steering rack CHRYSLER VOYAGER 2005 Owners Manual

FRONT SEAT RISER - MANUAL
- OCS
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OCCUPANT
CLASSIFICATION SYSTEM, SEAT BELT TEN-
SIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH ON VEHICLES EQUIPPED WITH THE OCCU-
PANT CLASSIFICATION SYSTEM (OCS), ONLY THE
OCCUPANT CLASSIFICATION MODULE (OCM) AND
THE SEAT CUSHION TRIM MAY BE SERVICED SEP-
ARATELY. ALL OTHER COMPONENTS OF THE PAS-
SENGER SIDE FRONT SEAT CUSHION ASSEMBLY
MUST BE SERVICED ONLY AS A COMPLETE FAC-
TORY-CALIBRATED, ASSEMBLED AND TAMPER-EV-
IDENT SERVICE REPLACEMENT PACKAGE. THIS
PACKAGE INCLUDES THE FRAME, SPRINGS, PAD,
BLADDER, SENSOR, FOAM, WIRING AND A CALI-
BRATED OCM. WHEN INSTALLING THIS PACKAGE
ALWAYS REPLACE ALL OF THE EXISTING COMPO-
NENTS WITH THE NEW COMPONENTS AS A UNIT.
DO NOT ATTEMPT TO SEPARATE OR DISCONNECT
ANY OF THE NEW OCS COMPONENTS IN THE SER-
VICE REPLACEMENT PACKAGE FROM EACH
OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF
THE REPLACED COMPONENTS IN THIS OR ANY
OTHER VEHICLE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN FAILURE OF
THE PASSENGER AIRBAG TO DEPLOY WHEN
REQUIRED, OR IN PASSENGER AIRBAG DEPLOY-
MENT WHEN NOT REQUIRED.(1) Remove seat from vehicle. (Refer to 23 - BODY/
SEATS/FRONT SEAT - REMOVAL)
(2) Remove storage bin from riser. (Refer to 23 -
BODY/SEATS/UNDER SEAT STORAGE BIN -
REMOVAL)
(3) Remove nuts attaching riser to manual seat
track (Fig. 36).
(4) Remove riser from seat.
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OCCUPANT
CLASSIFICATION SYSTEM, SEAT BELT TEN-
SIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
Fig. 36 FRONT SEAT RISER - MANUAL TRACK
1 - RISER
2 - SEAT TRACK
RSSEATS23 - 123

WARNING: TO AVOID PERSONAL INJURY OR
DEATH ON VEHICLES EQUIPPED WITH THE OCCU-
PANT CLASSIFICATION SYSTEM (OCS), ONLY THE
OCCUPANT CLASSIFICATION MODULE (OCM) AND
THE SEAT CUSHION TRIM MAY BE SERVICED SEP-
ARATELY. ALL OTHER COMPONENTS OF THE PAS-
SENGER SIDE FRONT SEAT CUSHION ASSEMBLY
MUST BE SERVICED ONLY AS A COMPLETE FAC-
TORY-CALIBRATED, ASSEMBLED AND TAMPER-EV-
IDENT SERVICE REPLACEMENT PACKAGE. THIS
PACKAGE INCLUDES THE FRAME, SPRINGS, PAD,
BLADDER, SENSOR, FOAM, WIRING AND A CALI-
BRATED OCM. WHEN INSTALLING THIS PACKAGE
ALWAYS REPLACE ALL OF THE EXISTING COMPO-
NENTS WITH THE NEW COMPONENTS AS A UNIT.
DO NOT ATTEMPT TO SEPARATE OR DISCONNECT
ANY OF THE NEW OCS COMPONENTS IN THE SER-
VICE REPLACEMENT PACKAGE FROM EACH
OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF
THE REPLACED COMPONENTS IN THIS OR ANY
OTHER VEHICLE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN FAILURE OF
THE PASSENGER AIRBAG TO DEPLOY WHEN
REQUIRED, OR IN PASSENGER AIRBAG DEPLOY-
MENT WHEN NOT REQUIRED.
(1) Place riser in position on seat.
(2) Install nuts attaching riser to manual seat
track (Fig. 36). Tighten fasteners to 88 N´m (65 ft.
lbs.) torque.
(3) If equipped, install storage bin into riser. (Refer
to 23 - BODY/SEATS/UNDER SEAT STORAGE BIN
- INSTALLATION)
(4) Install seat into vehicle. Tighten fasteners to
88 N´m (65 ft. lbs.) torque. (Refer to 23 - BODY/
SEATS/FRONT SEAT - INSTALLATION)
FRONT SEAT TRACK POWER
ADJUSTER
REMOVAL
The power seat track and motors are serviced as
an assembly.
(1) Remove seat from vehicle. (Refer to 23 - BODY/
SEATS/FRONT SEAT - REMOVAL)
(2) Remove seat cushion. (Refer to 23 - BODY/
SEATS/FRONT/QUAD SEAT CUSHION -
REMOVAL)(3) Remove nut attaching recliner to seat back
frame.
(4) Remove bolts attaching seat back frame to seat
track.
(5) Remove stud on seat back frame from recliner.
(6) Remove seat back.
(7) If power seat track is being replaced, transfer
power recliner, wire harness and trim covers to
replacement seat track.
INSTALLATION
The power seat track and motors are serviced as
an assembly.
(1) Install wire harness.
(2) Place seat back in position.
(3) Insert stud on seat back frame into recliner.
(4) Install bolts to hold seat back frame to seat
track.
(5) Install nut attaching recliner to seat back
frame.
(6) Install seat cushion. (Refer to 23 - BODY/
SEATS/FRONT/QUAD SEAT CUSHION - INSTAL-
LATION)
(7) Install seat in vehicle. Tighten fasteners to 60
N´m (44 ft. lbs.) torque. (Refer to 23 - BODY/SEATS/
FRONT SEAT - INSTALLATION)
FRONT SEAT TRACK
ADJUSTER/POWER - OCS
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OCCUPANT
CLASSIFICATION SYSTEM, SEAT BELT TEN-
SIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
23 - 124 SEATSRS
FRONT SEAT RISER - MANUAL - OCS (Continued)

WARNING: TO AVOID PERSONAL INJURY OR
DEATH ON VEHICLES EQUIPPED WITH THE OCCU-
PANT CLASSIFICATION SYSTEM (OCS), ONLY THE
OCCUPANT CLASSIFICATION MODULE (OCM) AND
THE SEAT CUSHION TRIM MAY BE SERVICED SEP-
ARATELY. ALL OTHER COMPONENTS OF THE PAS-
SENGER SIDE FRONT SEAT CUSHION ASSEMBLY
MUST BE SERVICED ONLY AS A COMPLETE FAC-
TORY-CALIBRATED, ASSEMBLED AND TAMPER-EV-
IDENT SERVICE REPLACEMENT PACKAGE. THIS
PACKAGE INCLUDES THE FRAME, SPRINGS, PAD,
BLADDER, SENSOR, FOAM, WIRING AND A CALI-
BRATED OCM. WHEN INSTALLING THIS PACKAGE
ALWAYS REPLACE ALL OF THE EXISTING COMPO-
NENTS WITH THE NEW COMPONENTS AS A UNIT.
DO NOT ATTEMPT TO SEPARATE OR DISCONNECT
ANY OF THE NEW OCS COMPONENTS IN THE SER-
VICE REPLACEMENT PACKAGE FROM EACH
OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF
THE REPLACED COMPONENTS IN THIS OR ANY
OTHER VEHICLE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN FAILURE OF
THE PASSENGER AIRBAG TO DEPLOY WHEN
REQUIRED, OR IN PASSENGER AIRBAG DEPLOY-
MENT WHEN NOT REQUIRED.
The power seat track and motors are serviced as
an assembly.
(1) Remove seat from vehicle. (Refer to 23 - BODY/
SEATS/FRONT SEAT - REMOVAL)
(2) Remove seat cushion. (Refer to 23 - BODY/
SEATS/FRONT/QUAD SEAT CUSHION -
REMOVAL)
(3) Remove nut attaching recliner to seat back
frame.
(4) Remove bolts attaching seat back frame to seat
track.
(5) Remove stud on seat back frame from recliner.
(6) Remove seat back.
(7) If power seat track is being replaced, transfer
power recliner, wire harness and trim covers to
replacement seat track.
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OCCUPANT
CLASSIFICATION SYSTEM, SEAT BELT TEN-
SIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS ORSERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH ON VEHICLES EQUIPPED WITH THE OCCU-
PANT CLASSIFICATION SYSTEM (OCS), ONLY THE
OCCUPANT CLASSIFICATION MODULE (OCM) AND
THE SEAT CUSHION TRIM MAY BE SERVICED SEP-
ARATELY. ALL OTHER COMPONENTS OF THE PAS-
SENGER SIDE FRONT SEAT CUSHION ASSEMBLY
MUST BE SERVICED ONLY AS A COMPLETE FAC-
TORY-CALIBRATED, ASSEMBLED AND TAMPER-EV-
IDENT SERVICE REPLACEMENT PACKAGE. THIS
PACKAGE INCLUDES THE FRAME, SPRINGS, PAD,
BLADDER, SENSOR, FOAM, WIRING AND A CALI-
BRATED OCM. WHEN INSTALLING THIS PACKAGE
ALWAYS REPLACE ALL OF THE EXISTING COMPO-
NENTS WITH THE NEW COMPONENTS AS A UNIT.
DO NOT ATTEMPT TO SEPARATE OR DISCONNECT
ANY OF THE NEW OCS COMPONENTS IN THE SER-
VICE REPLACEMENT PACKAGE FROM EACH
OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF
THE REPLACED COMPONENTS IN THIS OR ANY
OTHER VEHICLE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN FAILURE OF
THE PASSENGER AIRBAG TO DEPLOY WHEN
REQUIRED, OR IN PASSENGER AIRBAG DEPLOY-
MENT WHEN NOT REQUIRED.
The power seat track and motors are serviced as
an assembly.
(1) Install wire harness.
(2) Place seat back in position.
(3) Insert stud on seat back frame into recliner.
(4) Install bolts to hold seat back frame to seat
track.
(5) Install nut attaching recliner to seat back
frame.
(6) Install seat cushion. (Refer to 23 - BODY/
SEATS/FRONT/QUAD SEAT CUSHION - INSTAL-
LATION)
(7) Install seat in vehicle. Tighten fasteners to 88
N´m (65 ft. lbs.) torque. (Refer to 23 - BODY/SEATS/
FRONT SEAT - INSTALLATION)
FRONT SEAT TRACK MANUAL
ADJUSTER
REMOVAL
(1) Remove seat from vehicle. (Refer to 23 - BODY/
SEATS/FRONT SEAT - REMOVAL)
RSSEATS23 - 125
FRONT SEAT TRACK ADJUSTER/POWER - OCS (Continued)

(2) Remove seat cushion. (Refer to 23 - BODY/
SEATS/FRONT/QUAD SEAT CUSHION -
REMOVAL)
(3) Remove riser. (Refer to 23 - BODY/SEATS/
FRONT SEAT RISER - MANUAL TRACK -
REMOVAL)
(4) Remove bolt attaching seat back frame to seat
track (Fig. 37).
(5) Remove seat track from seat adjuster handle
(Fig. 38).
(6) Remove seat track from seat.INSTALLATION
(1) Place seat track in position on seat.
(2) Place adjuster handle in position on seat track
(Fig. 40).
(3) Insert stud on seat back frame into recliner.
(4) Install bolt attaching seat back frame to seat
track (Fig. 39).
(5) Install riser. (Refer to 23 - BODY/SEATS/
FRONT SEAT RISER - MANUAL TRACK - INSTAL-
LATION)
(6) Install seat cushion. (Refer to 23 - BODY/
SEATS/FRONT/QUAD SEAT CUSHION - INSTAL-
LATION)
(7) Install seat in vehicle. (Refer to 23 - BODY/
SEATS/FRONT SEAT - INSTALLATION)
FRONT SEAT TRACK
ADJUSTER/MANUAL - OCS
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OCCUPANT
CLASSIFICATION SYSTEM, SEAT BELT TEN-
SIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
Fig. 37 FRONT SEAT TRACK - MANUAL
1 - SHOULDER BOLT
2 - RECLINER
3 - MANUAL SEAT TRACK
Fig. 38 FRONT SEAT TRACK ADJUSTER HANDLE
1 - RECLINER
2 - SEAT ADJUSTER HANDLE
3 - MANUAL SEAT TRACK
23 - 126 SEATSRS
FRONT SEAT TRACK MANUAL ADJUSTER (Continued)

INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OCCUPANT
CLASSIFICATION SYSTEM, SEAT BELT TEN-
SIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH ON VEHICLES EQUIPPED WITH THE OCCU-
PANT CLASSIFICATION SYSTEM (OCS), ONLY THE
OCCUPANT CLASSIFICATION MODULE (OCM) AND
THE SEAT CUSHION TRIM MAY BE SERVICED SEP-
ARATELY. ALL OTHER COMPONENTS OF THE PAS-
SENGER SIDE FRONT SEAT CUSHION ASSEMBLY
MUST BE SERVICED ONLY AS A COMPLETE FAC-
TORY-CALIBRATED, ASSEMBLED AND TAMPER-EV-
IDENT SERVICE REPLACEMENT PACKAGE. THIS
PACKAGE INCLUDES THE FRAME, SPRINGS, PAD,
BLADDER, SENSOR, FOAM, WIRING AND A CALI-
BRATED OCM. WHEN INSTALLING THIS PACKAGE
ALWAYS REPLACE ALL OF THE EXISTING COMPO-
NENTS WITH THE NEW COMPONENTS AS A UNIT.
DO NOT ATTEMPT TO SEPARATE OR DISCONNECT
ANY OF THE NEW OCS COMPONENTS IN THE SER-
VICE REPLACEMENT PACKAGE FROM EACH
OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF
THE REPLACED COMPONENTS IN THIS OR ANY
OTHER VEHICLE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN FAILURE OF
THE PASSENGER AIRBAG TO DEPLOY WHEN
REQUIRED, OR IN PASSENGER AIRBAG DEPLOY-
MENT WHEN NOT REQUIRED.
(1) Place seat track in position on seat.
(2) Place adjuster handle in position on seat track
(Fig. 40).
(3) Insert stud on seat back frame into recliner.
(4) Install bolt attaching seat back frame to seat
track (Fig. 39).
(5) Install riser. (Refer to 23 - BODY/SEATS/
FRONT SEAT RISER - MANUAL TRACK - INSTAL-
LATION)(6) Install seat cushion. (Refer to 23 - BODY/
SEATS/FRONT/QUAD SEAT CUSHION - INSTAL-
LATION)
(7) Install seat in vehicle. (Refer to 23 - BODY/
SEATS/FRONT SEAT - INSTALLATION)
FRONT SEAT TRACK - REAR
COVER
REMOVAL
(1) Disengage arrowhead retainer from loop strip
attaching rear cover to power seat track crossbar
(Fig. 41).
(2) Disengage fasteners attaching rear cover to
slots on power seat track.
(3) Remove rear cover from seat.
INSTALLATION
(1) Place rear cover in position on seat.
(2) Engage fasteners attaching rear cover to slots
on power seat track.
(3) Engage arrowhead retainer into loop strip
attaching rear cover to power seat track crossbar
(Fig. 41).
Fig. 41 FRONT POWER SEAT TRACK - REAR
COVER
1 - PUSH IN FASTENER
2 - POWER SEAT TRACK REAR COVER
3 - POWER SEAT TRACK
23 - 128 SEATSRS
FRONT SEAT TRACK ADJUSTER/MANUAL - OCS (Continued)

FRONT SEAT TRACK REAR
COVER - OCS
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OCCUPANT
CLASSIFICATION SYSTEM, SEAT BELT TEN-
SIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH ON VEHICLES EQUIPPED WITH THE OCCU-
PANT CLASSIFICATION SYSTEM (OCS), ONLY THE
OCCUPANT CLASSIFICATION MODULE (OCM) AND
THE SEAT CUSHION TRIM MAY BE SERVICED SEP-
ARATELY. ALL OTHER COMPONENTS OF THE PAS-
SENGER SIDE FRONT SEAT CUSHION ASSEMBLY
MUST BE SERVICED ONLY AS A COMPLETE FAC-
TORY-CALIBRATED, ASSEMBLED AND TAMPER-EV-
IDENT SERVICE REPLACEMENT PACKAGE. THIS
PACKAGE INCLUDES THE FRAME, SPRINGS, PAD,
BLADDER, SENSOR, FOAM, WIRING AND A CALI-
BRATED OCM. WHEN INSTALLING THIS PACKAGE
ALWAYS REPLACE ALL OF THE EXISTING COMPO-
NENTS WITH THE NEW COMPONENTS AS A UNIT.
DO NOT ATTEMPT TO SEPARATE OR DISCONNECT
ANY OF THE NEW OCS COMPONENTS IN THE SER-
VICE REPLACEMENT PACKAGE FROM EACH
OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF
THE REPLACED COMPONENTS IN THIS OR ANY
OTHER VEHICLE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN FAILURE OF
THE PASSENGER AIRBAG TO DEPLOY WHEN
REQUIRED, OR IN PASSENGER AIRBAG DEPLOY-
MENT WHEN NOT REQUIRED.(1) Disengage arrowhead retainer from loop strip
attaching rear cover to power seat track crossbar
(Fig. 42).
(2) Disengage fasteners attaching rear cover to
slots on power seat track.
(3) Remove rear cover from seat.
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OCCUPANT
CLASSIFICATION SYSTEM, SEAT BELT TEN-
SIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
Fig. 42 FRONT POWER SEAT TRACK - REAR
COVER
1 - PUSH IN FASTENER
2 - POWER SEAT TRACK REAR COVER
3 - POWER SEAT TRACK
RSSEATS23 - 129

DESCRIPTION FIGURE
UPPER COWL PLENUM AND REINFORCEMENT - RIGHT HAND DRIVE 201
COWL SIDE PANEL AND DASH PANEL - RIGHT HAND DRIVE 202
LOWER COWL PLENUM, SUPPORT AND DASH PANEL - RIGHT HAND DRIVE 203
STEERING COLUMN REINFORCEMENT, BELT REINFORCEMENT AND DASH PANEL -
RIGHT HAND DRIVE204
INSTRUMENT PANEL TAPPING PLATE AND COWL SIDE PANEL - RIGHT HAND DRIVE 205
DASH PANEL AND BELT REINFORCEMENT - RIGHT HAND DRIVE 206
UPPER SUPPORT, UPPER REINFORCEMENT AND UPPER COWL PLENUM - RIGHT
HAND DRIVE207
UPPER SUPPORT, BRAKE PEDAL BRACKET REINFORCEMENT AND DASH PANEL -
RIGHT HAND DRIVE208
REINFORCEMENT, MOUNTING BRACKETS AND DASH PANEL - RIGHT HAND DRIVE 209
STRUT TOWER, COWL SIDE PANEL - RIGHT HAND DRIVE 210
REINFORCEMENTS, SIDE RAILS, COWL SIDE PANELS AND DASH PANEL - RIGHT
HAND DRIVE211
UPPER COWL PLENUM, GUSSETS, SIDE SHIELDS AND BODY SIDE APERTURE -
RIGHT HAND DRIVE212
SIDE GLASS ANTENNA TAPPING PLATE AND INNER BODY SIDE APERTURE - RIGHT
HAND DRIVE213
Fig. 85 FRONT FENDER SHIELD - RIGHT
RSBODY STRUCTURE23 - 237
WELD LOCATIONS (Continued)

FRONT HEATER CORE
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the silencer boot fasteners located
around the base of the lower steering shaft from the
dash panel so that it may be pushed aside.
(2) Remove the brake lamp switch from its mount-
ing bracket (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
REMOVAL).
(3) Disconnect the power brake booster input rod
(push rod) from the pin on the brake pedal arm
(Refer to 5 - BRAKES - ABS/HYDRAULIC/ME-
CHANICAL/POWER BRAKE BOOSTER -
REMOVAL).
(4) Remove the heater core tubes (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
HEATER CORE - REMOVAL).
(5) Remove the two screws that secure the heater
core mounting plate to the distribution housing.
(6) While pulling the accelerator pedal upward
(Fig. 18) and pushing the brake pedal downward
(Fig. 19) far enough for clearance, pull the heater
core out of the distribution housing.
(7) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation. Also, if
the heater core was leaking, use absorbent toweling
and reach into the heater core opening to mop up
any residual engine coolant within the distribution
housing.
INSTALLATION
FRONT HEATER CORE TUBES
(1) Remove the plugs or tape from both heater core
tube fittings and both heater core ports.
(2) Position the heater core tubes and sealing plate
as a unit beneath the instrument panel.
Fig. 18 Accelerator Pedal - LHD Shown, RHD Typical
1 - HEATER CORE
Fig. 19 Brake Pedal - LHD Shown, RHD Typical
1 - HEATER CORE
2 - BRAKE PEDAL
RSPLUMBING - FRONT24-85
HEATER CORE (Continued)

(3) Align the engine compartment ends of both
heater core tubes with the openings in the dash
panel seal and push them simultaneously forward
through the seal far enough to engage the heater
core ends of the tubes with the heater core supply
and return ports.
(4) Position both heater core tubes and the sealing
plate simultaneously to the heater core supply and
return ports.
NOTE: The heater core tubes each have a slot that
must be indexed to a location tab within each of the
heater core ports. Adjust the position of the tubes
as required so that the sealing plate fits flush
against the heater core supply and return ports,
which indicates that the tubes are properly indexed.
(5) Index both heater core tubes to the heater core
ports.
(6) Install the screw that secures the heater core
tube sealing plate to the heater core supply and
return ports. Tighten the screw to 3 N´m (27 in. lbs.).
(7) Install the silencer under the driver side end of
the instrument panel.
(8) Connect the heater hoses to the heater hose
tubes (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/HEATER INLET HOSE - INSTAL-
LATION) and(Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/HEATER RETURN
HOSE - INSTALLATION).
(9) Reconnect the battery negative cable.
(10) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
FRONT HEATER CORE
(1) While pushing the brake pedal downward and
pulling the accelerator pedal upward far enough for
clearance, slide the heater core into the distribution
housing.
(2) Install the two screws that secure the heater
core mounting plate to the distribution housing.
Tighten the screws to 2 N´m (17 in. lbs.).(3) Install the heater core tubes (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
HEATER CORE - INSTALLATION).
(4) Reconnect the power brake booster input rod
(push rod) to the pin on the brake pedal arm (Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/
POWER BRAKE BOOSTER - INSTALLATION).
(5) Reinstall the brake lamp switch into its mount-
ing bracket (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
INSTALLATION).
(6) Reinstall the silencer boot around the base of
the lower steering shaft on the dash panel.
(7) Reconnect the battery negative cable.
(8) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(9) Operate system for two thermostat cycles to
assure the elimination of any air that may be
trapped within the cooling system.
HEATER INLET HOSE
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING).
NOTE: The heater inlet hose is constructed from
formed steel tubing and rubber hoses. Depending
on application, the ends are secured to the heater
core, engine oil cooler or the engine by spring ten-
sion clamps.
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
24 - 86 PLUMBING - FRONTRS
HEATER CORE (Continued)

BACKLIGHT (EBL) SYSTEM, DIAGNOSISAND TESTING - ELECTRIC ..............8G-2
BACKSTOW STRAP - THIRD ROW - FOLD-IN-FLOOR - INSTALLATION, SEAT . . 23-158
BACKSTOW STRAP - THIRD ROW - FOLD-IN-FLOOR - REMOVAL, SEAT ......23-158
BAG RETAINER - INSTALLATION, PLASTIC GROCERY .................. 23-149
BAG RETAINER - REMOVAL, PLASTIC GROCERY ......................... 23-149
BALANCE - STANDARD PROCEDURE, TIRE AND WHEEL ..................... 22-5
BALANCE SHAFTS AND CARRIER ASSEMBLY - DESCRIPTION .............9-71
BALANCE SHAFTS AND CARRIER ASSEMBLY - INSTALLATION .............9-73
BALANCE SHAFTS AND CARRIER ASSEMBLY - OPERATION ...............9-71
BALANCE SHAFTS AND CARRIER ASSEMBLY - REMOVAL .................9-71
BALL JOINT - DESCRIPTION, LOWER ......2-10
BALL JOINT - DIAGNOSIS AND TESTING, LOWER ............................. 2-10
BALL JOINT - OPERATION, LOWER .......2-10
BAR - DESCRIPTION, STABILIZER ....2-16,2-44
BAR - DESCRIPTION, TRACK ............2-45
BAR - INSPECTION, STABILIZER ..........2-17
BAR - INSTALLATION, STABILIZER ........2-17
BAR - INSTALLATION, TRACK ............2-46
BAR - OPERATION, STABILIZER ......2-16,2-44
BAR - OPERATION, TRACK ................2-46
BAR - REMOVAL, STABILIZER ...........2-17
BAR - REMOVAL, TRACK ...............2-46
BAR CUSHION - INSTALLATION, STABILIZER ...........................2-4
BAR CUSHION - REMOVAL, STABILIZER ....2-4
BASE BRAKE BLEEDING - STANDARD PROCEDURE ..........................5-8
BASE BRAKE SYSTEM - DIAGNOSIS AND TESTING .............................5-4
BASE BRAKE SYSTEM, SPECIAL TOOLS ....5-10
BASE BRAKES - DESCRIPTION ............5-3
BASE BRAKES - OPERATION ..............5-3
BASE BRAKES (EXPORT) - DESCRIPTION . . . 5-3
BASE COAT/CLEARCOAT FINISH - DESCRIPTION ...................... 23-101
BASE RISER - SECOND ROW - FOLD-IN-FLOOR - INSTALLATION, SEAT . . 23-135
BASE RISER - SECOND ROW - FOLD-IN-FLOOR - REMOVAL, SEAT ......23-134
BASE TRAY - INSTALLATION, FLOOR CONSOLE ........................... 23-89
BASE TRAY - REMOVAL, FLOOR CONSOLE ........................... 23-89
BATTERY - DESCRIPTION ...............8F-7
BATTERY - OPERATION .................8F-9
BATTERY - REMOVAL .................8F-16
BATTERY - SPECIFICATIONS ............8N-24
BATTERY CABLES - DESCRIPTION .......8F-16
BATTERY CABLES - OPERATION .........8F-17
BATTERY CABLES, DIAGNOSIS AND TESTING ........................... 8F-17
BATTERY CHARGING, STANDARD PROCEDURE - CONVENTIONAL ..........8F-11
BATTERY CHARGING, STANDARD PROCEDURE - SPIRAL PLATE ...........8F-10
BATTERY, DIAGNOSIS AND TESTING ......8F-9
BATTERY ELECTROLYTE LEVEL, STANDARD PROCEDURE - CHECKING ....8F-14
BATTERY HOLDDOWN - INSTALLATION . . . 8F-16
BATTERY HOLDDOWN - REMOVAL .......8F-16
BATTERY REPLACEMENT - STANDARD PROCEDURE ........................ 8N-24
BATTERY, SPECIFICATIONS ..............8F-6
BATTERY SYSTEM - DESCRIPTION ........8F-1
BATTERY SYSTEM - OPERATION .........8F-2
BATTERY SYSTEM, DIAGNOSIS AND TESTING ............................ 8F-2
BATTERY SYSTEM SPECIAL TOOLS, SPECIAL TOOLS ...................... 8F-7
BATTERY TEMPERATURE SENSOR - DESCRIPTION ....................... 8F-24
BATTERY TEMPERATURE SENSOR - OPERATION ......................... 8F-24
BATTERY TEMPERATURE SENSOR - REMOVAL .......................... 8F-24
BATTERY TEMPERATURE SENSOR - SPECIFICATIONS ..................... 8F-23BATTERY TESTER, STANDARD
PROCEDURE - MICRO 420 .............8F-15
BATTERY TRAY - DESCRIPTION .........8F-19
BATTERY TRAY - INSTALLATION .........8F-20
BATTERY TRAY - REMOVAL ............8F-19
BEARING - DESCRIPTION, HUB .......2-30,2-5
BEARING - DIAGNOSIS AND TESTING, HUB............................. 2-31,2-5
BEARING - INSTALLATION, HUB .......2-33,2-5
BEARING - OPERATION, HUB .........2-30,2-5
BEARING - REMOVAL, HUB ..........2-31,2-5
BEARING CLEARANCE - STANDARD PROCEDURE, MEASURING
CONNECTING ROD ................... 9-123
BEARING CLEARANCE USING PLASTIGAGE - STANDARD
PROCEDURE, MEASURING ..........9-12,9-86
BEARING FITTING - STANDARD PROCEDURE, MAIN ................... 9-125
BEARING PRELOAD - ADJUSTMENT, DIFFERENTIAL ...................... 21-228
BEARING PRELOAD MEASUREMENT AND ADJUSTMENT, ADJUSTMENTS -
DIFFERENTIAL ....................... 21-79
BEARINGS - INSTALLATION, CRANKSHAFT MAIN .................. 9-127
BEARINGS - REMOVAL, CRANKSHAFT MAIN .............................. 9-127
BEARINGS (IN BLOCK) - DESCRIPTION, CAMSHAFT ......................... 9-118
BEARINGS (IN BLOCK) - INSPECTION, CAMSHAFT ......................... 9-118
BEARINGS (IN BLOCK) - INSTALLATION, CAMSHAFT ......................... 9-118
BEARINGS (IN BLOCK) - OPERATION, CAMSHAFT ......................... 9-118
BEARINGS (IN BLOCK) - REMOVAL, CAMSHAFT ......................... 9-118
BELLCRANK - INSTALLATION ...........23-35
BELLCRANK - REMOVAL ...............23-35
BELT - DIAGNOSIS AND TESTING, ACCESSORY DRIVE .....................7-7
BELT - FOLD-IN-FLOOR - INSTALLATION, SEAT BELT CENTER LAP ..............23-157
BELT - FOLD-IN-FLOOR - REMOVAL, SEAT BELT CENTER LAP ..............23-157
BELT - INSTALLATION, TIMING ...........9-67
BELT - REMOVAL, TIMING ..............9-65
BELT & RETRACTOR - FIRST ROW - OUTBOARD - INSTALLATION, SEAT ......8O-40
BELT & RETRACTOR - FIRST ROW - OUTBOARD - REMOVAL, SEAT ..........8O-39
BELT & RETRACTOR - OUTBOARD - FRONT - INSTALLATION, SEAT ..........8O-39
BELT & RETRACTOR - OUTBOARD - FRONT - REMOVAL, SEAT ..............8O-38
BELT & RETRACTOR - SECOND ROW - LEFT OUTBOARD - INSTALLATION,
SEAT .............................. 8O-42
BELT & RETRACTOR - SECOND ROW - LEFT OUTBOARD - REMOVAL, SEAT .....8O-42
BELT & RETRACTOR - SECOND ROW - RIGHT OUTBOARD - INSTALLATION,
SEAT .............................. 8O-40
BELT & RETRACTOR - SECOND ROW - RIGHT OUTBOARD - REMOVAL, SEAT ....8O-40
BELT & RETRACTOR - SECOND ROW - RIGHT OUTBOARD WITH REAR HVAC -
LWB - INSTALLATION, SEAT ............8O-41
BELT & RETRACTOR - SECOND ROW - RIGHT OUTBOARD WITH REAR HVAC -
LWB - REMOVAL, SEAT ...............8O-41
BELT BUCKLE - FIRST ROW - BENCH - INSTALLATION, SEAT .................8O-37
BELT BUCKLE - FIRST ROW - BENCH - REMOVAL, SEAT ..................... 8O-36
BELT BUCKLE - FIRST ROW INBOARD - QUAD BUCKET - INSTALLATION, SEAT ....8O-36
BELT BUCKLE - FIRST ROW INBOARD - QUAD BUCKET - REMOVAL, SEAT .......8O-35
BELT BUCKLE - FRONT INBOARD - INSTALLATION, SEAT .................8O-35
BELT BUCKLE - FRONT INBOARD - REMOVAL, SEAT ..................... 8O-35
BELT BUCKLE - SECOND ROW - THREE PASSENGER BENCH - INSTALLATION,
SEAT .............................. 8O-40BELT BUCKLE - SECOND ROW - THREE
PASSENGER BENCH - REMOVAL, SEAT . . . 8O-40
BELT BUCKLE - SECOND ROW INBOARD - 50/50 BENCH - INSTALLATION, SEAT . . . 8O-38
BELT BUCKLE - SECOND ROW INBOARD - 50/50 BENCH - REMOVAL, SEAT .......8O-37
BELT CENTER LAP BELT - FOLD-IN- FLOOR - INSTALLATION, SEAT .........23-157
BELT CENTER LAP BELT - FOLD-IN- FLOOR - REMOVAL, SEAT .............23-157
BELT COVER(S) - INSTALLATION, TIMING ............................. 9-64
BELT COVER(S) - REMOVAL, TIMING ......9-63
BELT HEIGHT ADJUSTE R-BOR
C-PILLAR - INSTALLATION, SEAT ........8O-38
BELT HEIGHT ADJUSTE R-BOR
C-PILLAR - REMOVAL, SEAT ...........8O-38
BELT HEIGHT ADJUSTER KNOB - INSTALLATION, SEAT .................8O-38
BELT HEIGHT ADJUSTER KNOB - REMOVAL, SEAT ..................... 8O-38
BELT MOLDING - INSTALLATION, FRONT DOOR INNER ....................... 23-168
BELT MOLDING - INSTALLATION, FRONT DOOR OUTER ...................... 23-167
BELT MOLDING - REMOVAL, FRONT DOOR INNER ....................... 23-168
BELT MOLDING - REMOVAL, FRONT DOOR OUTER ...................... 23-167
BELT TENSION - STANDARD PROCEDURE, CHECKING POWER
STEERING ............................7-8
BELT TENSION SENSOR - DESCRIPTION . . . 8O-8
BELT TENSION SENSOR - OPERATION .....8O-9
BELT TENSION, SPECIFICATIONS - ACCESSORY DRIVE .....................7-5
BELT TENSIONER - 2.4L - INSTALLATION . . 7-11
BELT TENSIONER - 2.4L - REMOVAL ......7-11
BELT TENSIONER - 3.3/3.8L - INSTALLATION ........................ 7-12
BELT TENSIONER - 3.3/3.8L - REMOVAL . . . 7-12
BELT TENSIONER - DESCRIPTION, SEAT . . 8O-43
BELT TENSIONER - OPERATION, SEAT ....8O-43
BELT TENSIONER & PULLEY - INSTALLATION, TIMING .................9-70
BELT TENSIONER & PULLEY - REMOVAL, TIMING .................... 9-69
BELTS - 2.4L - ADJUSTMENTS, DRIVE .....7-10
BELTS - 2.4L - INSTALLATION, DRIVE ......7-9
BELTS - 2.4L - REMOVAL, DRIVE ..........7-9
BELTS - 3.3/3.8L - INSTALLATION, DRIVE . . 7-12
BELTS - 3.3/3.8L - REMOVAL, DRIVE ......7-11
BELTS - CLEANING, DRIVE ...............7-8
BELTS - INSPECTION, DRIVE .............7-8
BENCH - INSTALLATION, SEAT BACK HINGE COVERS - QUAD BUCKET, 50/50
SPLIT ............................. 23-146
BENCH - INSTALLATION, SEAT BELT BUCKLE - FIRST ROW ................8O-37
BENCH - INSTALLATION, SEAT BELT BUCKLE - SECOND ROW - THREE
PASSENGER ........................ 8O-40
BENCH - INSTALLATION, SEAT BELT BUCKLE - SECOND ROW INBOARD -
50/50 .............................. 8O-38
BENCH - INSTALLATION, SEAT CUSHION COVER - QUAD BUCKET, 50/50 SPLIT . . . 23-144
BENCH - REMOVAL, SEAT BACK HINGE COVERS - QUAD BUCKET, 50/50 SPLIT . . 23-146
BENCH - REMOVAL, SEAT BELT BUCKLE - FIRST ROW ....................... 8O-36
BENCH - REMOVAL, SEAT BELT BUCKLE - SECOND ROW - THREE PASSENGER ....8O-40
BENCH - REMOVAL, SEAT BELT BUCKLE - SECOND ROW INBOARD - 50/50 .......8O-37
BENCH - REMOVAL, SEAT CUSHION COVER - QUAD BUCKET, 50/50 SPLIT . . . 23-144
BENCH SEAT - REMOVAL, CHILD SEAT MODULE .......................... 23-104
BENCH SEAT BACK - INSTALLATION .....23-147
BENCH SEAT BACK - REMOVAL ........23-147
BENCH SEAT BACK COVER - INSTALLATION ...................... 23-148
BENCH SEAT BACK COVER - REMOVAL . . 23-148
BENCH SEAT BACK HINGE - REMOVAL . . 23-146
BENCH SEAT BACK PANEL - INSTALLATION ...................... 23-144
BENCH SEAT BACK PANEL - REMOVAL . . 23-143
RS INDEX3
Description Group-Page Description Group-Page Description Group-Page