belt CHRYSLER CARAVAN 2003 Workshop Manual
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LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS.....................25
CENTER CONSOLE LAMP SWITCH
REMOVAL.............................26
INSTALLATION.........................26
CLUSTER ILLUMINATION LAMPS
REMOVAL.............................26
INSTALLATION.........................26
COURTESY LAMP
REMOVAL.............................26
INSTALLATION.........................26
DOME/CARGO LAMP
REMOVAL.............................26INSTALLATION.........................26
GLOVE BOX LAMP SWITCH
REMOVAL.............................26
INSTALLATION.........................26
LIFTGATE LAMP
REMOVAL.............................27
INSTALLATION.........................27
READING LAMP
REMOVAL.............................27
INSTALLATION.........................28
VANITY LAMP
REMOVAL.............................28
INSTALLATION.........................28
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
ABS LED
AIRBAG LED
ALARM SET PC74
AUTOSTICK VFD*
BRAKE SYSTEM
WARNINGLED
CONSOLE 194
CRUISE INDICATOR VFD*
DOME/RAIL LAMPS 578
DOOR AJAR INDICATOR LED
DOOR COURTESY
LAMP578
FRONT DOOR
COURTESY567
GLOVE BOX 194
HIGH BEAM INDICATOR
(BASE CLUSTER)LED
HIGH BEAM INDICATOR PC74
LAMP BULB
CLUSTER
ILLUMINATIONPC74
LIFTGATE 578
LIFTGATE AJAR LED
LOW FUEL INDICATOR LED
LOW WASHER FLUID
INDICATORLED
MIL (BASE CLUSTER) LED
MIL PC74
OIL INDICATOR (BASE
CLUSTER)LED
OIL INDICATOR PC74
OVERHEAD CONSOLE
READINGPC579
OVERDRIVE OFF
INDICATORVFD*
READING 578
SEAT BELT INDICATOR LED
TEMPERATURE
INDICATORLED
TRAC OFF INDICATOR VFD*
TURN SIGNAL
INDICATOR (BASE
CLUSTER)LED
TURN SIGNAL
INDICATORPC74
VISOR VANITY 6501966
RSLAMPS/LIGHTING - INTERIOR8L-25
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RESTRAINTS
TABLE OF CONTENTS
page page
RESTRAINTS
DESCRIPTION..........................2
OPERATION............................2
WARNING.............................2
DIAGNOSIS AND TESTING - AIRBAG SYSTEM . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
AIRBAGS.............................3
STANDARD PROCEDURE - SERVICE
AFTER AN AIRBAG DEPLOYMENT.........3
CLOCK SPRING
DESCRIPTION..........................4
OPERATION............................4
STANDARD PROCEDURE - CLOCK SPRING
CENTERING..........................4
REMOVAL.............................4
INSTALLATION..........................5
DRIVER AIRBAG
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................6
DRIVER AIRBAG TRIM COVER
REMOVAL.............................6
INSTALLATION..........................7
OCCUPANT RESTRAINT CONTROLLER
DESCRIPTION..........................7
OPERATION............................7
REMOVAL.............................7
INSTALLATION..........................7
PASSENGER AIRBAG
DESCRIPTION..........................7
OPERATION............................8
REMOVAL.............................8
INSTALLATION..........................9
SEAT AIRBAG
DESCRIPTION.........................10
OPERATION...........................11
SEAT BELT BUCKLE - FRONT INBOARD
REMOVAL.............................11
INSTALLATION.........................11
SEAT BELT BUCKLE - FIRST ROW INBOARD -
QUAD BUCKET
REMOVAL.............................11
INSTALLATION.........................11
SEAT BELT BUCKLE - FIRST ROW - BENCH
REMOVAL.............................12INSTALLATION.........................12
SEAT BELT BUCKLE - SECOND ROW
INBOARD - 50/50 BENCH
REMOVAL.............................12
INSTALLATION.........................12
SEAT BELT HEIGHT ADJUSTER-BOR
C-PILLAR
REMOVAL.............................12
INSTALLATION.........................12
SEAT BELT HEIGHT ADJUSTER KNOB
REMOVAL.............................13
INSTALLATION.........................13
SEAT BELT & RETRACTOR - OUTBOARD -
FRONT
REMOVAL.............................13
INSTALLATION.........................13
SEAT BELT & RETRACTOR - FIRST ROW -
OUTBOARD
REMOVAL.............................13
INSTALLATION.........................13
SEAT BELT BUCKLE - SECOND ROW - THREE
PASSENGER BENCH
REMOVAL.............................14
INSTALLATION.........................14
SEAT BELT & RETRACTOR - SECOND ROW -
RIGHT OUTBOARD
REMOVAL.............................14
INSTALLATION.........................14
SEAT BELT & RETRACTOR - SECOND ROW -
RIGHT OUTBOARD WITH REAR HVAC - LWB
REMOVAL.............................15
INSTALLATION.........................15
SEAT BELT & RETRACTOR - SECOND ROW -
LEFT OUTBOARD
REMOVAL.............................16
INSTALLATION.........................16
SEAT BELT TENSIONER
DESCRIPTION.........................16
OPERATION...........................16
SIDE IMPACT AIRBAG CONTROL MODULE
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL.............................17
INSTALLATION.........................17
RSRESTRAINTS8O-1
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RESTRAINTS
DESCRIPTION
This vehicle is equipped with a Frontal Impact Air-
bag System, which utilizes the driver/passenger air-
bags and seatbelt pretensioners. This system is
designed to protect occupants in the event of a front
impact collision. These airbags and seatbelt preten-
sioners are all serviceable parts. If these pyrotechnics
are deployed or defective, they must be replaced, as
well as the Occupant Restraint Controller (ORC)
must be diagnosed following procedures outlined in
the service/diagnostic manuals.
Vehicles equipped with the Side Impact Airbag
System, the seat back assembly must be replaced, as
well as the Side Impact Airbag Control Module
(SIACM) must be diagnosed following procedures
outlined in the service/diagnostic manuals.
OPERATION
The Occupant Restraint Controller (ORC) controls
the driver/passenger airbags and seat belt tensioners.
If the ORC determines that the impact is severe
enough, the driver/passenger/side airbags and seat
belt tensioners will deploy. Once a deployment
occurs, these devices, and all damaged parts must be
replaced, as well as the ORC must be diagnosed fol-
lowing procedures outlined in the service/diagnostic
manuals.
The Side Impact Airbag Control Module (SIACM),
the seat back assemblies and all damaged parts must
be replaced, as well as the SIACM must be diagnosed
following procedures outlined in the service/diagnos-
tic manuals.
WARNING
WARNING: THIS SYSTEM IS A SENSITIVE, COM-
PLEX ELECTRO±MECHANICAL UNIT. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE
BEFORE BEGINNING AIRBAG SYSTEM COMPO-
NENT REMOVAL OR INSTALLATION PROCEDURES.
THIS WILL DISABLE THE AIRBAG SYSTEM. FAIL-
URE TO DISCONNECT THE BATTERY COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR
TWO MINUTES BEFORE REMOVING AIRBAG COM-
PONENTS.
DO NOT PLACE AN INTACT UNDEPLOYED AIRBAG
FACE DOWN ON A SOLID SURFACE, THE AIRBAG
WILL PROPEL INTO THE AIR IF ACCIDENTALLY
DEPLOYED AND COULD RESULT IN PERSONAL
INJURY. WHEN CARRYING OR HANDLING AN
UNDEPLOYED AIRBAG MODULE, THE TRIM SIDE
OF THE AIRBAG SHOULD BE POINTING AWAYFROM THE BODY TO MINIMIZE POSSIBILITY OF
INJURY IF ACCIDENTAL DEPLOYMENT OCCURS.
REPLACE AIRBAG SYSTEM COMPONENTS WITH
MOPARTREPLACEMENT PARTS. SUBSTITUTE
PARTS MAY APPEAR INTERCHANGEABLE, BUT
INTERNAL DIFFERENCES MAY RESULT IN INFE-
RIOR OCCUPANT PROTECTION.
WEAR SAFETY GLASSES, RUBBER GLOVES, AND
LONG SLEEVED CLOTHING WHEN CLEANING
POWDER RESIDUE FROM VEHICLE AFTER AIRBAG
DEPLOYMENT. SODIUM HYDROXIDE POWDER
RESIDUE EMITTED FROM A DEPLOYED AIRBAG
CAN CAUSE SKIN IRRITATION. FLUSH AFFECTED
AREA WITH COOL WATER IF IRRITATION IS EXPE-
RIENCED. IF NASAL OR THROAT IRRITATION IS
EXPERIENCED, EXIT THE VEHICLE FOR FRESH AIR
UNTIL THE IRRITATION CEASES. IF IRRITATION
CONTINUES, SEE A PHYSICIAN.
DO NOT USE A REPLACEMENT AIRBAG THAT IS
NOT IN THE ORIGINAL PACKAGING, IMPROPER
DEPLOYMENT AND PERSONAL INJURY CAN
RESULT.
THE FACTORY INSTALLED FASTENERS, SCREWS
AND BOLTS USED TO FASTEN AIRBAG COMPO-
NENTS HAVE A SPECIAL COATING AND ARE SPE-
CIFICALLY DESIGNED FOR THE AIRBAG SYSTEM.
DO NOT USE SUBSTITUTE FASTENERS, USE ONLY
ORIGINAL EQUIPMENT FASTENERS LISTED IN THE
PARTS CATALOG WHEN FASTENER REPLACE-
MENT IS REQUIRED.
CAUTION:
Deployed and Nondeployed Air Bags may or may
not have live pyrotechnic material within the air bag
inflator. Do not dispose of Driver and Passenger
Airbags unless you are sure of complete deploy-
ment. Please refer to the Hazardous Substance
Control System for Proper Disposal. Dispose of
deployed air bags in a manner consistent with
state, provincial, local, and federal regulations.
DIAGNOSIS AND TESTING - AIRBAG SYSTEM
(1) With the battery negative remote cable discon-
nected, connect the DRB IIItscan tool to the Data
Link connector.
(2) Turn the ignition key to the ON position. Exit
vehicle with the scan tool.
(3) After checking that no one is inside the vehicle,
connect the battery negative remote terminal.
(4) Read and record theACTIVEDiagnostic Trou-
ble Code (DTC) data.
(5) Read and record anySTOREDDTC's.
(6) Refer to the proper Body Diagnostic Procedures
manual if any DTC's are found in Step 4 and Step 5.
(7) If the airbag warning lamp either fails to light,
or goes ON and stays ON, there is a system malfunc-
8O - 2 RESTRAINTSRS
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Page 524 of 2177
tion. To test the airbag warning lamp (bulb) opera-
tion in the cluster, refer to Electrical, Instrument
Cluster, Diagnosis and Testing - Instrument Cluster.
Refer to the proper Body Diagnostic Procedures man-
ual for any other system problems.
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
AIRBAGS
DEPLOYED AIRBAG
The vehicle interior may contain a very small
amount of sodium hydroxide powder, a by-product of
airbag deployment. Sodium hydroxide powder can
irritate the skin, eyes, nose and throat. Wear safety
glasses, rubber gloves, and long sleeved clothing
when cleaning any of the powder residue from the
vehicle.
If you find that the cleanup is irritating your skin,
run cool water over the affected area. Also, if you
experience nasal or throat irritation, exit the vehicle
for fresh air until the irritation ceases. If irritation
continues, see a physician.
UNDEPLOYED AIRBAG
The airbags must be stored in its 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 module. When carrying or han-
dling an undeployed airbag module, the trim side of
the airbag should be pointing away from the body to
minimize possibility of injury if accidental deploy-
ment occurs. Do not place undeployed airbag face
down on a solid surface, the airbag will propel into
the air if accidental deployment occurs.
STANDARD PROCEDURE - SERVICE AFTER AN
AIRBAG DEPLOYMENT
DRIVER AIRBAG
After a Driver Airbag has been deployed due to a
collision, the followingMUSTbe replaced:
²Driver Airbag
²Clock Spring Assembly
²Steering Wheel
²Complete Steering Column Assembly w/Lower
Steering Column Coupler
All other airbag and vehicle components should be
closely inspected following any airbag deployment,
and should be replaced when visible damage is
incurred.
PASSENGER AIRBAG
After a Passenger Airbag has been deployed due to
a collision. the followingMUSTbe replaced:
²Passenger Airbag
²Instrument Panel and Pad Assembly
All other airbag and vehicle components should be
closely inspected following any airbag deployment,
and should be replaced when visible damage is
incurred.
SEAT AIRBAG
After a Seat Airbag has been deployed due to a col-
lision. the followingMUSTbe replaced:
²Complete Seat Back Assembly
All other airbag and vehicle components should be
closely inspected following any airbag deployment,
and should be replaced when visible damage is
incurred.
SEAT BELT TENSIONERS
After a frontal impact where an airbag has been
deployed due to a collision. the followingMUSTbe
replaced:
²Front Seat Belt Buckle (driver and passenger)
with integral Tensioners.
All other seat belts should be closely inspected for
cuts, tears, fraying, or damage in any way following
any frontal impact or airbag deployment. The other
seat belts are to be replaced when visible damage is
incurred.
CLEAN UP PROCEDURE
Roll or fold the airbag towards its mounting point
(i.e. instrument panel, steering wheel, or seat back).
Then tape the ripped cover over the deployed airbag
if applicable.
Use a vacuum cleaner to remove any residual pow-
der from the vehicle interior. Work from the outside
in to avoid kneeling or sitting in a contaminated
area. Vacuum the heater and A/C outlets as well (Fig.
1). If the heater or air conditioner was in RECIRC
mode at time of airbag deployment, operate blower
motor on low speed and vacuum powder residue
expelled from the heater and A/C outlets. Multiple
vacuum cleaning may be necessary to decontaminate
the interior of the vehicle.
RSRESTRAINTS8O-3
RESTRAINTS (Continued)
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OPERATION
Only the Side Impact Airbag Control Module
(SIACM) can deploy the side airbags. When supplied
with the proper electrical signal, the seat airbag
inflator will produce a gas and discharge the bag
directly between the occupant and the side of the
vehicle, protecting the occupant. Upon deployment,
the seat back trim cover will tear open and allow the
side airbag to fully inflate and quickly deflate.
SEAT BELT BUCKLE - FRONT
INBOARD
REMOVAL
The seat belt tensioners are integral to the front
seat belt buckles. They are not serviceable and must
be replaced after a frontal impact event. The entire
front seat belt buckle assembly must be replaced as
an assembly.
(1) Disconnect and isolate the battery negative
cable.
(2) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service procedure.
(3) Remove screws attaching front inboard side
cover to seat cushion frame.
(4) Remove side cover from vehicle.
(5) Disconnect the tensioner wire connector from
seat belt buckle.
(6) Remove bolt attaching seat belt buckle to front
seat track.
(7) Remove buckle from vehicle.
INSTALLATION
The seat belt tensioners are integral to the front
seat belt buckles. They are not serviceable and must
be replaced after a frontal impact event. The entire
front seat belt buckle assembly must be replaced as
an assembly.
(1) Place buckle into position.
(2) Install bolt attaching seat belt buckle to front
seat track. Torque bolt to 39 N´m (29 ft. lbs.).
(3) Connect the seat belt tensioner electrical con-
nector.
(4) Install side cover into position.
(5) Install screws attaching front inboard side
cover to seat cushion frame.
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
SEAT BELT BUCKLE - FIRST
ROW INBOARD - QUAD
BUCKET
REMOVAL
(1) Remove seat from vehicle.
(2) Remove screws attaching inboard side cover to
seat cushion.
(3) Remove side cover from seat.
(4) Remove bolts attaching recliner bracket to seat
cushion.
(5) Remove recliner bracket from seat.
(6) Remove bolt attaching seat belt buckle to seat
track (Fig. 4).
(7) Remove buckle from vehicle.
INSTALLATION
(1) Place buckle into position.
(2) Install bolt attaching seat belt buckle to seat
track. Torque bolt to 39 N´m (29 ft. lbs.).
(3) Install recliner bracket onto the seat.
(4) Install bolts attaching recliner bracket to seat
cushion.
(5) Install side cover from seat.
(6) Install screws attaching inboard side cover to
seat cushion.
(7) Install seat into position.
Fig. 4 SEAT BELT BUCKLE - FIRST ROW INBOARD
- QUAD BUCKET
1 - SEAT CUSHION
2 - SEAT BELT BUCKLE
3 - SEAT TRACK
RSRESTRAINTS8O-11
SEAT AIRBAG (Continued)
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Page 533 of 2177
SEAT BELT BUCKLE - FIRST
ROW - BENCH
REMOVAL
(1) Remove seat from vehicle.
(2) Remove bolt attaching inboard seat belt buckle
to seat frame (Fig. 5).
(3) Remove belt from seat.
INSTALLATION
(1) Place seat belt into position to the seat.
(2) Install bolt attaching inboard seat belt buckle
to seat frame. Tighten all seat belt anchor bolts to 39
N´m (29 ft. lbs.) torque.
(3) Install seat into position.
SEAT BELT BUCKLE - SECOND
ROW INBOARD - 50/50 BENCH
REMOVAL
(1) Open rear liftgate.
(2) Pull handle #1 and fold seat back forward.
(3) Pull handle #2, and lift seat bottom up.
(4) Pull #3 strap and remove seat from latching
area.
(5) While looking at the bottom of the seat, locate
retaining bolt on the left side of the seat riser.
Remove retaining bolt from seat riser (Fig. 6).
(6) Pull belt through seat cushion.
INSTALLATION
(1) Push belt through seat cushion.(2) While looking at the bottom of the seat, locate
retaining bolt hole on the left side of the seat riser.
Install retaining bolt into seat riser (Fig. 6). Torque
anchor bolt to 39 N´m (29 ft. lbs.).
(3) Place seat into track and on front anchors.
(4) Pull #3 strap and install seat onto latching
area.
(5) Pull seat assembly down firmly and snap into
track.
(6) Pull handle #1 and fold seat back rearward.
(7) Close rear liftgate.
SEAT BELT HEIGHT
ADJUSTER-BORC-PILLAR
REMOVAL
(1) Remove turning loop retaining bolt.
(2) Remove B or C-pillar trim cover.
(3) Remove two screws attaching shoulder belt
height adjuster to pillar.
(4) Remove height adjuster from vehicle.
INSTALLATION
(1) Place height adjuster into position.
(2) Install screws attaching shoulder belt height
adjuster to pillar.
(3) Install B or C-pillar trim cover.
Fig. 5 SEAT BELT BUCKLE - FIRST ROW - BENCH
1 - ANCHOR BOLT
2 - TWO (2) PASS REAR SEAT BELT BUCKLE
3 - RISER
4 - REAR FRAME
Fig. 6 SEAT BELT BUCKLE - SECOND ROW
INBOARD - 50/50 BENCH
1 - SEAT BELT BUCKLE
2 - BUCKLE RETAINING BOLT
3 - 50/50 SPLIT BENCH RISER
4 - BOTTOM OF SEAT CUSHION
8O - 12 RESTRAINTSRS
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(4) Install turning loop to height adjuster. Torque
anchor bolt to 39 N´m (29 ft. lbs.).
SEAT BELT HEIGHT
ADJUSTER KNOB
REMOVAL
(1) Disengage clips attaching clam shell cover to
seat belt turning loop and open cover.
(2) Using a trim tool (special tool #C-4755), gently
pry knob from seat belt height adjuster.
INSTALLATION
(1) Place seat belt height adjuster knob in position
on height adjuster.
(2) Firmly push knob on until retainers engage.
(3) Reinstall turning loop clam shell cover.
(4) Verify seat belt operation. Make sure it moves
through loop without binding.
SEAT BELT & RETRACTOR -
OUTBOARD - FRONT
REMOVAL
(1) Open door.
(2) Move seat all the way forward.
(3) Open hood.
(4) Disconnect and isolate the negative battery
cable.
(5) Remove shoulder harness height adjuster knob
by pulling it straight away from adjuster.
(6) Remove cover from seat belt turning loop.
(7) Remove bolt attaching turning loop to shoulder
belt height adjuster.
(8) Remove upper B-pillar trim cover.
(9) Remove the lower seat belt anchor bolt.
(10) Remove front door sill plate.
(11) Remove sliding door sill plate.
(12) Remove lower B-pillar trim cover.
(13) Disconnect the seat belt retractor electrical
connector.
(14) Remove seat belt retractor attaching bolt.
(15) Remove the seat belt and retractor from vehi-
cle.
INSTALLATION
Inspect the condition of the shoulder belt and lap
belt. Replace any belt that is cut, frayed, torn, or
damaged in any way. Also, replace the shoulder belt
if the retractor is either damaged or inoperative.
(1) Place seat belt and retractor into position.
(2) Install bolt attaching seat belt retractor to
B-pillar. Torque bolt to 39 N´m (29 ft. lbs.).(3) Connect the seat belt retractor electrical con-
nector.
(4) Install the lower B-pillar trim cover.
(5) Install the sliding door sill plate.
(6) Install the front door sill plate.
(7) Install the lower seat belt anchor bolt. Torque
bolt to 39 N´m (29 ft. lbs.).
(8) Install the upper B-pillar trim cover.
(9) Install the bolt attaching turning loop to shoul-
der belt height adjuster. Torque bolt to 39 N´m (29 ft.
lbs.).
(10) Install the cover to the seat belt turning loop.
(11) Install the shoulder harness height adjuster
knob by pushing it straight onto the adjuster.
(12) Connect the battery negative cable.
(13) Verify vehicle and system operation.
(14) Move seat back to approximate customer posi-
tion.
(15) Close hood and door.
SEAT BELT & RETRACTOR -
FIRST ROW - OUTBOARD
REMOVAL
(1) Remove first and second row seats.
(2) Remove first row seat belt lower anchor bolt.
(3) Remove first row seat belt upper turning loop
anchor bolt.
(4) Remove liftgate sill plate.
(5) Remove upper liftgate trim.
(6) Remove second seat lower anchor bolt.
(7) Remove second seat upper turning loop anchor
bolt.
(8) Remove D-pillar trim cover.
(9) Disconnect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(10) Remove quarter trim bolster.
(11) Remove quarter trim panel screws.
(12) Remove quarter trim panel.
(13) Remove first row seat belt and retractor
retaining bolt.
(14) Remove first row seat belt and retractor from
vehicle.
INSTALLATION
(1) Install first row seat belt and retractor. Torque
bolt to 39 N´m (29 ft. lbs.).
(2) Install quarter trim panel.
(3) Install quarter trim panel screws.
(4) Install quarter trim bolster.
RSRESTRAINTS8O-13
SEAT BELT HEIGHT ADJUSTER-BORC-PILLAR (Continued)
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Page 535 of 2177
(5) Connect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(6) Install D-pillar trim cover.
(7) Install second seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(8) Install second seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(9) Install upper liftgate trim.
(10) Install liftgate sill plate.
(11) Install first row seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(12) Install first row seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(13) Install first and second row seats.
SEAT BELT BUCKLE - SECOND
ROW - THREE PASSENGER
BENCH
REMOVAL
(1) Remove bolt attaching seat belt buckle to seat
rear frame rail (Fig. 7).
(2) Remove seat belt buckle from seat.
INSTALLATION
(1) Place seat belt buckle in position on seat.
(2) Install bolt to attach seat belt buckle to seat
rear frame rail. Tighten all seat belt bolts to 39 N´m
(29 ft. lbs.) torque.
SEAT BELT & RETRACTOR -
SECOND ROW - RIGHT
OUTBOARD
REMOVAL
(1) Remove first and second row seats.
(2) Remove first row seat belt lower anchor bolt.
(3) Remove first row seat belt upper anchor bolt.
(4) Remove liftgate sill plate.
(5) Remove upper liftgate trim.
(6) Remove second seat belt lower anchor bolt.
(7) Remove second seat belt upper anchor bolt.
(8) Remove D-pillar trim cover.
(9) Disconnect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(10) Remove quarter trim bolster.
(11) Remove quarter trim panel screws.
(12) Remove quarter trim panel.
(13) Remove retractor retaining bolt.
(14) Remove second row seat belt and retractor.
INSTALLATION
(1) Install second row seat belt and retractor.
Torque bolt to 39 N´m (29 ft. lbs.).
(2) Install quarter trim panel.
(3) Install quarter trim panel screws.
(4) Install quarter trim bolster.
(5) Connect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(6) Install D-pillar trim cover.
(7) Install second seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(8) Install second seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(9) Install upper liftgate trim.
(10) Install liftgate sill plate.
(11) Install first row seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(12) Install first row seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(13) Install first and second row seats.
Fig. 7 SEAT BELT BUCKLE - SECOND ROW -
THREE PASSENGER BENCH
1 - ANCHOR BOLT
2 - SEAT BELTS
3 - ANCHOR
4 - RISER
8O - 14 RESTRAINTSRS
SEAT BELT & RETRACTOR - FIRST ROW - OUTBOARD (Continued)
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Page 536 of 2177
SEAT BELT & RETRACTOR -
SECOND ROW - RIGHT
OUTBOARD WITH REAR HVAC
-LWB
REMOVAL
(1) Remove first and second row seats.
(2) Remove first row seat belt lower anchor bolt.
(3) Remove first row seat belt upper anchor bolt.
(4) Remove liftgate sill plate.
(5) Remove upper liftgate trim.
(6) Remove second seat belt lower anchor bolt.
(7) Remove second seat belt upper anchor bolt.
(8) Remove D-pillar trim cover.
(9) Disconnect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(10) Remove quarter trim bolster.
(11) Remove quarter trim panel screws.
(12) Remove quarter trim panel.
(13) Loosen HVAC unit enough to gain access to
seat belt retractor fasteners.
(a) Remove bracket around HVAC unit (Fig. 8).
(b) Remove air duct (Fig. 9).
(c) Remove fasteners attaching HVAC unit to
inner quarter panel (Fig. 10).
(d) Gently pry out on rear HVAC unit to gain
access to the seat belt and retractor.
(14) Remove bolts attaching seat belt guide loop to
inner quarter panel.
(15) Pull outward on HVAC unit and remove bolt
attaching retractor to inner quarter panel.(16) Remove second row seat belt and retractor
from vehicle.
INSTALLATION
(1) Position second row seat belt and retractor to
vehicle.
(2) Pull outward on HVAC unit and install bolt
attaching retractor to inner quarter panel. Torque
bolt to 39 N´m (29 ft. lbs.).
(3) Install bolts attaching seat belt guide loop to
inner quarter panel.
(4) Install fasteners attaching HVAC unit to inner
quarter panel.
(5) Install air duct.
(6) Install trim panel retaining bracket around
HVAC unit.
(7) Install quarter trim panel.
Fig. 8 TRIM PANEL MOUNTING BRACKET
1 - TRIM PANEL MOUNTING BRACKET
Fig. 9 LOWER HEATER DUCT
1 - LOWER HEAT DUCT MOUNTING
Fig. 10 REAR HVAC MOUNTING
1 - REAR HVAC MODULE MOUNTING
2 - REAR EVAPORATOR LOWER HOUSING
3 - REAR EVAPORATOR UPPER HOUSING
RSRESTRAINTS8O-15
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(8) Install quarter trim panel screws.
(9) Install quarter trim bolster.
(10) Connect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(11) Install D-pillar trim cover.
(12) Install second seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(13) Install second seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(14) Install upper liftgate trim.
(15) Install liftgate sill plate.
(16) Install first row seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(17) Install first row seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(18) Install first and second row seats.
SEAT BELT & RETRACTOR -
SECOND ROW - LEFT
OUTBOARD
REMOVAL
(1) Remove first and second row seats.
(2) Remove first row seat belt lower anchor bolt.
(3) Remove first row seat belt upper anchor bolt.
(4) Remove liftgate sill plate.
(5) Remove upper liftgate trim.
(6) Remove second seat belt lower anchor bolt.
(7) Remove second seat belt upper anchor bolt.
(8) Remove D-pillar trim cover.
(9) Disconnect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(10) Remove quarter trim bolster.
(11) Remove quarter trim panel screws.
(12) Remove quarter trim panel.
(13) Remove retractor retaining bolt.
(14) Remove second row seat belt and retractor
from vehicle.
INSTALLATION
(1) Install second row seat belt and retractor.
Torque bolt to 39 N´m (29 ft. lbs.).
(2) Install quarter trim panel.
(3) Install quarter trim panel screws.
(4) Install quarter trim bolster.(5) Connect speaker connector. The left side has
the speaker mounted in the D-pillar trim cover and
the right side will have the speaker mounted in the
rear of the quarter trim panel, but the connector is
accessible from the rear after the D-pillar trim is
removed.
(6) Install D-pillar trim cover.
(7) Install second seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(8) Install second seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(9) Install upper liftgate trim.
(10) Install liftgate sill plate.
(11) Install first row seat belt upper turning loop
anchor bolt. Torque bolt to 39 N´m (29 ft. lbs.).
(12) Install first row seat belt lower anchor bolt.
Torque bolt to 39 N´m (29 ft. lbs.).
(13) Install first and second row seats.
SEAT BELT TENSIONER
DESCRIPTION
The seat belt system incorporates Seat Belt Ten-
sioners. The tensioner is designed to hold the occu-
pant in their respective seat by retracting the seat
belt up to four inches. They are integral to the front
seat belt buckles and cannot be serviced. If found
defective they must be replaced. After an airbag
deployment, the tensioner must be replaced.
OPERATION
At the onset of an impact event, each tensioner
uses a pyrotechnic device which is triggered simulta-
neously with the airbags to rapidly retract the seat
belts. With the slack removed, the occupant's forward
motion in an impact will be reduced as will the like-
lihood of contacting interior components. After an
impact that deploys the airbags, the seat belt ten-
sioner assembly must be replaced.
The Occupant Restraint Controller (ORC) monitors
the seat belt tensioner circuit resistance and reports
active and stored Diagnostic Trouble Codes (DTC's) if
any problem is found.
Once a vehicle has been in an accident, the ten-
sioner must be replaced along with any deployed air-
bags and broken or damaged parts. Refer to the
proper Body Diagnostic Procedures manual for diag-
nosis and testing.
WARNING: WHEN THE FRONT AIRBAG IS
DEPLOYED, THE TENSIONER WILL HAVE
DEPLOYED ALSO AND SHOULD BE REPLACED.
8O - 16 RESTRAINTSRS
SEAT BELT & RETRACTOR - SECOND ROW - RIGHT OUTBOARD WITH REAR HVAC - LWB (Continued)
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