heater CHRYSLER VOYAGER 1996 Service Manual

FUEL HEATER
The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation. The fuel
heater is located in the bottom plastic bowl of the
fuel filter/water separator (Fig. 10).
The element inside the heater assembly is made of
a Positive Temperature Coefficient (PTC) material,
and has power applied to it by the fuel heater relayanytime the ignition key is in the ªonº position. PTC
material has a high resistance to current flow when
its temperature is high, which means that it will not
generate heat when the temperature is above a cer-
tain value. When the temperature is below 7ÉC (45É
F), the resistance of the PTC element is lowered, and
allows current to flow through the fuel heater ele-
ment warming the fuel. When the temperature is
above 29ÉC (85É F), the PTC element's resistance
rises, and current flow through the heater element
stops.
Voltage to operate the fuel heater is supplied from
the ignition (key) switch and through the fuel heater
relay. Refer to the following Fuel Heater Relay for
additional information.The fuel heater and fuel
heater relay are not controlled by the Power-
train Control Module (PCM).
Current draw for the heater element is 150 watts
at 14 volts (DC).
FUEL HEATER RELAY
Voltage to operate the fuel heater is supplied from
the ignition (key) switch through the fuel heater
relay.The PCM is not used to control this relay.
The fuel heater relay is located in the PDC. The
PDC is located next to the battery in the engine com-
partment (Fig. 11). For the location of the relay
within the PDC, refer to label on PDC cover.
WASTEGATE (TURBOCHARGER)
Refer to Group 11, Exhaust System and Intake
Manifold for information.
Fig. 9 Fuel Drain Tubes
Fig. 10 Fuel Heater Temperature Sensor and
Element LocationFig. 11 Relay Location
14 - 8 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
DESCRIPTION AND OPERATION (Continued)

DIAGNOSIS AND TESTING
GENERAL INFORMATION
This section of the group will cover a general diag-
nosis of diesel engine fuel system components.
Diagnostic Trouble Codes:Refer to On-Board
Diagnostics in Group 25, Emission Control System
for a list of Diagnostic Trouble Codes (DTC's) for cer-
tain fuel system components.
The PCM must be tested with the DRBIII scan
tool. The DRBIII should be the first step in any diag-
nosis of engine performance complaints. Refer to the
1997 GS 2.5L Diesel Powertrain Diagnostic Proce-
dures manual for diagnosis and testing of the diesel
engine control system.
VISUAL INSPECTION
A visual inspection for loose, disconnected, or incor-
rectly routed wires and hoses should be made before
attempting to diagnose or service the diesel fuel
injection system. A visual check will help find these
conditions. It also saves unnecessary test and diag-
nostic time. A thorough visual inspection of the fuel
injection system includes the following checks:
(1) Be sure that the battery connections are tight
and not corroded.
(2) Be sure that the 68 way connector is fully
engaged with the PCM (Fig. 12).
(3) Verify that the electrical connections for the
Diesel PCM relay are clean and free of corrosion.
This relay is located in the PDC. For the location ofthe relay within the PDC, refer to label on PDC
cover.
(4) Verify that the electrical connections for the
fuel heater relay are clean and free of corrosion. This
relay is located in the PDC. For the location of the
relay within the PDC, refer to label on PDC cover.
(5) Be sure the electrical connectors at the ends of
the glow plugs (Fig. 13) are tight and free of corro-
sion.
(6) Be sure that the electrical connections at the
glow plug relay are tight and not corroded. The glow
plug relay is located in the engine compartment on
the left±inner fender (Fig. 14).
Fig. 12 PCM LocationÐTypical
Fig. 13 Glow Plug Connector
Fig. 14 Glow Plug Relay Location
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 9

(7) Inspect the starter motor and starter solenoid
connections for tightness and corrosion.
(8) Verify that the electrical connector is firmly
connected to the fuel shutdown solenoid. Inspect the
connector for corrosion or damaged wires. The sole-
noid is mounted to the rear of the injection pump
(Fig. 15).
(9) Verify that the fuel heater electrical connector
is firmly attached to the filter bowl at the bottom of
the fuel filter/water separator. Inspect the connector
for corrosion or damaged wires.
(10) Verify that the electrical pigtail connector
(sensor connector) (Fig. 16) for the fuel injector sen-
sor is firmly connected to the engine wiring harness.
Inspect the connector for corrosion or damaged wires.
This sensor is used on the #1 cylinder injector only.
(11) Verify that the electrical pigtail connector
(sensor connector) (Fig. 17) for the fuel timing sole-
noid is firmly connected to the engine wiring har-
ness. Inspect the connector for corrosion or damaged
wires. The fuel timing solenoid is located on the bot-
tom of the fuel injection pump (Fig. 17).
(12) Inspect for exhaust system restrictions such
as pinched exhaust pipes or a collapsed or plugged
muffler.
(13) Verify that the harness connector is firmly
connected to the vehicle speed sensor (Fig. 18).
(14) Verify turbocharger wastegate operation.
Refer to Group 11, Exhaust System and Intake Man-
ifold Group for information.
(15) Verify that the harness connector is firmly
connected to the engine coolant temperature sensor.The sensor is located on the side of cylinder head
near the rear of fuel injection pump (Fig. 19).
(16) Check for air in the fuel system. Refer to the
Air Bleed Procedure.
(17) Inspect all fuel supply and return lines for
signs of leakage.
(18) Be sure that the ground connections are tight
and free of corrosion. Refer to Group 8, Wiring for
locations of ground connections.
(19) Inspect the air cleaner element (filter) for
restrictions.
(20) Be sure that the turbocharger output hose is
properly connected to the charge air cooler (inter-
cooler) inlet tube. Verify that the charge air cooler
output hose is properly connected to the cooler and
Fig. 15 Fuel Shutdown Solenoid Location
Fig. 16 Fuel Injector Sensor
Fig. 17 Fuel Timing Solenoid
14 - 10 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
DIAGNOSIS AND TESTING (Continued)

FUEL HEATER RELAY TEST
The fuel heater relay is located in the Power Dis-
tribution Center (PDC). Refer to RelaysÐOperation/
Testing in Fuel Ingection System section of this
group for test procedures.
FUEL INJECTOR TEST
The fuel injection nozzels, located on the engine
cylinder head, spray fuel under high pressure into
the individual combustion chambers. Pressurized
fuel, delivered by the fuel injection pump, unseats a
spring-loaded needle valve inside the injector, and
the fuel is atomized as it escapes through the injector
opening into the engine's combustion chamber. If the
fuel injector does not operate properly, the engine
may misfire, or cause other driveability problems.
A leak in the injection pump±to±injector high±pres-
sure fuel line can cause many of the same symptoms
as a malfunctioning injector. Inspect for a leak in the
high±pressure lines before checking for a malfunc-
tioning fuel injector.
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
±PRESSURE FUEL OF UP TO APPROXIMATELY
45,000 KPA (6526 PSI) TO EACH INDIVIDUAL INJEC-
TOR THROUGH THE HIGH±PRESSURE LINES. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE THE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING. AVOID CONTACT WITH FUEL
SPRAY WHEN BLEEDING HIGH±PRESSURE FUEL
LINES.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
To determine which fuel injector is malfunctioning,
run the engine and loosen the high±pressure fuel line
nut at the injector (Fig. 21). Listen for a change in
engine speed. If engine speed drops, the injector was
operating normally. If engine speed remains the
same, the injector may be malfunctioning. After test-
ing, tighten the line nut to 30 N´m (22 ft. lbs.)
torque. Test all injectors in the same manner one at
a time.
Once an injector has been found to be malfunction-
ing, remove it from the engine and test it. Refer to
the Removal/Installation section of this group for pro-
cedures.
After the injector has been removed, install it to a
bench±mount injector tester. Refer to operating
instructions supplied with tester for procedures.
The opening pressure or ªpopº pressure should be
15,000±15,800 kPa (2175±2291 psi). If the fuel injec-tor needle valve is opening (ªpoppingº) to early or to
late, replace the injector.
FUEL INJECTOR SENSOR TEST
The fuel injector sensor is used only on the fuel
injector for the number±1 cylinder (Fig. 22). It is not
used on the injectors for cylinders number 2, 3, or 4.
To test the sensor, unplug the sensor connector
(Fig. 22) from the engine wiring harness. Check
resistance across terminals. Resistance should be 110
ohms610 ohms at 20ÉC (68ÉF). Replace sensor if
specification cannot be met.
FUEL INJECTION PUMP TEST
The injection pump is not to be serviced or
the warranty may be voided. If the injection
pump requires service, the complete assembly
must be replaced.
Incorrect injection pump timing (mechanical or
electrical) can cause poor performance, excessive
smoke and emissions and poor fuel economy.
Fig. 21 Typical Inspection of Fuel Injector
Fig. 22 Fuel Injector Sensor Location
14 - 12 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
DIAGNOSIS AND TESTING (Continued)

REMOVAL AND INSTALLATION
ACCELERATOR PEDAL
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing the accelerator pedal or throttle cable.
REMOVAL
(1) Disconnect electrical connector.
(2) Remove accelerator pedal mounting bracket
nuts. Remove accelerator pedal assembly.
INSTALLATION
(1) Place accelerator pedal assembly over studs
protruding from floor pan. Tighten mounting nuts to
5 N´m (46 in. lbs.) torque.
(2) Connect electrical connector.
(3) Before starting the engine, operate the acceler-
ator pedal to check for any binding.
AIR CLEANER ELEMENT
REMOVAL
(1) Remove hose clamp at Mass Air Flow Sensor.
(2) Remove hose from Mass Air Flow Sensor.(3) Loosen 2 clamps holding air cleaner housing
halves together.
(4) Remove left side of air cleaner housing.
(5) Remove element from air cleaner housing.
INSTALLATION
(1) Install a new element in housing.
(2) Position left side of housing.
(3) Snap clamps into place.
(4) Install hoses and clamps.
FUEL DRAIN TUBES
The fuel drain tubes (Fig. 28) are low±pressure
type.
Pull each tube from the injector for removal. Push
on for installation. Clamps are not required for these
tubes.
FUEL FILTER/WATER SEPARATOR
The fuel filter/water separator is located in the
engine compartment on the right side near the shock
tower. (Fig. 29).
The fuel filter/water separator assembly contains
the fuel filter, fuel heater element, and fuel drain
valve (Fig. 29).
DRAINING WATER FROM FILTER BOWL
Moisture (water) collects at the bottom of the filter/
separator in a plastic bowl. Water entering the fuel
injection pump can cause serious damage to the
pump.Note that the bulb will be illuminated for
approximately 2 seconds each time the key is
initially placed in the ON position. This is done
for a bulb check.
Fig. 27 Accelerator Pedal Mounting-Typical
Fig. 28 Fuel Drain Tubes
14 - 16 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS

WARNING: DO NOT ATTEMPT TO DRAIN WATER
FROM THE FILTER/SEPARATOR WITH THE ENGINE
HOT.
(1) The bottom of the filter/separator bowl is
equipped with a drain valve (Fig. 29). The drain
valve is equipped with a fitting. Attach a piece of
rubber hose to this fitting. This hose is to be used as
a drain hose.
(2) Place a drain pan under the drain hose.
(3) With the engine not running, open the drain
valve (unscrewÐdrain valve has right hand threads)
from the filter/separator bowl. To gain access to this
fitting, the two filter±to±mounting bracket nuts (Fig.
29) may have to be loosened a few turns.
(4) Hold the drain open until clean fuel exits the
drain.
(5) After draining, close drain valve.
(6) Remove rubber drain hose.
(7) Dispose of mixture in drain pan according to
applicable local or federal regulations.
FUEL FILTER REMOVAL
(1) Drain all fuel and/or water from fuel filter/wa-
ter separator assembly. Refer to the previous Drain-
ing Water From Filter Bowl.
(2) Unplug the electrical connectors at bottom of
plastic bowl.
(3) Remove plastic bowl from bottom of fuel filter
(unscrews).
(4) Remove fuel filter from bottom of filter base
(unscrews).
FUEL FILTER INSTALLATION
(1) Clean bottom of fuel filter base.
(2) Apply clean diesel fuel to new fuel filter gasket.
(3) Install and tighten filter to filter base. The bev-
eled part of the rubber gasket should be facing up
towards the filter base.
(4) Clean the inside of bowl with a soap and water
mixture before installation. Carefully clean any resi-
due between the two metal probes at the top of the
water±in±fuel sensor. Do not use chemical cleaners
as damage to the plastic bowl may result.
(5) Pour diesel fuel into the plastic bowl before
installing bowl to bottom of fuel filter. Do this to help
prevent air from entering fuel injection pump while
attempting to starting engine.
(6) Install filter bowl to bottom of filter.
(7) Install the electrical connectors at bottom of
bowl.
(8) Tighten the filter±to±mounting bracket nuts
(Fig. 29) to 28 N´m (250 in. lbs.) torque.
FUEL HEATER
If the fuel heater element needs replacement, the
plastic filter bowl assembly must be replaced. Refer
to Fuel Filter/Water Separator for information.
FUEL HEATER RELAY
The fuel heater relay is located in the PDC. For
the location of the relay within the PDC (Fig. 30),
refer to label on PDC cover.
Fig. 29 Fuel Filter/Water Separator Location
Fig. 30 Power Distribution Center (PDC) Location
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 17
REMOVAL AND INSTALLATION (Continued)

FUEL INJECTION SYSTEMÐ2.5L DIESEL ENGINE
INDEX
page page
GENERAL INFORMATION
INTRODUCTION....................... 43
DESCRIPTION AND OPERATION
AIR CONDITIONING (A/C) CONTROLSÐ
PCM INPUTS........................ 47
AIR CONDITIONING RELAYÐPCM OUTPUT . . 48
BATTERY VOLTAGEÐPCM INPUT.......... 45
BOOST PRESSURE SENSOR............. 45
BRAKE SWITCHÐPCM INPUT............. 47
DATA LINK CONNECTORÐ
PCM INPUT AND OUTPUT.............. 47
DIESEL PCM RELAYÐPCM INPUT......... 48
ENGINE COOLANT GAUGEÐPCM OUTPUT . . 48
ENGINE COOLANT TEMPERATURE SENSORÐ
PCM INPUT......................... 46
ENGINE OIL PRESSURE GAUGEÐ
PCM OUTPUT........................ 48
ENGINE SPEED SENSORÐPCM INPUT..... 46
EXHAUST GAS RECIRCULATION (EGR)
SOLENOIDÐPCM OUTPUT............. 50
FIVE VOLT POWERÐPCM OUTPUT........ 48
FUEL INJECTOR SENSORÐGROUND...... 46
FUEL TIMING SOLENOIDÐPCM OUTPUT.... 48
GLOW PLUG LAMPÐPCM OUTPUT........ 48
GLOW PLUG RELAYÐPCM OUTPUT....... 49
GLOW PLUGS......................... 49
IGNITION CIRCUIT SENSEÐPCM INPUT.... 45
NEEDLE MOVEMENT OR INSTRUMENTED
FIRST INJECTORÐPCM INPUT.......... 45
POWER GROUND...................... 45
POWERTRAIN CONTROL MODULE (PCM) . . . 44
SENSOR RETURNÐPCM INPUT (ANALOG
GROUND)........................... 45SIGNAL GROUNDÐPCM INPUT........... 45
SPEED CONTROLÐPCM INPUTS.......... 48
SPEED CONTROLÐPCM OUTPUTS........ 48
START SIGNALÐPCM INPUT............. 45
TACHOMETERÐPCM OUTPUT............ 49
VEHICLE SPEED SENSORÐPCM INPUT.... 47
VEHICLE THEFT ALARM................. 45
DIAGNOSIS AND TESTING
BOOST PRESSURE SENSOR............. 53
DIAGNOSTIC TROUBLE CODES........... 53
DIESEL DIAGNOSTICS.................. 50
DIESEL PCM RELAY TEST............... 50
ENGINE COOLANT TEMPERATURE
SENSOR TEST....................... 50
ENGINE SPEED SENSOR TEST........... 50
GLOW PLUG RELAY TEST............... 51
GLOW PLUG TEST..................... 51
RELAYSÐOPERATION/TESTING........... 52
VEHICLE SPEED SENSOR TEST........... 53
REMOVAL AND INSTALLATION
A/C CLUTCH RELAY.................... 53
DIESEL PCM RELAY.................... 53
ENGINE COOLANT TEMPERATURE
SENSOR............................ 54
ENGINE SPEED SENSOR................ 53
GLOW PLUG RELAY.................... 55
GLOW PLUGS......................... 54
POWERTRAIN CONTROL MODULE (PCM) . . . 55
VEHICLE SPEED SENSOR............... 55
SPECIFICATIONS
GLOW PLUG CURRENT DRAW............ 56
TORQUE CHARTÐ2.5L DIESEL............ 57
GENERAL INFORMATION
INTRODUCTION
This section will cover components either regulated
or controlled by the Powertrain Control Module
(PCM). The fuel heater relay, fuel heater and fuel
gauge are not operated by the PCM. These compo-
nents are controlled by the ignition (key) switch. All
other fuel system electrical components necessary to
operate the engine are controlled or regulated by the
PCM. Refer to the following PCM description for
more information.
Certain fuel system component failures may cause
a no start, or prevent the engine from running. It is
important to know that the PCM has a featurewhere, if possible, it will ignore the failed sensor, set
a code related to the sensor, and operate the engine
in a ªLimp Homeº mode. When the PCM is operating
in a ªLimp Homeº mode, the Diesel Glow Plug lamp
on the instrument panel will be constantly illumi-
nated, and the engine will most likely have a notice-
able loss of performance. An example of this would be
an Accelerator Pedal Position Sensor failure, and in
that situation, the engine would run at a constant
1100 RPM, regardless of the actual position of the
pedal. This is the most extreme of the three ªLimp
Homeº modes.
In addition to indicating that the glow plugs are
hot enough to start combustion, the Glow Plug Lamp
is also used in the diagnosis of the PCM, and when
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 43

(8) Disconnect electrical connector at transmission
range sensor.
(9) Remove upper bellhousing upper bolts.
(10) Remove heater tube mounting bolt.(11) Remove vehicle speed sensor wiring at sensor.
(12) Remove one rear engine mount bolt from top.
(13) Remove rear engine mount shield screw.
(14) Install engine support fixture and support
engine (Fig. 39).
(15) Raise vehicle. Remove front wheels. Refer to
Group 2, Suspension to remove wheel hub nuts and
both drive shafts.
CAUTION: The exhaust flex joint must be discon-
nected from the exhaust manifold anytime the
engine is lowered. If the engine is lowered while the
flex pipe is attached, damage will occur.
(16) Remove bolts securing exhaust flex joint to
exhaust manifold. Disconnect exhaust pipe from
manifold.
(17) Remove torque converter dust shield to gain
access to torque converter bolts (Fig. 40).
Fig. 36 Remove Cable From Bracket
Fig. 37 Input (Turbine) Speed Sensor
Fig. 38 Output Speed Sensor
Fig. 39 Engine Support Fixture
Fig. 40 Remove Torque Converter Dust Shield
21 - 90 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)

Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will not
always seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during highcrosswinds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
Wind noise can also be caused by improperly fitted
exterior moldings or body ornamentation. Loose
moldings can flutter, creating a buzzing or chattering
noise. An open cavity or protruding edge can create a
whistling or howling noise. Inspect the exterior of the
vehicle to verify that these conditions do not exist.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If component
alignment or sealing is necessary, refer to the appro-
priate section of this group for proper procedures.
ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehi-
cle. If noise goes away after a piece of tape is applied,
remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
²Moldings standing away from body surface can
catch wind and whistle.
²Gaps in sealed areas behind overhanging body
flanges can cause wind-rushing sounds.
²Misaligned movable components.
²Missing or improperly installed plugs in pillars.
²Weld burn through holes.
SERVICE PROCEDURES
HEAT STAKING
(1) Remove trim panel.
(2) Bend or move the trim panel components at
the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.
(3) Heat stake the components.
(a) If the heat staked or component seam loca-
tion is loose, hold the two components tightly
together and using a soldering gun with a flat tip,
melt the material securing the components
together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.
(b) If the heat staked material is broken or miss-
ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-
ing the glue. Once the new material is in place, it
23 - 24 BODYNS
DIAGNOSIS AND TESTING (Continued)

(6) Remove bolt attaching turning loop to exten-
sion bracket above quarter glass.
(7) Remove turning loop from extension bracket.
(8) Remove D-pillar trim panel.
(9) Remove quarter trim bolster.
(10) Remove quarter trim panel as necessary to
gain access to HVAC unit.
(11) Route seat belt webbing and turning loop
through access hole in quarter trim.
(12) Loosen HVAC unit enough to gain access to
seat belt retractor fasteners.
(a) Remove bracket around HVAC unit (Fig. 91).
(b) Remove air duct (Fig. 92).
(c) Remove fasteners holding HVAC unit to
inner quarter panel (Fig. 93).
(d) Remove screws attaching upper evaporator
housing to lower evaporator housing.
(e) Remove coolant line retaining bracket hold-
down bolt.
(13) Remove bolts attaching seat belt guide loop to
inner quarter panel.
(14) Pull outward on HVAC unit and remove bolt
holding retractor to inner quarter panel.
(15) Remove screw attaching retractor to inner
quarter panel.
(16) Remove second rear seat belt retractor from
vehicle.
INSTALLATION
(1) Position second rear seat belt retractor to vehi-
cle.
(2) I
nstall screw attaching retractor to inner
quarter panel.
(3) Pull outward on HVAC unit and install bolt
attaching retractor to inner quarter panel.
(4) Install bolts attaching seat belt guide loop to
inner quarter panel.
(5) Install coolant line retaining bracket holdown
bolt.(6) Install screws holding upper evaporator hous-
ing to lower evaporator housing.
(7) Install fasteners attaching HVAC unit to inner
quarter panel.
(8) Install air duct.
(9) Install bracket around HVAC unit.
(10) Route seat belt webbing and turning loop
through access hole in quarter trim.
(11) Install quarter trim panel as necessary to gain
access to HVAC unit.
(12) Install quarter trim bolster.
(13) Install D-pillar trim panel.
(14) Position turning loop to extension bracket.
(15) Install bolt attaching turning loop to exten-
sion bracket above quarter glass.
(16) Pull upper turning loop extension cover
upward over anchor bolt.
(17) Install lower anchor shoulder-nut.
(18) S
lide lower anchor cover over anchor shoulder-
nut.
(19) Install second rear seat from vehicle. Refer to
Owner's Manual for proper procedures.
Fig. 91 Trim Panel Mounting Bracket
Fig. 92 Lower Heater Duct
Fig. 93 Rear HVAC Mounting
NSBODY 23 - 63
REMOVAL AND INSTALLATION (Continued)