air condition CHRYSLER VOYAGER 2003 Service Manual
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Page 1721 of 2177
If a road tire is replaced by the spare, the TPM
system will detect the swap and the message9SPARE
TIRE IN USE? Y/N9(along with a chime) will be dis-
played.
For further information, refer to the Owners Man-
ual or the Appropriate Diagnostic Information.
TPM THRESHOLD PRESSURES
High Pressure ON Threshold 48 PSI (331 kPa)
High Pressure OFF Threshold 43 PSI (296 kPa)
Placard Pressure (Cold) 36 PSI (248 kPa)
Low Pressure OFF Threshold 33 PSI (228 kPa)
Low Pressure ON Threshold 28 PSI (193 kPa)
SENSOR - TPM
DESCRIPTION
On vehicles equipped with Tire Pressure Monitor-
ing, one tire pressure sensor is mounted to each
wheel (Fig. 19). Each sensor has an internal battery
that lasts up to 10 years. The battery is not service-
able. At the time of battery failure, the sensor must
be replaced. The serviceable components of the tire
pressure sensor are:
²Sensor-To-Wheel Grommet
²Valve Stem Cap
²Valve Stem Core
Valve stem caps and cores are specifically designed
for the tire pressure monitoring sensors. Although
similar to standard valve stem caps and cores, they
are different.
CAUTION: Do not use a standard valve stem cap or
core in a tire pressure sensor. Always use the orig-
inal equipment style sensor cap and core.
CAUTION: Do not reuse the Sensor-To Wheel Grom-
met. Always use a new grommet when installing a
pressure sensor and properly torque the sensor
nut.
CAUTION: Do not try to install a tire pressure sen-
sor in a steel wheel or aftermarket wheel. Use only
in original style factory wheels.
OPERATION
Tire pressure sensors are battery operated. They
transmit tire pressure data once every minute at
speeds above 20 mph (32 km/h) or up to once every
hour when stationary (parked). For additional infor-
mation, refer to Appropriate Diagnostic Information.
CAUTION
CAUTION: The use of tire sealants is strictly prohib-
ited for vehicles equipped with the Tire Pressure
Monitoring system. Tire sealants can clog tire pres-
sure sensors.
CAUTION: Tire pressure sensor valve stem caps
and cores are specially designed for the sensors.
Due to risk of corrosion, do not use a standard
valve stem cap or core in a tire pressure sensor in
place of the original equipment style sensor cap
and core.
CAUTION: Do not attempt to install a tire pressure
sensor in a steel wheel or aftermarket wheel. Use
tire pressure sensors in original style factory
wheels only.
NOTE: TPM thresholds have been established for
the original tire size equipped on the vehicle. Use
original size tires only to maintain system accuracy.
DIAGNOSIS AND TESTING - TIRE PRESSURE
SENSOR
NOTE: Tire pressure may increase from 2 to 6 psi
(14 to 41 kPa) during normal driving conditions. Do
NOT reduce this normal pressure build up.
If a fault in the system is detected, always check
air pressure in the tires first with a known accurate
air gauge and correct the inflation pressure. If any
tire is low, inspectalltires.
If gauge-read pressure in the tires does not reflect
the reading on the EVIC, retrain the sensors, then
reevaluate (Refer to 22 - TIRES/WHEELS/TIRE
PRESSURE MONITORING/SENSOR - STANDARD
PROCEDURE). Refer to the appropriate diagnostic
information for complete diagnosis of the Tire Pres-
sure Monitoring System.
STANDARD PROCEDURE - TIRE PRESSURE
SENSOR RETRAIN
WARNING: DEATH OR SERIOUS INJURY CAN
OCCUR IF MAGNETICALLY SENSITIVE DEVICES
ARE EXPOSED TO THE RELEARN MAGNET. MAG-
NETS CAN AFFECT PACEMAKERS.
22 - 10 TIRES/WHEELSRS
TIRE PRESSURE MONITORING (Continued)
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Page 1734 of 2177
BODY
TABLE OF CONTENTS
page page
BODY
DESCRIPTION - VEHICLE IDENTIFICATION....1
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 2
DIAGNOSIS AND TESTING - WIND NOISE . . . 3
STANDARD PROCEDURE
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR........................3
STANDARD PROCEDURE - HEAT STAKING . 10
SPECIFICATIONS
TORQUE............................11
BODY LUBRICATION...................12
SPECIAL TOOLS
BODY..............................13DOOR - FRONT.........................14
DOORS - SLIDING.......................24
DECKLID/HATCH/LIFTGATE/TAILGATE.......39
EXTERIOR.............................44
HOOD.................................59
INSTRUMENT PANEL.....................62
INTERIOR..............................72
PAINT.................................83
SEATS................................85
STATIONARY GLASS....................105
WEATHERSTRIP/SEALS..................110
SUNROOF.............................113
BODY STRUCTURE.....................121
BODY
DESCRIPTION - VEHICLE IDENTIFICATION
Throughout this group, references to the
DaimlerChrysler Corporation vehicle family identifi-
cation code are used when describing a procedure
that is unique to that vehicle. Refer to Introduction
Group of this manual for detailed information on
vehicle identification. If a procedure is common to all
vehicles covered in this manual, no reference will be
made to a vehicle family code.
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE A OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL ± BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE THATIS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use when
welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning solvents
on painted or upholstered surfaces. Damage to fin-
ish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
RSBODY23-1
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Page 1735 of 2177
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-cle. For hoisting recommendations (Refer to LUBRI-
CATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE).
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
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 vehicle
in a brightly lit area. From inside the darkened lug-
gage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage com-
partment. If light is visible through a normally sealed
location, water could enter through the opening.
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.
23 - 2 BODYRS
BODY (Continued)
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Page 1736 of 2177
DIAGNOSIS AND TESTING - 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 high
cross winds. 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.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
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.
STANDARD PROCEDURE
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR
There are many different types of plastics used in
today's automotive environment. We group plastics in
three different categories: Rigid, Semi-Rigid, and
Flexible. Any of these plastics may require the use of
an adhesion promoter for repair. These types of plas-
tic are used extensively on DaimlerChrysler Motors
vehicles. Always follow repair material manufactur-
er's plastic identification and repair procedures.
Rigid Plastics:
Examples of rigid plastic use: Fascias, Hoods,
Doors, and other Body Panels, which include SMC,
ABS, and Polycarbonates.
Semi-Rigid Plastics:
Examples of semi-rigid plastic use: Interior Panels,
Under Hood Panels, and other Body Trim Panels.
Flexible Plastics:
Examples of flexible plastic use: Fascias, Body
Moldings, and upper and lower Fascia Covers.
Repair Procedure:
The repair procedure for all three categories of
plastics is basically the same. The one difference is
the material used for the repair. The materials must
be specific for each substrate, rigid repair material
for rigid plastic repair, semi-rigid repair material for
semi-rigid plastic repair and flexible repair material
for flexible plastic repair.
Adhesion Promoter/Surface Modifier:
Adhesion Promoters/Surface Modifiers are required
for certain plastics. All three categories may have
plastics that require the use of adhesion promoter/
surface modifiers. Always follow repair material man-
ufacturer's plastic identification and repair
procedures.
SAFETY PRECAUTION AND WARNINGS
WARNING:
²EYE PROTECTION SHOULD BE USED WHEN
SERVICING COMPONENTS. PERSONAL INJURY
CAN RESULT.
²USE AN OSHA APPROVED BREATHING MASK
WHEN MIXING EPOXY, GRINDING, AND SPRAYING
PAINT OR SOLVENTS IN A CONFINED AREA. PER-
SONAL INJURY CAN RESULT.
²AVOID PROLONGED SKIN CONTACT WITH
RESIN, PETROLEUM, OR ALCOHOL BASED SOL-
VENTS. PERSONAL INJURY CAN RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT PROPERLY SUPPORTED ON
SAFETY STANDS. PERSONAL INJURY CAN
RESULT.
NOTE:
²When holes must be drilled or cut in body pan-
els, verify locations of internal body components
and electrical wiring. Damage to vehicle can result.
²Do not use abrasive chemicals or compounds
on undamaged painted surfaces around repair
areas. Damage to finish can result.
RSBODY23-3
BODY (Continued)
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Page 1789 of 2177
INSTALLATION
NOTE: The crossbar assemblies are designed to be
installed in only one way. Check top and bottom
surfaces of the crossbar for the word FRONT and
directional arrows. The directional arrows must
point toward the front of the vehicle.
(1) Place crossbar in position on vehicle.
(2) Work from side to side sliding the crossbar
assembly back a little at a time to ensure it remains
perpendicular to the side rails.
(3) Position first crossbar assembly crossbar at the
second most rearward locator holes. Press the top of
the stanchion lever to lock it into position.
(4) Position the second crossbar assembly in the
second hole from the front. Lock into place.
(5) Place luggage rack riser into position.
(6) Install two fasteners into riser. Tighten fasten-
ers to 4 mm (35 in. lbs.) torque.
REAR QUARTER PANEL/
FENDER AIR EXHAUSTER
DESCRIPTION
Air exhausters, designed to conform to the body
structure, allow air entering at the front of the vehi-
cle to flow out the back. By reducing air pressure
within the vehicle, the exhausters also reduce blower
noise at any given air flow level compared to operat-
ing without them and help reduce door closing effort.
They are located in the lower rear comers of the
body.
REMOVAL
SHORT WHEELBASE
(1) Remove the rear fascia from the body. (Refer to
13 - FRAMES & BUMPERS/BUMPERS/REAR FAS-
CIA - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 19).
(3) Remove the air exhauster from the hole in the
lower aperture panel.
LONG WHEELBASE
NOTE: Models with the optional rear heater and air
conditioner do not have an air exhauster on the
right side of the vehicle, but have a plastic plug
installed in the right lower aperture panel. This plug
is removed using the same procedure used toremove the air exhauster from the short wheelbase
model. Refer to SHORT WHEELBASE.
(1) Remove the quarter trim panel from the inside
of the left or right quarter inner panel (Refer to 23 -
BODY/INTERIOR/RIGHT QUARTER TRIM PANEL
- REMOVAL) or (Refer to 23 - BODY/INTERIOR/
LEFT QUARTER TRIM PANEL - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 20).
(1) Remove the air exhauster from the hole in the
lower aperture panel.
Fig. 19 AIR EXHAUSTER - SWB
1 - LOWER APERTURE PANEL
2 - AIR EXHAUSTER
Fig. 20 AIR EXHAUSTER - LWB
1 - AIR EXHAUSTER
2 - PLUG
3 - LOWER APERTURE PANEL
23 - 56 EXTERIORRS
LUGGAGE RACK CROSSBAR (Continued)
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Page 1790 of 2177
INSTALLATION
SHORT WHEELBASE
(1) Position the air exhauster to the hole in the
lower aperture panel (Fig. 19).
(2) Using hand pressure, press the air exhauster
into the opening in the lower aperture panel until
the snap features are fully engaged.
(3) Reinstall the rear fascia onto the body. (Refer
to 13 - FRAMES & BUMPERS/BUMPERS/REAR
FASCIA - INSTALLATION).
LONG WHEELBASE
NOTE: Models with the optional rear heater and air
conditioner do not have an air exhauster on the
right side of the vehicle, but have a plastic plug
installed in the right lower aperture panel. This plug
is installed using the same procedure used to
install the air exhauster onto the short wheelbase
model. Refer to SHORT WHEELBASE.
(1) Position the air exhauster to the hole in the
lower aperture panel (Fig. 20).
(2) Using hand pressure, press the air exhauster
into the opening in the lower aperture panel until
the snap features are fully engaged.
(3) Reinstall the quarter trim panel onto the inside
of the left or right quarter inner panel. (Refer to 23 -
BODY/INTERIOR/RIGHT QUARTER TRIM PANEL
- INSTALLATION) or (Refer to 23 - BODY/INTERI-
OR/LEFT QUARTER TRIM PANEL - INSTALLA-
TION).
ROOF JOINT MOLDING
REMOVAL
The RAP molding is set with body side molding
tape. The temperature in the work area and the vehi-
cle should be at least 21É C (70É F) to avoid damag-
ing the RAP moldings.
(1) Warm the affected stick-on molding and body
metal to approximately 38É C (100É F) using a suit-
able heat lamp or heat gun.
(2) Pull stick-on molding from painted surface.
(3) Remove adhesive tape residue from painted
surface of vehicle. Use a 3M Scotch-BriteŸ Molding
Adhesive and Stripe Removal Discs, or equivalent, to
clean adhesive residue from painted surfaces. The
adhesive removal discs are available from automotive
paint suppliers. Refer to instructions supplied with
the discs for proper usage.
INSTALLATION
The RAP molding is set with body side molding
tape. The temperature in the work area and the vehi-
cle should be at least 21É C (70É F) to avoid damag-
ing the RAP moldings.
(1) If molding is to be reused;
(a) Remove tape residue from molding.
(b) Clean back of molding with MopartSuper
Kleen solvent, or equivalent.
(c) Wipe molding dry with lint free cloth.
(d) Apply new body side molding (two sided
adhesive) tape to back of molding.
(2) Clean body surface with MopartSuper Kleen
solvent, or equivalent. Wipe surface dry with lint free
cloth.
(3) Remove protective cover from tape on back of
molding.
(4) Apply molding to body from front of vehicle to
rear.
(5) Using a roller tool, roll molding onto body
panel with enough force to assure adhesion and not
bend roof panels.
SIDE VIEW MIRROR
REMOVAL
(1) Using a trim stick C-4755 or equivalent, lift up
the end of the instrument panel top pad enough to
gain access to the mirror electrical connector, if
equipped. (Refer to 23 - BODY/INSTRUMENT PAN-
EL/INSTRUMENT PANEL TOP COVER -
REMOVAL)
(2) Disconnect the electrical connector, if equipped.
(3) Using a trim stick or equivalent, remove the
trim cover (Fig. 21).
(4) Remove the bolts.
(5) Remove the mirror from the pillar.
INSTALLATION
(1) Route the mirror wire harness, if equipped,
through the a-pillar and place side view mirror in
position on vehicle (Fig. 21).
(2) Install the bolts and tighten to 10 N´m (85 in.
lbs.).
(3) Install the mirror trim cover.
(4) Connect the electrical connector, if equipped.
(5) Install the instrument panel top cover, if
equipped with the electric mirror. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION)
RSEXTERIOR23-57
REAR QUARTER PANEL/FENDER AIR EXHAUSTER (Continued)
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Page 1811 of 2177
(2) Engage hook retainer attaching front of trim
bolster to quarter trim panel, if applicable.
(3) Engage hidden clips attaching trim bolster to
quarter trim panel.
RIGHT QUARTER TRIM PANEL
REMOVAL
CAUTION: Disconnect the battery negative cable.
Damage to accessory feed circuit can result.
(1) Remove first row seat.
(2) Remove second row seat.
(3) Remove sliding door sill trim panel.
(4) Remove quarter trim bolster.
(5) Remove D-pillar trim panel.
(6) Remove first row seat belt anchor.
(7) Remove second row seat belt anchor.
(8) Remove screws attaching quarter trim to quar-
ter panel from bolster area.
(9) Remove screws attaching rear edge of quarter
trim to attaching bracket.
(10) Disengage hidden clips attaching front of
quarter trim to quarter panel rearward of sliding
door opening and at locators.
(11) Remove quarter trim from quarter panel.
(12) Disconnect speaker wire connector on LWB
quarter trim panel with rear air conditioning.
(13) Pass second row seat belt through slot in trim
panel on long wheel base vehicle.
(14) Pass first row seat belt through slot in trim
panel.
(15) Remove quarter trim panel from vehicle.
INSTALLATION
(1) Position quarter trim panel on vehicle.
(2) Pass first row seat belt through slot in trim
panel.
(3) Pass second row seat belt through access hole
in trim panel on long wheel base vehicle.
(4) Connect wire connector into speaker on LWB
with rear air conditioning.
(5) Align locating pins on backside of trim panel to
mating holes in inner quarter panel.
(6) Engage hidden clips attaching front of quarter
trim to quarter panel rearward of sliding door open-
ing and at locators.
(7) Install screws attaching rear edge of quarter
trim to attaching bracket.
(8) Install screws attaching quarter trim to inner
quarter panel in bolster area.
(9) Install second row seat belt anchor on long
wheel base vehicle. Tighten all seat belt bolts to 39
N´m (29 ft. lbs.) torque.
(10) Install first row seat belt anchor.(11) Install D-pillar trim panel.
(12) Install C-pillar trim panel.
(13) Install quarter trim bolster.
(14) Install sliding door sill trim panel.
(15) Install second row seat, if equipped.
(16) Install first row seat.
(17) Connect the battery negative cable.
LEFT QUARTER TRIM PANEL
REMOVAL
CAUTION: Disconnect the negative cable clamp
from battery post. Damage to accessory feed circuit
can result.
(1) Remove first row seat.
(2) Remove second row seat, if equipped.
(3) Remove front door sill plate on three door vehi-
cle.
(4) Remove sliding door sill plate on four door
vehicle.
(5) Remove left quarter trim bolster.
(6) Remove C-pillar trim panel.
(7) Remove left D-pillar trim panel.
(8) Remove first row seat belt anchor.
(9) Remove second row seat belt anchor on long
wheel base vehicle.
(10) Remove screws attaching quarter trim to
quarter panel from bolster area.
(11) Remove screws attaching rear edge of quarter
trim to attaching bracket or inner quarter trim
panel.
(12) Disconnect wire connector from accessory
power outlet, if equipped.
(13) Remove quarter trim from quarter panel.
(14) Pass front seat belt and turning loop through
slot in quarter trim panel on three door vehicle.
(15) Pass first row seat belt through slot in quar-
ter trim panel.
(16) Pass second row seat belt, if equipped,
through slot in quarter trim panel on long wheel
base vehicle.
(17) Remove quarter trim panel from vehicle.
INSTALLATION
(1) Position quarter trim panel on vehicle.
(2) Pass second row seat belt, if equipped, through
slot in quarter trim panel on long wheel base vehicle.
(3) Pass first row seat belt through slot in quarter
trim panel.
(4) Connect wire connector into accessory power
outlet, if equipped.
(5) Align locating pins on backside of trim panel to
mating holes in inner panels.
23 - 78 INTERIORRS
QUARTER TRIM BOLSTER (Continued)
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Page 1998 of 2177
HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - SINGLE ZONE...........1
DESCRIPTION - DUAL ZONE.............1
DESCRIPTION - MANUAL THREE ZONE.....1
DESCRIPTION - AUTOMATIC
TEMPERATURE CONTROL...............2
OPERATION
OPERATION - DUAL ZONE...............3
OPERATION - MANUAL THREE ZONE......3
OPERATION - THREE ZONE ATC..........3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C COOL
DOWN TEST..........................4DIAGNOSIS AND TESTING - A/C
PERFORMANCE TEST..................5
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST..................6
SPECIFICATIONS - HEATER-A/C SYSTEM.....7
CONTROLS - FRONT......................8
CONTROLS - REAR......................29
DISTRIBUTION - FRONT...................39
DISTRIBUTION - REAR....................52
PLUMBING - FRONT.....................60
PLUMBING - REAR......................94
DIESEL SUPPLEMENTAL HEATER - DCHA -
EXPORT..............................106
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - SINGLE ZONE
A single zone heating and air conditioning system
allows one temperature setting for the entire vehicle.
The full range of temperatures that the system can
produce are available by rotating the temperature
control located in control panel.
The control panel and integral computer is
mounted in the instrument panel.
DESCRIPTION - DUAL ZONE
A manual Dual Zone Heating and Air Conditioning
system allows completely independent side-to-side
tempeture control of the discharge air.
The control panel and integral computer is located
in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²a power button which allows the system to be
completely turned off. Contains an LED that illumi-
nates to show when the function is operational.
²rear window defogger on/off switch. Contains an
LED that illuminates to show when the function is
operational.
²slide controls for completely independent side-to-
side temperature control of the discharged air. The
full range of temperature that the system can pro-
duce in any mode is available on either side of thevehicle by independently positioning the slide con-
trols on the instrument panel.
²air recirculation on/off switch. The Recirculate
button contains an LED that illuminates to show
when the function is in operation.
²air conditioning on/off switch. The Snowflake
button contains an LED that illuminates to shown
when the function is in operation.
²rotary knob for fan speed selection.
²a rotary knob for mode control.
DESCRIPTION - MANUAL THREE ZONE
The fully adjustable Three-Zone front and rear
heating and air conditioning system allows interme-
diate seat passengers the ability to regulate air tem-
perature as well as fan speed. All controls are
identified by ISO graphic symbols.
FRONT CONTROL PANEL
The front control panel and integral computer is
mounted in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²a power button which allows the system to be
completely turned off.
²rear window defogger on/off switch.
²slide controls for completely independent side-to-
side temperature control of the discharge air. The full
range of temperature that the system can produce in
any mode is available on either side of the vehicle by
independently positioning the slide controls on the
instrument panel.
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²air recirculation button. The Recirculate button
contains an LED that illuminates to show when the
function is in operation.
²an air conditioning button that allows the com-
pressor to be turned on/off. The Snowflake button
contains an LED that illuminates to shown when the
function is in operation.
²rotary knobs for front and rear fan speed selec-
tion.
²a rotary knob for mode control.
REAR CONTROL PANEL
A rear control panel centrally mounted on the
headliner has a rotary adjustment for temperature
and fan speed control of the rear unit by intermedi-
ate seat passengers when the front control rear knob
is set to the rear position.
DESCRIPTION - AUTOMATIC TEMPERATURE
CONTROL
The Automatic Temperature Control (ATC) allows
occupants to select a comfort temperature, which is
the perceived temperature level not the actual pas-
senger compartment air temperature.
The Automatic Temperature Control system
includes a dust and odor air filter. The filter element
is the same size as the air conditioning evaporator to
ensure ample capacity. A door at the base of the
heater and air conditioning housing below the glove
box provides easy access to the filter element.
The ATC computer utilizes integrated circuitry and
information carried on the Programmable Communi-
cations Interface (PCI) data bus network to monitor
many sensors and switch inputs throughout the vehi-
cle. In response to those inputs, the internal circuitry
and programming of the ATC computer allow it to
control electronic functions and features of the ATC
system. The inputs to the ATC computer are:
²Vehicle Speed/Engine RPM± The ATC com-
puter monitors engine RPM, vehicle speed and Man-
ifold Absolute Pressure information from the PCM.
²Coolant Temperature± ATC computer moni-
tors Coolant temperature received from the PCM and
converts it to degrees Fahrenheit.
²Ambient Temperature± ATC computer moni-
tors Ambient temperature from the Compass Mini
Trip Computer (CMTC) and converts it to degrees
Fahrenheit.
²Engine Miscellaneous Sensor Status±ATC
computer monitors A/C disable information from the
PCM.
²Refrigerant Pressure± ATC computer moni-
tors Barometric Pressure, Intake Air Temperature,
High Side Pressure and Methanol Content as broad-
cast by the PCM.²Door Ajar Status± The ATC computer moni-
tors Driver Front Door, Passenger Front Door, Left
Rear Door, Right Rear Door and Liftgate ajar infor-
mation, as identified by the Body Control Module
(BCM), to determine if all in-car temperatures should
be maintained.
²Dimming± The ATC computer monitors dim-
ming status from the BCM to determine the required
level of brightness and will dim accordingly.
²Vehicle Odometer± The ATC computer moni-
tors the vehicle odometer information from the BCM
to prevent flashing the VF tube icons if the manual
motor calibration or manual cool down tests have
failed. Flashing of the display icons will cease when
the vehicle odometer is greater than 3 miles.
²English/Metric± The ATC computer monitors
the English/Metric information broadcast by the
CMTC. The set temp displays for both the front and
rear control heads will be set accordingly.
²Vehicle Identification Number± The ATC
computer monitors the last eight characters of the
VIN broadcast by the PCM and compares it to the
information stored in EEPROM. If it is different, the
new number will be stored over the old one and a
motor calibration shall be initiated.
²A/C System Information± The ATC computer
will send a message for Evaporator Temperature too
Low, Fan Blower Relay status, Evaporator Sensor
Failure, Rear Window Defogger Relay and A/C Select.
FRONT CONTROL PANEL
The front control panel and integral computer is
mounted in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²A power button which allows the system to be
completely turned off. The display is blank when the
system is off.
²Three rocker switches that select comfort tem-
peratures from 15É to 30É C (59É to 85É F), which are
shown in the vacuum-fluorescent digital control dis-
play. If the set temp is 59 and the down button is
pressed, the set temp value will become 55 but the
display will show LO. If the set temp is 85 and the
up button is pressed, the set temp value will become
90 but the display will show HIGH. Temperatures
can be displayed in either metric or Fahrenheit,
which is controlled from the overhead console.
²A rocker switch that selects a cool-down rate.
LO-AUTO or HI-AUTO are displayed when the sys-
tem is in automatic operation.
²A defroster button which turns on the defroster
independently during full automatic control. A
defroster symbol illuminates in the display when the
button is pressed.
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²Air recirculation button. A Recirculation symbol
appears in the display when the button is pressed, or
when the system exceeds 80 percent circulated air
under automatic control due to high air conditioning
demand.
²Rear window defogger on/off switch. A graphic
symbol shows when the defroster is on.
²An air conditioning button that allows the com-
pressor to be turned off. A Snowflake symbol is illu-
minated when air conditioning is on, whether under
manual or automatic control.
²Rotary knob for front fan speed selection can
override the automatic controls. LEDs surrounding
the knob show the current setting.
²Rotary knob for control of the Rear system.
²A rotary knob for mode control can override the
automatic controls. LEDs surrounding the knob show
the current setting.
²Computer logic remembers the settings of the
controls when the ignition is turned off and retains
those settings after a restart. If the system is off
when the ignition is turned off it will be off when the
engine is restarted, etc.
²Computer logic provides variable air recircula-
tion under high temperature and humidity condi-
tions. Because recirculation is generally accompanied
by increased fan noise, the proportion of recirculated
to outside air gradually approaches full recirculation
over a broad temperature range.
²Computer logic enables additional heat for diesel
equipped vehicles via a supplemental diesel heater.
REAR CONTROL PANEL
A rear control panel centrally mounted on the
headliner includes a vacuum-flourescent digital dis-
play, a rocker control for temperature and rotary con-
trols for adjustment of mode and fan speed control of
the rear unit by intermediate seat passengers.
OPERATION
OPERATION - DUAL ZONE
²The mode control knob enables continously vari-
able proportioning of air flow between modes but has
detents adjacent to each icon.
²The blower control provides five separate speeds.
²When the fan is off, the HVAC computer closes
the recirculation door to prevent outside air from
entering the passenger compartment.
²Interior air may be recirculated to speed up
heating or cooling in all modes except defrost and
mix by pressing the Recirculate button on the control
panel.
²To reduce humidity for rapid defogging the A/C
compressor runs automatically in modes from ªmix'to full defrost when outside temperatures are above
freezing.
²Air conditioning is available in any mode by
pressing the snowflake, A/C on/off, button.
OPERATION - MANUAL THREE ZONE
FRONT CONTROL PANEL
²Primary control of the rear compartment unit is
on the instrument panel. This control allows the
driver to set the rear compartment fan speed, to turn
the rear unit off, or to give control to the intermedi-
ate seat occupants by switching to the REAR posi-
tion. When the rear unit is controlled from the
instrument panel, rear air temperature is based on
the driver-side temperature control position, and the
mode (floor or overhead air) is based on the front
control's mode position.
²The mode control knob enables continously vari-
able proportioning of air flow between modes but has
detents adjacent to each icon.
²The blower control provides five separate speeds
and Off. When the fan is off, the HVAC computer
closes the recirculation door to prevent outside air
from entering the passenger compartment.
²Interior air may be recirculated to speed up
heating or cooling in all modes exccept defrost and
mix by pressing the Recirculate button on the control
panel.
²To reduce humidity for rapid defogging the A/C
compressor runs automatically in modes from ªmix'
to full defrost when outside temperatures are above
freezing.
²Air conditioning is available in any mode by
pressing the snowflake, A/C on/off, button.
REAR CONTROL PANEL
With the rear control active, temperature selection
dictates indirectly the mode (floor or overhead air) of
the rear unit: a low temperature setting directs flow
to the overhead outlets and a high temperature set-
ting to the floor.
OPERATION - THREE ZONE ATC
Comfort temperature or perceived temperature is
affected by air flow, sun impinging on exposed skin,
etc. The air temperature may be higher or lower than
the comfort temperature. Two infrared sensors, in the
instrument panel center stack i measure the temper-
ature of the occupants to determine their comfort
level relative to the selected comfort temperature.
The HVAC computer in the control module adjusts
the air flow rate and temperature to maintain the
customer-perceived comfort temperature. The air
temperature in the passenger compartment at any
time may be slightly higher or lower than the com-
RSHEATING & AIR CONDITIONING24-3
HEATING & AIR CONDITIONING (Continued)
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