbag face down on a solid surface,
the airbag will propel into the air if accidental
deployment occurs.
REMOVAL
DEPLOYED AIRBAG
(1) Clean powder residue from interior of vehicle
(Refer to 8 - ELECTRICAL/RESTRAINTS - STAN-DARD PROCEDURE - SERVICE AFTER AN AIR-
BAG DEPLOYMENT).
(2) Remove instrument panel (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
ASSEMBLY - REMOVAL).
(3) Remove all reusable components from the
upper instrument panel and transfer to the new
instrument panel.
UNDEPLOYED AIRBAG
(1) Open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Wait two minutes for the airbag system reserve
capacitor to discharge before attempting any airbag
or instrument panel service.
(4) Remove center console bin between front seats.
(5) Remove left front door sill plate using a trim
stick (special tool #C-4755) or equivalent, and gently
prying up on sill plate.
(6) Remove left cowl panel using a trim stick or
equivalent, and gently prying out on cowl panel.
(7) Remove four screws to lower steering column
cover and remove cover.
(8) Unsnap parking brake lever from knee blocker
reinforcement.
(9) Remove Data Link Connector (DLC) from knee
blocker.
(10) Remove screws to knee blocker.
(11) Unsnap left A-pillar lower extension trim
using a trim stick or equivalent.
(12) Remove three left side instrument panel A-pil-
lar retaining bolts and loosen the instrument panel
roll down bolt.
(13) Remove four nuts at brake pedal support
bracket to instrument panel.
(14) Using a trim stick or equivalent, gently pry
off left side upper A-pillar trim.
(15) Remove six screws and two wiring connectors
to lower instrument panel cubby bin at bottom of
center stack.
(16) Remove two left side nuts at instrument panel
center stack support to floor.
(17) Remove two right side nuts at instrument
panel center stack support to floor.
(18) Remove right front door sill plate using a trim
stick or equivalent, and gently prying up on sill
plate.
(19) Remove right cowl panel using a trim stick or
equivalent, and gently prying out on cowl panel.
(20) Using a trim stick or equivalent, gently pry
out on right instrument panel end cap.
(21) Unsnap right A-pillar lower extension trim
using a trim stick or equivalent.
8O - 8 RESTRAINTSRS
PASSENGER AIRBAG (Continued)
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