electric CHRYSLER VOYAGER 2003 Service Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2003, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2003Pages: 2177, PDF Size: 59.81 MB
Page 513 of 2177
(3) Reconnect the power seat wire harness connec-
tor to the power seat switch connector receptacle.
(4) Position the outboard seat cushion side shield
onto the seat cushion frame
(5) Install and tighten the screws that secure the
outboard seat cushion side shield to the seat cushion
frame. Tighten the screws to 1.5 N´m (14 in. lbs.).
(6) Install the switch knobs on the switch control
levers, if equipped.
(7) Reconnect the battery negative cable.
DRIVER POWER SEAT TRACK
DESCRIPTION
The eight-way driver side power seat option
includes a electrically operated power seat track
located under the driver side front seat. The front
power seat track on the driver side of the vehicle also
provides the mounting location for the Memory Seat/
Mirror Module (MSMM). The power seat circuit
breakers are mounted on the rear of the driver side
power seat track, just behind the seat rear trim
panel. The lower half of the power seat track is
secured to the floor panel via four studs and nuts
that must be accessed from the underside of the vehi-
cle. Four bolts secure the bottom of the seat cushion
pan to the upper half of the power seat track unit.
Four additional bolts secure the seat back frame to
the power seat track unit.
The power seat track unit includes four reversible
electric motors that are secured to the upper half of
the track unit. Each motor moves the seat adjuster
through a combination of worm-drive gearboxes and
screw-type drive units. Each of the four power seat
track motors used on models equipped with the
optional memory system incorporates a position
potentiometer integral to the motor assembly, which
electronically monitors the motor position. This
enables the memory system to function by referenc-
ing the motor positions programmed into the memory
seat/mirror module.
The front and rear of the seat are operated by two
separate vertical adjustment motors. These motors
can be operated independently of each other, tilting
the entire seat assembly forward or rearward; or,
they can be operated in unison by selecting the
proper power seat switch functions, which will raise
or lower the entire seat assembly. A third motor is
the horizontal adjustment motor, which moves the
seat track in the forward and rearward directions.
The forth motor is the recliner adjustment motor,
which moves the seat back in the forward and rear-
ward directions.
The power seat track unit cannot be repaired, and
is serviced only as a complete unit. If any componentin this unit is faulty or damaged, the entire power
seat track unit must be replaced.
OPERATION
When the driver side power seat switch control
knob or knobs are actuated, a battery feed and a
ground path are applied through the switch contacts
to the power seat track or recliner adjuster motor.
The selected adjuster motor operates to move the
seat track or recliner through its drive unit in the
selected direction until the switch is released, or
until the travel limit of the adjuster is reached.
When the switch is moved in the opposite direction,
the battery feed and ground path to the motor are
reversed through the switch contacts. This causes the
adjuster motor to run in the opposite direction.
No power seat switch should be held applied in any
direction after the adjuster has reached its travel
limit. The power seat adjuster motors each contain a
self-resetting circuit breaker to protect them from
overload. However, consecutive or frequent resetting
of the circuit breaker must not be allowed to con-
tinue, or the motor may be damaged.
See the owner's manual in the vehicle glove box for
more information on the power seat switch functions
and the seat adjusting procedures.
DIAGNOSIS AND TESTING - DRIVER POWER
SEAT TRACK
WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
UTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
Actuate the driver side power seat switch to move
all three power seat track adjusters in each direction.
The power seat track adjusters should move in each
of the selected directions. If a power seat track
adjuster fails to operate in only one direction, move
the adjuster a short distance in the opposite direction
and test again to be certain that the adjuster is not
at its travel limit. If the power seat track adjuster
still fails to operate in only one direction, refer to
Diagnosis and Testing Power Seat Switchin this
section. If the power seat track adjuster fails to oper-
ate in more than one direction, perform the following
tests. For complete circuit diagrams, refer toWiring
Diagrams.
8N - 58 POWER SEAT SYSTEMRS
PASSENGER SEAT SWITCH (Continued)
ProCarManuals.com
Page 514 of 2177
TESTING POWER SEAT TRACK MOTORS
(1) Check the power seat circuit breaker under the
seat. If OK, go to Step 2. If not OK, replace the
faulty power seat circuit breaker.
(2) Check for battery voltage at the power seat cir-
cuit breaker under the seat. If OK, go to Step 3. If
not OK, repair the open fused B(+) circuit to the fuse
in the Intelligent Power Module as required.
(3) Remove the outboard seat cushion side shield
from the seat. Disconnect the seat wire harness con-
nector from the power seat switch connector recepta-
cle. Check for battery voltage at the fused B(+)
circuit cavity of the power seat wire harness connec-
tor for the power seat switch. If OK, go to Step 4. If
not OK, repair the open fused B(+) circuit to the
power seat circuit breaker under the seat as
required.
(4) Check for continuity between the ground cir-
cuit cavity of the power seat wire harness connector
for the power seat switch and a good ground. There
should be continuity. If OK, go to Step 5. If not OK,
repair the open ground circuit to ground as required.
(5) Test the power seat switch. Refer toDiagnosis
and Testing Power Seat Switchin this section. If
the switch tests OK, test the circuits of the power
seat wire harness between the inoperative power seat
track adjuster motor and the power seat switch for
shorts or opens. If the circuits check OK, replace the
faulty power seat track unit. If the circuits are not
OK, repair the power seat wire harness as required.
REMOVAL
WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
UTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Remove the appropriate seat from the vehicle
and place it on a clean work surface(Refer to 23 -
BODY/SEATS/SEAT - REMOVAL).
(2) If the vehicle is so equipped, remove the Mem-
ory Seat/Mirror Module (MSMM) retaining screws.
(3) If the vehicle is so equipped, disconnect the
MSMM electrical connectors and remove the MSMM
from the power seat track.
(4) Remove the rear fabric blocker trim panel from
the rear of the front seat.(5) Remove the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION SIDE COVERS - REMOVAL).
(6) Disconnect all electrical connectors connecting
the power seat track to the seat assembly.
(7) Pull the seat back trim cover up slightly to
access and remove the two seat back frame mounting
bolts and also remove two seat back recliner bolts.
(8) Remove four seat track mounting bolts from
the seat cushion pan.
(9) Remove the power seat track from the seat.
INSTALLATION
(1) Position the seat cushion on the seat track.
(2) Install the four seat track retaining bolts in the
seat cushion pan. Torque the bolts to 28.5 N´m.
(3) Position the seat back and install the two seat
back frame mounting bolts and the two seat back
recliner bolts. Torque the bolts to 55 N´m.
(4) Route and connect the electrical connectors
between the power seat track and the seat assembly.
(5) Install the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION SIDE COVERS - INSTALLATION).
(6) Install the rear fabric blocker trim panel on the
rear of the front seat.
(7) If the vehicle is so equipped, position the Mem-
ory Seat/Mirror Module (MSMM) and connect the
MSMM electrical connectors.
(8) Install the MSMM retaining screws.
(9) Install the seat assembly in the vehicle (Refer
to 23 - BODY/SEATS/SEAT - INSTALLATION).
PASSENGER POWER SEAT
TRACK
DESCRIPTION
The four-way passenger side power seat option
includes a electrically operated power seat track unit
located under the passenger side front seat. The
power seat circuit breaker is mounted on the rear of
the power seat track, just behind the seat rear trim
panel. The lower half of the power seat track is
secured to the floor panel via four studs and nuts
that must be accessed from the underside of the vehi-
cle. Four bolts secure the bottom of the seat cushion
frame to the upper half of the power seat track unit.
Four additional bolts secure the seat back frame to
the power seat track unit.
The passenger side power seat track unit includes
two reversible electric motors that are secured to the
upper half of the track unit. Each motor moves the
seat adjuster through a combination of worm-drive
gearboxes and screw-type drive units. The horizontal
adjustment motor moves the seat track in the for-
RSPOWER SEAT SYSTEM8N-59
DRIVER POWER SEAT TRACK (Continued)
ProCarManuals.com
Page 516 of 2177
REMOVAL
WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
UTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Remove the appropriate seat from the vehicle
(Refer to 23 - BODY/SEATS/SEAT - REMOVAL).
(2) Remove the rear fabric blocker trim panel from
the rear of the front seat.
(3) Remove the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION SIDE COVERS - REMOVAL).
(4) Disconnect all electrical connectors connecting
the power seat track to the seat assembly.(5) Pull the seat back trim cover up slightly to
access and remove the two seat back frame mounting
bolts and seat back recliner bolts.
(6) Remove four seat track mounting bolts from
the seat cushion pan.
(7) Remove the power seat track from the seat.
INSTALLATION
(1) Position the seat cushion on the seat track.
(2) Install the four seat track retaining bolts in the
seat cushion pan. Torque the bolts to 28.5 N´m.
(3) Position the seat back and install the two seat
back frame mounting bolts and the two seat back
recliner bolts. Torque the bolts to 55 N´m.
(4) Route and connect the electrical connectors
between the power seat track and the seat assembly.
(5) Install the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION - INSTALLATION).
(6) Install the rear fabric blocker trim panel on the
rear of the front seat.
(7) Install the seat assembly in the vehicle (Refer
to 23 - BODY/SEATS/SEAT - INSTALLATION).
RSPOWER SEAT SYSTEM8N-61
PASSENGER POWER SEAT TRACK (Continued)
ProCarManuals.com
Page 518 of 2177
WIRING VOLTAGE TEST
The following wiring test determines whether or
not voltage is continuous through the body harness
to switch.
(1) Remove the power window switch and bezel
assembly from the driver door. (Refer to 8 - ELEC-
TRICAL/POWER WINDOWS/POWER WINDOW
SWITCH - REMOVAL).
(2) Disconnect wire connector from back of power
window switch.
(3) Switch ignition ON position.
(4) Connect the clip end of a 12 volt test light to
Pin 13 in door harness connector at the window
switch. Touch the test light probe to Pin 9 and then
to Pin 11.
²If the test light illuminates, the wiring circuit
between the battery and switch is OK.
²If the lamp does not illuminate, first check the
25 amp circuit breaker attached to the electrical dis-
tribution wiring bracket. If the circuit breaker is OK,
then check the 40 amp fuse (#28) in the Integrated
Power Module (IPM). If both components are OK,
then check for a broken wire.
²Refer to the appropriate wiring information.
The wiring information includes wiring diagrams,
proper wire and connector repair procedures, details
of wire harness routing and retention, connector pin-
out information and location views for the various
wire harness connectors, splices and grounds.
VENT WINDOW MOTOR
DIAGNOSIS AND TESTING - VENT WINDOW
MOTOR
If the power vent window motor is receiving proper
current and ground and does not operate proceed
with motor test. Refer to the appropriate wiring
information. The wiring information includes wiring
diagrams, proper wire and connector repair proce-
dures, details of wire harness routing and retention,
connector pin-out information and location views for
the various wire harness connectors, splices and
grounds.
(1) Remove D-pillar trim panel necessary to gain
access to power vent window motor wire connector,
(Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR
TRIM PANEL - REMOVAL) or (Refer to 23 - BODY/
INTERIOR/RIGHT D-PILLAR TRIM PANEL -
REMOVAL).
(2) Disconnect power vent window motor wire con-
nector from body harness.
(3) Using two jumper wires, connect one to a bat-
tery (+) source and the other to a good ground (-).
(4) Connect the Negative (-) jumper probe to one of
the motor connector terminals.(5) Momentarily touch the Positive (+) jumper
probe to the other motor connector terminal.
When positive probe is connected the motor should
rotate in one direction to either move window open or
closed. If window is all the way open or closed the
motor will grunt and the crank system will flex when
actuated in that one direction.
Reverse jumper probes at the motor connector ter-
minals and window should now move in opposite
direction. If window does not move or grunt, replace
the motor.
If window moved completely open or closed, reverse
the jumper probes and cycle window to the opposite
position to verify full operation.
If motor grunts and does not move, verify that
crank system is not binding.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove D-pillar trim panel. (Refer to 23 -
BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL -
REMOVAL) or (Refer to 23 - BODY/INTERIOR/
RIGHT D-PILLAR TRIM PANEL - REMOVAL).
(3) Disconnect wire connector from power vent
motor.
(4) Using a flat bladed tool, carefully lift the circu-
lar actuator link tab. Remove link from window ball
socket.
(5) Remove bolts holding power vent motor to
D-pillar (Fig. 1).
(6) Remove power vent motor.
Fig. 1 VENT WINDOW MOTOR
1 - VENT WINDOW MOTOR
2 - WIRE HARNESS CONNECTOR
3 - BOLT
4 - VENT WINDOW
RSPOWER WINDOWS8N-63
POWER WINDOWS (Continued)
ProCarManuals.com
Page 519 of 2177
INSTALLATION
(1) Obtain new vent window motor.
(2) Snap the actuator link socket onto the quarter
window ball socket. Using a soft rubber mallet, push
the circular link tab flush with link surface.
(3) Install bolts holding power vent motor to D-pil-
lar.
(4) Reconnect wire connector to power vent motor.
(5) Reconnect the battery negative cable.
(6) Cycle quarter window open/close to verify func-
tion.
(7) Install D-pillar trim panel.
WINDOW MOTOR
REMOVAL
The window motor is incorporated into the window
regulator assembly. If the window motor requires
replacement, the window regulator must be replaced.
(Refer to 23 - BODY/DOOR - FRONT/WINDOW
REGULATOR - REMOVAL).
WINDOW SWITCH
DIAGNOSIS AND TESTING - WINDOW SWITCH
(1) Remove the desired switch to be tested from
the door trim panel. Driver's side (master) or passen-
ger side. (Refer to 8 - ELECTRICAL/POWER WIN-
DOWS/POWER WINDOW SWITCH - REMOVAL).
(2) Using an ohmmeter, Test driver door switch for
continuity as described in (Fig. 2).
POWER WINDOW MASTER SWITCH TEST
SWITCH POSITION CONTINUITY BETWEEN
OFF 13 and 1
13 and 2
13 and 3
13 and 4
13 and 5
13 and 6
13 and 7
13 and 8
SWITCH POSITION CONTINUITY BETWEEN
UP DRIVER 11 and 8
*DOWN DRIVER 11 and 6
*X DOWN DRIVER 11and 6
UP PASSENGER 9 and 4
DOWN PASSENGER 9 and 2
LEFT VENT OPEN 11 and 7
LEFT VENT CLOSE 9 and 3
RIGHT VENT OPEN 9 and 1
RIGHT VENT CLOSE 11 and 5
* MUST TEST WITH B+ ON PIN 9 AND
GROUND ON PIN 13 FOR CONTINUITY
BETWEEN PINS 11 AND 6
(3) If the result are not OK, replace the driver side
window lift switch.
(4) Test passenger door switch for continuity as
described in (Fig. 3).
PASSENGER WINDOW SWITCH TEST
SWITCH POSITION CONTINUITY BETWEEN
OFF 3 AND 8
OFF 2 AND 5
UP 1 AND 8
DOWN 1 AND 5
(5) If the results are not OK, replace the switch.
The power window master switch has a Auto-Down
feature. The switch is equipped with two detent posi-
tions when actuating the power window OPEN. The
first detent position allows the window to roll down
and stop when the switch is released. The second
detent position actuates an integral express roll
down relay that rolls the window down after the
switch is released. When the express down circuit
Fig. 2 Power Window Master Switch Connector
Fig. 3 Passenger Door Power Window Switch
8N - 64 POWER WINDOWSRS
VENT WINDOW MOTOR (Continued)
ProCarManuals.com
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)
ProCarManuals.com
Page 525 of 2177
CLOCK SPRING
DESCRIPTION
The clock spring is screwed to a plastic mounting
platform on the steering column behind the steering
wheel. The clock spring is used to maintain a contin-
uous electrical circuit between the wiring harness
and the drivers airbag.
OPERATION
This assembly consists of a flat ribbon like electri-
cally conductive tape which winds and unwinds with
the steering wheel rotation. The clock spring cannot
be repaired. If the clock spring is faulty, damaged, or
if the airbag has been deployed, the clock spring
must be replaced.
STANDARD PROCEDURE - CLOCK SPRING
CENTERING
If the rotating tape (wire coil) in the clock spring is
not positioned properly with the steering wheel and
the front wheels, the clock spring may fail. The fol-
lowing procedure MUST BE USED to center the
clock spring if it is not known to be properly posi-
tioned, or if the front wheels were moved from the
straight ahead position.
(1) Position steering wheel and front wheels
straight ahead.
(2) Release hood latch and open hood.
(3) Disconnect and isolate the battery negative
cable.
(4) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(5) Remove driver airbag from steering wheel
(Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER
AIRBAG - REMOVAL).
(6) Disconnect wire connectors from back of driver
airbag.(7) Disconnect the 2±way connector from remote
radio control harness.
(8) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
(9) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(10) Rotate the clock spring rotor clockwise until
the rotor stops. Do not apply excessive force.
(11) From the end of travel, rotate the rotor two
turns counterclockwise until the wires end up at the
top.
(12) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(13) Connect the 4±way harness connector to the
speed control/horn harness to the clock spring.
(14) Connect the 2±way connector to the remote
radio control harness.
(15) Install the driver airbag (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION). Torque the two screws to 10 N´m (90 in.
lbs.).
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
REMOVAL
(1) Position steering wheel and front wheels
straight ahead.
(2) Release hood latch and open hood.
(3) Disconnect and isolate the battery negative
cable.
(4) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(5) Remove driver airbag from steering wheel
(Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER
AIRBAG - REMOVAL).
(6) Disconnect wire connectors from back of driver
airbag.
(7) Disconnect the 2±way connector from remote
radio control harness.
(8) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
(9) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(10) Remove steering column shrouds and discon-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - REMOVAL).
(11) Disconnect 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
Fig. 1 VACUUM HEATER AND A/C OUTLETS -
TYPICAL
8O - 4 RESTRAINTSRS
RESTRAINTS (Continued)
ProCarManuals.com
Page 526 of 2177
(12) Remove clock spring from column assembly by
removing the two retaining screws that attach the
clock spring to the column.
INSTALLATION
(1) Install the clock spring on the column.
(2) Connect the 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(3) Install the steering column shrouds and con-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - INSTALLATION).
(4) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(5) Connect the 4±way harness connector to the
speed control/horn harness to the clock spring.
(6) Connect the 2±way connector to the remote
radio control harness.
(7) Install the driver airbag (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION). Torque the two screws to 10 N´m (90 in.
lbs.).
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
DRIVER AIRBAG
DESCRIPTION
The Driver Airbag is located in the center of the
steering wheel. The most visible part of the airbag is
the cover/horn switch. The Driver Airbag and Driver
Airbag Cover/Horn Pad are serviced separately from
each other.
OPERATION
The Driver Airbag cover contains the horn switch,
inflator device, and a fabric bag. The airbag cover/
horn switch is serviced separately from the inflator
and bag components.
When the front airbag system is deployed, the fol-
lowingMUSTbe replaced:
²Complete Steering Column Assembly.
²Lower Steering Column Coupler.
²Steering Wheel.
²Clock Spring.
²Driver Airbag
²Passenger Airbag
²Upper Instrument Panel with Pad.
CARE OF UNDEPLOYED AIRBAGS
Airbags must be stored in their original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag. When carrying or handling an
undeployed airbag, the trim side of the airbag should
be pointing away from the body to minimize possibil-
ity of injury if accidental deployment occurs. Do not
place undeployed airbag face down on a solid surface,
the airbag will propel into the air if accidental
deployment occurs.
REMOVAL
DEPLOYED AIRBAG
(1) Clean powder residue from interior of vehicle
(Fig. 1).
(2) Position steering wheel and front wheels
straight ahead.
(3) Release hood latch and open hood.
(4) Disconnect and isolate the battery negative
cable.
(5) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(6) Remove two screws retaining driver airbag to
steering wheel.
(7) Disconnect wire connectors from back of driver
airbag.
(8) Disconnect the 2±way connector from remote
radio control harness.
(9) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
(10) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(11) Remove steering column shrouds and discon-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - REMOVAL).
(12) Disconnect 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(13) Remove clock spring from column assembly by
removing the two retaining screws that attach the
clock spring to the column.
NOTE: The clock spring, steering wheel, and com-
plete steering column assembly w/lower steering
column coupler must be replaced also in the event
of a driver airbag deployment
UNDEPLOYED AIRBAG
(1) Release hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
RSRESTRAINTS8O-5
CLOCK SPRING (Continued)
ProCarManuals.com
Page 527 of 2177
(3) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(4) Remove two screws retaining driver airbag to
steering wheel.
(5) Disconnect wire connectors from back of driver
airbag (Fig. 2).
(6) Disconnect the 2±way connector from remote
radio control harness.
(7) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
INSTALLATION
DEPLOYED AIRBAG
(1) Perform clean up procedure (Refer to 8 - ELEC-
TRICAL/RESTRAINTS - STANDARD PROCEDURE
- SERVICE AFTER AN AIRBAG DEPLOYMENT).
(2) Install a new steering column assembly and
lower steering column coupler (Refer to 19 - STEER-
ING/COLUMN - INSTALLATION).
(3) Install the new clock spring.
(4) Connect the 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(5) Install the steering column shrouds and con-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - INSTALLATION).
(6) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(7) Connect the 4±way harness connector to the
speed control/horn harness to the clock spring.(8) Connect the 2±way connector to the remote
radio control harness.
(9) Install the driver airbag and the two screws
retaining the airbag. Tighten screws to 10 N´m (90
in. lbs.)
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
UNDEPLOYED AIRBAG
(1) Connect the harness connector on the DAB
cover (horn, speed controls) to the clock spring.
(2) Connect the squib connectors to the DAB.
(3) Position a new airbag into the airbag cavity.
(4) Install the two screws retaining the airbag.
Tighten screws to 10 N´m (90 in. lbs.)
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
DRIVER AIRBAG TRIM COVER
REMOVAL
The horn switch is integral to the driver airbag
trim cover. If either component is faulty or damaged,
the entire driver airbag trim cover and horn switch
unit must be replaced.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge.
(2) Remove the driver airbag from the steering
wheel (Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL).
(3) Remove the plastic wire retainer that captures
the horn switch feed pigtail wire between the upper
left inflator stud and the inflator on the back of the
driver airbag housing and disconnect the speed con-
trol switches (if equipped).
(4) Remove the four nuts that secure the trim
cover retainer to the studs on the back of the driver
airbag housing.
(5) Remove the horn switch ground pigtail wire
eyelet terminal from the upper left airbag housing
stud.
(6) Remove the trim cover retainer from the airbag
housing studs.
(7) Disengage the six trim cover locking blocks
from the lip around the outside edge of the driver
airbag housing and remove the housing from the
cover.
Fig. 2 DRIVER AIRBAG WIRE CONNECTIONS
1 - AIRBAG SQUIB CONNECTORS
2 - DRIVER AIRBAG
3 - HORN/SPEED CONTROL CONNECTOR
4 - CLOCK SPRING
8O - 6 RESTRAINTSRS
DRIVER AIRBAG (Continued)
ProCarManuals.com
Page 528 of 2177
INSTALLATION
(1) Install the housing into the cover. Engage the
six trim cover locking blocks to the lip around the
outside edge of the driver airbag housing.
(2) Install the trim cover retainer to the airbag
housing studs.
(3) Install the horn switch ground pigtail wire eye-
let terminal to the upper left airbag housing stud.
(4) Install the four nuts that secure the upper and
lower trim cover retainers to the studs on the back of
the driver airbag housing. Torque nuts to 6.8 N´m (60
in. lbs.).
(5) Install the plastic wire retainer that captures
the horn switch feed pigtail wire between the upper
left inflator stud and the inflator on the back of the
driver airbag housing.
(6) Connect speed control switches (if equipped).
(7) Install the driver airbag onto the steering
wheel (Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - INSTALLATION).
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. FIRST (Refer to 8 - ELECTRICAL/RE-
STRAINTS/DIAGNOSIS AND TESTING - AIRBAG
SYSTEM).
OCCUPANT RESTRAINT
CONTROLLER
DESCRIPTION
The front driver and passenger airbag system is
designed to reduce the risk of fatality or serious
injury, caused by a frontal impact of the vehicle.
The Occupant Restraint Controller (ORC) is also
sometimes referred to as the Airbag Control Module
(ACM). The ORC contains the impact sensor and
energy reserve capacitor. It is mounted on a bracket,
under the instrument panel, just forward of the stor-
age bin. The ORC monitors the system to determine
the system readiness. The ORC contains on-board
diagnostics and will light the AIRBAG warning lamp
in the message center when a problem occurs.
OPERATION
The impact sensor provides verification of the
direction and severity of the impact. One impact sen-
sor is used. It is located inside the Occupant
Restraint Controller (ORC). The impact sensor is an
accelerometer that senses deceleration. The decelera-
tion pulses are sent to a microprocessor which con-
tains a decision algorithm. When an impact is severe
enough to require airbag protection, the ORC micro-
processor sends a signal that completes the electrical
circuit to the driver and passenger airbags. Theimpact sensor is calibrated for the specific vehicle
and reacts to the severity and direction of an impact.
REMOVAL
NOTE: Diagnose the ORC using the service/diag-
nostic manual.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove storage bin from instrument panel.
Refer to Body, Instrument Panel, Storage Bin,
Removal.
(3) Remove three bolts holding ORC to floor
bracket.
(4) Disconnect the wire connector from ORC.
(5) Remove the ORC assembly from vehicle.
INSTALLATION
WARNING: DO NOT INSTALL ORC IF MOUNTING
LOCATION IS DEFORMED OR DAMAGED.
CAUTION: Use correct screws when installing the
ORC.
(1) Install the ORC assembly into vehicle.
(2) Connect the wire connector to the ORC.
(3) Install three bolts holding ORC to floor
bracket. Torque bolts to 7.3 - 9.6 N´m (65 to 85 in.
lbs.)
(4) Install the storage bin onto the instrument
panel. Refer to Body, Instrument Panel, Storage Bin,
Installation.
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
PASSENGER AIRBAG
DESCRIPTION
WARNING: NEVER DISASSEMBLE THE PASSEN-
GER AIRBAG, THE PASSENGER AIRBAG HAS NO
SERVICEABLE PARTS.
The Passenger Airbag is located beneath the
instrument panel and pad assembly. The airbag is
mounted to the back side of the instrument panel
reinforcement.
The instrument panel top pad is the most visible
part of the passenger airbag system. Located under
the instrument panel top pad are the airbag door, the
RSRESTRAINTS8O-7
DRIVER AIRBAG TRIM COVER (Continued)
ProCarManuals.com