warning CHRYSLER VOYAGER 2005 Service Manual

INSTALLATION
(1) Place sill plate in position on vehicle.
(2) Engage hooks to hold outside edge of sill plate
to door sill.
(3) Align guide pins to holes in door sill.
(4) Engage hidden clips to hold sill plate to sliding
door opening sill.
(5) Engage interlock tabs at lower B-pillar and
quarter trim panel.
SUN VISOR
REMOVAL
All vehicles with driver and passenger side air
bags must have a colored coded five Bullet point air
bag warning label applied to the sun visor, verify
label availability and ensure the label is installed.
(1) Disengage sun visor from center support.
(2) Remove screws attaching sun visor to roof
header (Fig. 37).
(3) Remove sun visor from roof.
(4) If equipped, disconnect illuminated vanity mir-
ror wire connector from body harness.
(5) Remove sun visor from vehicle.
INSTALLATION
All vehicles with driver and passenger side air
bags must have a colored coded five Bullet point air
bag warning label applied to the sun visor, verify
label availability and ensure the label is installed.
(1) Place sun visor in position on vehicle.
(2) Connect illuminated vanity mirror wire connec-
tor into body harness.
(3) Place sun visor in position on roof.
(4) Install screws to hold sun visor to roof header
(Fig. 37).
(5) Engage sun visor into center support.
SUN VISOR SUPPORT
REMOVAL
(1) Disengage sun visor from support.
(2) Remove screw holding support to roof header
(Fig. 38).
(3) Remove sun visor support from vehicle.
INSTALLATION
(1) Place sun visor support in position on vehicle.
(2) Install screw holding support to roof header
(Fig. 38).
(3) Engage sun visor into support.
Fig. 36 SLIDING DOOR SILL PLATE
1 - HOOKS
2 - SILL PLATE
3 - CLIPS
4 - SLIDING DOOR SILL
5 - CLIPS
Fig. 37 SUN VISOR
1 - HEADLINING
2 - SUN VISOR
Fig. 38 SUN VISOR SUPPORT
1 - OVERHEAD CONSOLE
2 - SUN VISOR SUPPORT
3 - HEADLINING
RSINTERIOR23-99
SLIDING DOOR SILL PLATE (Continued)

INTERIOR COLORS
INTERIOR COLOR DAIMLERCHRYSLER
COLOR CODEINTERIOR COLOR DAIMLERCHRYSLER
COLOR CODE
DARK KHAKI/LIGHT
GRAYSTONEJ1 MEDIUM SLATE
GRAYD5
KHAKI J3
BASE COAT/CLEARCOAT
FINISH
DESCRIPTION
On most vehicles a two-part paint application
(basecoat/clearcoat) is used. Color paint that is
applied to primer is called basecoat. The clearcoat
protects the basecoat from ultraviolet light and pro-
vides a durable high-gloss finish.
CAUTION: Do not use abrasive chemicals or com-
pounds on painted surfaces. Damage to finish can
result.
Do not use harsh alkaline based cleaning solvents on
painted surfaces. Damage to finish or color can result.
PAINT CODE
DESCRIPTION
Exterior vehicle body colors are identified on the
Body Code plate. (Refer to VEHICLE DATA/VEHI-
CLE INFORMATION/BODY CODE PLATE -
DESCRIPTION). The paint code is also identified on
the Vehicle Safety Certification Label which is
located on the drivers door shut face. The first digit
of the paint code listed on the vehicle indicates the
sequence of application, i.e.: P = primary coat, Q =
secondary coat. The codes listed in the Color Code
Chart are used for manufacturing purposes.
PAINTED TOUCH-UP
DESCRIPTION
When a painted metal surface has been scratched
or chipped, it should be touched up as soon as possi-
ble to avoid corrosion. For best results, use Mopart
Scratch Filler/Primer, Touch Up Paints and Clear Top
Coat. (Refer to VEHICLE DATA/VEHICLE INFOR-
MATION/BODY CODE PLATE - DESCRIPTION).
WARNING: USE AN OSHA APPROVED RESPIRATOR
AND SAFETY GLASSES WHEN SPRAYING PAINT
OR SOLVENTS IN A CONFINED AREA. PERSONAL
INJURY CAN RESULT.
TOUCH UP PROCEDURE
(1) Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with MopartTar/Road Oil
Remover, and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur-
face finish. The applicator brush should be wet
enough to puddle-fill the scratch or chip without run-
ning. Do not stroke brush applicator on body surface.
Allow the filler/primer to dry hard.
(4) Cover the filler/primer with color touch up
paint. Do not overlap touch up color onto the original
color coat around the scratch or chip. Butt the new
color to the original color, if possible. Do not stroke
applicator brush on body surface. Allow touch up
paint to dry hard.
(5) On vehicles without clearcoat, the touch up
color can be lightly finesse sanded (1500 grit) and
polished with rubbing compound.
(6) On vehicles with clearcoat, apply clear top coat
to touch up paint with the same technique as
described in Step 4. Allow clear top coat to dry hard.
If desired, Step 5 can be performed on clear top coat.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL ± BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN RESULT.
FINESSE SANDING/BUFFING &
POLISHING
DESCRIPTION
Minor acid etching, orange peel, or smudging in
clearcoat or single-stage finishes can be reduced with
light finesse sanding, hand buffing, and polishing.If
the finish has been finesse sanded in the past,
it cannot be repeated. Finesse sanding opera-
tion should be performed by a trained automo-
tive paint technician.
CAUTION: Do not remove clearcoat finish, if
equipped. Basecoat paint must retain clearcoat for
durability.
RSPAINT23 - 101
PAINT (Continued)

If any of the remaining OCS components of the
passenger side front seat cushion require replace-
ment, they are serviced only as a factory-calibrated,
assembled, and tamper-evident service replacement
package. This package includes the assembled frame,
springs, pad, bladder, sensor, foam, wiring and a cal-
ibrated OCM. When installing this package, always
replace all of the existing components with the new
components as a unit. Do not attempt to separate or
disconnect any of the new OCS components con-
tained in the service replacement package from each
other, and do not attempt to reuse any of the
replaced components in this or any other vehicle.
Once any of the original factory-installed compo-
nents except the OCM have been replaced with the
service replacement package components, the OCM
can only be serviced by replacing the entire passen-
ger side front seat cushion unit with another com-
plete service replacement package. (Refer to 23 -
BODY/SEATS/SEAT CUSHION - FRONT -
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 DISCONNECTANY 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 access winch cover (spare tire) plug
(Fig. 14).
(2) Lower spare tire approximately 18 inches
before raising vehicle to access the nuts.
(3) From under vehicle, remove nuts attaching
front seat risers to the floor.
(4) Lower vehicle.
(5) Remove seat and riser from floor (Fig. 15).
(6) Tip seat rearward and disconnect wire connec-
tors from body harness, if equipped.
(7) Remove seat from vehicle.
Fig. 14 ACCESS TO WINCH
1 - WINCH PLUG
2 - ACCESS HOLE TO WINCH
RSSEATS23 - 109
FRONT SEAT (Continued)

INSTALLATION
A non-calibrated Occupant Classification Module
(OCM) is the only component of the Occupant Clas-
sification System (OCS) that is available for separate
service replacement, as outlined in the procedures
that follow. The OCS components of the passenger
side front seat cushion including the cushion frame,
springs, pad, occupant detection bladder, pressure
sensor, seat cushion foam and the OCM are a factory-
calibrated and assembled unit. Once this unit is con-
nected to a vehicle electrically, the calibration
settings are uploaded from the OCM and stored in
the memory of the Airbag Control Module (ACM). If
only the OCM is subsequently replaced, the new,
non-calibrated OCM learns the proper calibration
settings from the ACM after it is connected to the
vehicle electrically.
If any of the remaining OCS components of the
passenger side front seat cushion require replace-
ment, they are serviced only as a factory-calibrated,
assembled, and tamper-evident service replacement
package. This package includes the assembled frame,
springs, pad, bladder, sensor, foam, wiring and a cal-
ibrated OCM. When installing this package, always
replace all of the existing components with the new
components as a unit. Do not attempt to separate or
disconnect any of the new OCS components con-
tained in the service replacement package from each
other, and do not attempt to reuse any of the
replaced components in this or any other vehicle.
Once any of the original factory-installed compo-
nents except the OCM have been replaced with the
service replacement package components, the OCM
can only be serviced by replacing the entire passen-
ger side front seat cushion unit with another com-plete service replacement package. (Refer to 23 -
BODY/SEATS/SEAT CUSHION - FRONT -
REMOVAL).
WARNING: TO AVOID PERSONAL INJURY OR DEATH,
ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE
THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, AIRBAG, OCCUPANT CLASSIFICATION
SYSTEM, SEAT BELT TENSIONER, IMPACT SENSOR,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM. FAILURE TO TAKE THE PROPER PRECAU-
TIONS COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT.
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 into position (Fig. 15).
(2) Tip seat rearward and connect wire connectors
to body harness, if equipped.
(3) Place seat riser studs into openings in the floor.
(4) From under vehicle, install nuts attaching
front seat risers to the floor. Tighten nuts to 88 N´m
(65 ft. lbs.) torque.
(5) Crank winch to raise spare tire into position,
and install winch plug (Fig. 14).
Fig. 15 FRONT SEAT
1 - FRONT SEAT
2 - CONNECTORS
3 - B-PILLAR
23 - 110 SEATSRS
FRONT SEAT (Continued)

FRONT SEAT BACK
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 head rest sleeves. (Refer to 23 - BODY/
SEATS/HEADREST SLEEVE - REMOVAL).
(2) Remove the armrest. (Refer to 23 - BODY/
SEATS/ARMREST - REMOVAL).
(3) Remove the seat back recliner lever.
(4) Remove the lumbar adjustment lever.(5) Remove both seat cushion side covers. (Refer to
23 - BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - REMOVAL).
(6) Remove nut attaching the recliner to the seat
back frame (Fig. 16).
(7) Remove both pivot bolts and remove seat back
from recliner.
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. 16 FRONT SEAT BACK
RSSEATS23 - 111

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 back into position.
(2) Install both pivot bolts attaching seat back
frame to seat track (Fig. 16). Tighten bolts to 48 N´m
(35 ft. lbs.) torque.
(3) Install nut attaching the recliner to the seat
back frame. Tighten nut to 12 N´m (105 in. lbs.)
torque.
(4) Install both seat cushion side covers. (Refer to
23 - BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - INSTALLATION).
(5) Install the lumbar adjustment lever.
(6) Install the seat back recliner lever.
(7) Install the armrest. (Refer to 23 - BODY/
SEATS/ARMREST - INSTALLATION).
(8) Install headrest sleeves. (Refer to 23 - BODY/
SEATS/HEADREST SLEEVE - INSTALLATION).
FRONT SEAT BACK ASSIST
STRAP
REMOVAL
(1) Using a small screw driver, pry screw plugs
from ends of assist strap (Fig. 17).
(2) Remove screws attaching assist strap to seat
back.
(3) Remove assist strap from vehicle.
INSTALLATION
(1) Place assist strap in position on vehicle.(2) Install screws attaching assist strap to seat
back. Tighten screws to 7.0 N´m (60 in. lbs.).
(3) Insert screw plugs into ends of assist strap
(Fig. 17).
FRONT SEAT BACK PANEL
REMOVAL
(1) Remove the screws (Fig. 18).
(2) Tip the top of the panel away from the seat
back and lift off the hooks at the bottom to remove.
Fig. 17 FRONT SEAT BACK ASSIST STRAP
1 - ASSIST STRAP
2 - SCREW PLUG
3 - SEAT BACK
Fig. 18 FRONT SEAT BACK PANEL - TYPICAL
1 - SCREWS
2 - SEAT BACK PANEL
3 - SEAT BACK
23 - 112 SEATSRS
FRONT SEAT BACK (Continued)

INSTALLATION
(1) Place seat back cover into position and engage
the bottom hooks (Fig. 18).
(2) Install the top screws.
FRONT SEAT BACK COVER
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 headrest sleeves (Fig. 19).
(2) Remove armrest cap and attaching bolt (Fig.
20) and (Fig. 21).
Fig. 19 HEADREST SLEEVE
1 - REMOVE SLEEVE
Fig. 20 FRONT SEAT ARMREST
1 - ARMREST CAP
2 - LUMBAR HANDLE
RSSEATS23 - 113
FRONT SEAT BACK PANEL (Continued)

(9) Separate seat back cover from the foam by sid-
ing the locking strips through the keepers (Fig. 29)
and (Fig. 30).
(10) Remove seat back cover from vehicle.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 back cover on to the foam and push
locking strip into the keepers to lock seat back cover
into position (Fig. 29) and (Fig. 30).
(2) Fit seat back cover and foam on to seat back
frame (Fig. 28).
(3) Place seat back cover into position to clip
J-straps (Fig. 25) and (Fig. 26).
(4) Pull seat back cover tight, and attach the hook
and loop strip (Fig. 24).
Fig. 29 FRONT SEAT BACK COVER
1 - LOCKING STRIPS
Fig. 30 FRONT SEAT BACK FOAM
1 - KEEPERS
23 - 116 SEATSRS
FRONT SEAT BACK COVER (Continued)

(5) Install seat back panel (Fig. 23). (Refer to 23 -
BODY/SEATS/SEAT BACK - INSTALLATION).
(6) Install lumbar handle (Fig. 22).
(7) Install armrest cap and attaching bolt (Fig. 20)
and (Fig. 21).
(8) Install headrest sleeves and install headrest
(Fig. 31).
FRONT SEAT CUSHION
REMOVAL
A non-calibrated Occupant Classification Module
(OCM) is the only component of the Occupant Clas-
sification System (OCS) that is available for separate
service replacement, as outlined in the procedures
that follow. The OCS components of the passenger
side front seat cushion including the cushion frame,
springs, pad, occupant detection bladder, pressure
sensor, seat cushion foam and the OCM are a factory-
calibrated and assembled unit. Once this unit is con-
nected to a vehicle electrically, the calibration
settings are uploaded from the OCM and stored in
the memory of the Airbag Control Module (ACM). If
only the OCM is subsequently replaced, the new,
non-calibrated OCM learns the proper calibration
settings from the ACM after it is connected to the
vehicle electrically.
If any of the remaining OCS components of the
passenger side front seat cushion require replace-
ment, they are serviced only as a factory-calibrated,
assembled, and tamper-evident service replacement
package. This package includes the assembled frame,
springs, pad, bladder, sensor, foam, wiring and a cal-
ibrated OCM. When installing this package, always
replace all of the existing components with the newcomponents as a unit. Do not attempt to separate or
disconnect any of the new OCS components con-
tained in the service replacement package from each
other, and do not attempt to reuse any of the
replaced components in this or any other vehicle.
Once any of the original factory-installed compo-
nents except the OCM have been replaced with the
service replacement package components, the OCM
can only be serviced by replacing the entire passen-
ger side front seat cushion unit with another com-
plete service replacement package.
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.
Fig. 31 FRONT SEAT HEADREST SLEEVE
1 - SLEEVE
RSSEATS23 - 117
FRONT SEAT BACK COVER (Continued)

(1) Remove seat cushion side covers, and leave
connector connected, if equipped. (Refer to 23 -
BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - REMOVAL)
(2) Remove seat track front and rear covers if
equipped. (Refer to 23 - BODY/SEATS/SEAT TRACK
REAR COVER - REMOVAL) and (Refer to 23 -
BODY/SEATS/SEAT TRACK FRONT COVER -
REMOVAL)
(3) If equipped, open storage bin to access front
pan bolts.
(4) Remove bolts attaching seat cushion pan to
seat track.
(5) Disconnect wire connectors, if equipment.
(6) Remove seat cushion from seat.
(7) Disengage J-strap retainers holding seat cover
to cushion.
(8) Remove seat cushion pan from cover and pad.
INSTALLATION
A non-calibrated Occupant Classification Module
(OCM) is the only component of the Occupant Clas-
sification System (OCS) that is available for separate
service replacement, as outlined in the procedures
that follow. The OCS components of the passenger
side front seat cushion including the cushion frame,
springs, pad, occupant detection bladder, pressure
sensor, seat cushion foam and the OCM are a factory-
calibrated and assembled unit. Once this unit is con-
nected to a vehicle electrically, the calibration
settings are uploaded from the OCM and stored in
the memory of the Airbag Control Module (ACM). If
only the OCM is subsequently replaced, the new,
non-calibrated OCM learns the proper calibration
settings from the ACM after it is connected to the
vehicle electrically.
If any of the remaining OCS components of the
passenger side front seat cushion require replace-
ment, they are serviced only as a factory-calibrated,
assembled, and tamper-evident service replacement
package. This package includes the assembled frame,
springs, pad, bladder, sensor, foam, wiring and a cal-
ibrated OCM. When installing this package, always
replace all of the existing components with the new
components as a unit. Do not attempt to separate or
disconnect any of the new OCS components con-
tained in the service replacement package from each
other, and do not attempt to reuse any of the
replaced components in this or any other vehicle.
Once any of the original factory-installed compo-
nents except the OCM have been replaced with the
service replacement package components, the OCM
can only be serviced by replacing the entire passen-
ger side front seat cushion unit with another com-
plete service replacement package.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 cushion cover in position on seat
cushion.
(2) Engage J-strap retainers to hold seat cover to
cushion.
(3) Place seat cushion in position on seat.
(4) Connect wire connectors, if equipment.
(5) Install bolts attaching seat cushion to seat
track. Tighten bolts to 28.5 N´m (21 ft. lbs.) torque.
(6) If equipped, close storage bin.
23 - 118 SEATSRS
FRONT SEAT CUSHION (Continued)