Rear control CHRYSLER VOYAGER 2005 Service Manual

(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)

(7) Install seat track front and rear covers, if
equipped. (Refer to 23 - BODY/SEATS/SEAT TRACK
REAR COVER - INSTALLATION) and (Refer to 23 -
BODY/SEATS/SEAT TRACK FRONT COVER -
INSTALLATION)
(8) Install seat cushion side covers. (Refer to 23 -
BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - INSTALLATION)
FRONT SEAT CUSHION - OCS
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 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) 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.
RSSEATS23 - 119
FRONT SEAT CUSHION (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.
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.
(7) Install seat track front and rear covers, if
equipped. (Refer to 23 - BODY/SEATS/SEAT TRACK
REAR COVER - INSTALLATION) and (Refer to 23 -
BODY/SEATS/SEAT TRACK FRONT COVER -
INSTALLATION)
(8) Install seat cushion side covers. (Refer to 23 -
BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - INSTALLATION)
FRONT SEAT CUSHION SIDE
COVER
REMOVAL
(1) Remove screws and plastic push pin attaching
seat cushion side cover to bucket seat (Fig. 32).
(2) Disengage J-strap along rear of seat cushion to
access screw.
(3) Remove screw attaching rear of side cover to
seat cushion frame.
(4) Remove side cover from seat cushion.
23 - 120 SEATSRS
FRONT SEAT CUSHION - OCS (Continued)

QUARTER WINDOW
REMOVAL
(1) Remove C-pillar trim.
(2) Open quarter glass to vent position.
(3) Disengage quarter window retainer from vent
motor arm.
(4) Remove nuts attaching quarter glass to C-pillar
(Fig. 5).
(5) Use magnetic socket to prevent dropping into
the pillar.
(6) Remove quarter glass from vehicle.
INSTALLATION
(1) Place quarter glass in position on vehicle.
(2) Install nuts attaching quarter glass to C-pillar.
(3) Engage quarter window retainer to vent motor
arm.
(4) Install screw attaching quarter window
retainer to vent motor arm.
(5) Close quarter glass.
(6) Verify alignment and flushness.
(7) Install C-pillar trim.
LIFTGATE GLASS
REMOVAL
Refer to the Safety Precautions in this section for
description of tools and adhesive systems that are
recommended for use in this procedure.
REAR WINDOW REMOVAL ± EXTERIOR METHOD
(1) Remove rear window wiper arm.
(2) Remove interior trim covers.
(3) Disconnect wires for electrically heated win-
dow, if equipped.
(4) Using a sharp cold knife, cut urethane adhe-
sive attaching the rear window to the liftgate. A
power cutting device can be used if available (Fig. 1).
(5) Remove rear window from vehicle.
INSTALLATION
Refer to the Safety Precautions in this section for
description of tools and adhesive systems that are
recommended for use in this procedure.
CAUTION: Open the left front door glass before
installing rear window to avoid pressurizing the
passenger compartment. If a door is slammed
before urethane bonding is cured, water leaks can
result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.
To avoid stressing the replacement rear window,
the urethane bonding material on the rear window
fence should be smooth and consistent to the
shape of the replacement glass.
(1) Place replacement glass into rear window open-
ing.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement rear window. If not, the urethane adhe-
sive remaining on the fence must be formed to the
shape of the new glass.
(3) Using a grease pencil, mark the glass and lift-
gate in several locations to aid installation.
(4) Remove replacement glass from liftgate open-
ing.
(5) Position the rear window inside up on a suit-
able work surface with two padded, wood 10 cm by
10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks,
placed parallel 75 cm (2.5 ft.) apart (Fig. 2).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN REAR WINDOW BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
Fig. 5 QUARTER GLASS
1 - VENT CONTROL
2 - QUARTER GLASS
3 - CLIP
23 - 164 STATIONARY GLASSRS

SUNROOF
TABLE OF CONTENTS
page page
SUNROOF
DESCRIPTION........................169
DIAGNOSIS AND TESTING
SUNROOF DIAGNOSIS AND TESTING....169
DRAIN TUBE
REMOVAL............................172
INSTALLATION........................172
GLASS PANEL
REMOVAL............................173
INSTALLATION........................173
ADJUSTMENTS
SUNROOF GLASS PANEL ADJUSTMENT . . 173
SUNROOF ASSEMBLY
REMOVAL............................173
INSTALLATION........................173
SUNSHADE
REMOVAL............................173INSTALLATION........................173
WIND DEFLECTOR
REMOVAL............................174
INSTALLATION........................174
WATER CHANNEL
REMOVAL............................174
INSTALLATION........................174
SUNROOF MOTOR
REMOVAL............................174
INSTALLATION........................174
ADJUSTMENTS
ADJUSTMENT.......................175
SUNROOF SWITCH
REMOVAL............................176
INSTALLATION........................176
SUNROOF
DESCRIPTION
WARNING: Keep fingers and other body parts out
of sunroof opening at all times.
The sun roof features consists of: (Fig. 1)
²Sun roof glass
²Sun roof sun shade
The sunroof power sliding glass panel and sun-
shade can be positioned anywhere along its travel,
rearward of glass panel front edge.
The sunroof is electrically operated from a switch
located in the overhead console. To operate the sun-
roof the ignition switch must be in the Accessory or
On/Run position. Both switchs are a rocker style
design that open or close the sunroof. When pressing
and releasing the open button once, the sunroof will
express open to the comfort stop and the wind deflec-
tor will raise. If the button is pressed a second time,
the sunroof will continue to open to full travel unless
the button is released, at which time it will stop in
that position. Pressing and holding the close button
will close the sunroof. If the close button is released
before the glass fully closes, the sunroof will stop in
that position. The vent switch operates in a similar
manor. The sunroof will also operate for up to fifteen
minutes after the ignition key is turned off for cus-
tomer comfort and convenance while parking.
DIAGNOSIS AND TESTING
SUNROOF DIAGNOSIS AND TESTING
Refer to Sunroof Diagnostic Chart for possible
causes. Before beginning sunroof diagnostics verify
that all other power accessories are in proper operat-
ing condition. If not, a common electrical problem
may exist. Refer to Wiring Diagrams, in this publica-
tion for circuit, splice and component descriptions.
Check the condition of the circuit protection (20 amp
circuit breaker in the Junction Block). Inspect all
wiring connector pins for proper engagement and
continuity. Check for battery voltage at the power
sunroof controller, refer to Wiring Diagrams, for cir-
cuit information. If battery voltage of more than 10
volts is detected at the controller, proceed with the
following tests (the controller will not operate at less
than 10 volts).
Before beginning diagnosis for wind noise or water
leaks, verify that the problem was not caused by
releasing the control switch before the sunroof was
fully closed. The sunroof module has a water-man-
agement system. If however, the sunroof glass is in a
partial closed position, high pressure water may be
forced beyond the water management system bound-
aries and onto the headlining.
RSSUNROOF23 - 169

SYMPTOM POSSIBLE CAUSE
Sunshade will not function or does not
operate smoothlySunshade feet are missing, broken or loose.
No lubracation in track.
Track obstructions or interference.
Glass movement not consistant or glass does
not operate smoothlyGlass and Track timing.
Glass and Track alignment
Cables and Guide alignment
WATER DRAINAGE AND WIND NOISE DIAGNOSIS
The sliding glass panel is designed to seal water
entry with a snug fit between the roof and the seal.
The fit can be checked by inserting a piece of paper
between the roof and the seal. The piece of paper
should have some resistance when pulled out when
the glass panel is in the closed position. Excessive
wind noise could result if the gap clearances are
exceeded. The sunroof glass panel may need to be
adjusted. Refer to Sunroof Glass Panel Adjustment
for proper procedures.
Adequate drainage is provided by a drain trough in
the sunroof housing which encircles the sliding glass
panel and leads to drain hoses. If a wet headliner or
other water leak complaints are encountered, before
performing any adjustments, first ensure that the
drainage system is not plugged or disconnected. Use
a pint container to pour water into the sunroof hous-
ing drain trough. If water flow is restricted in any of
the four drain holes, use compressed air to blow out
any material plugging the drain system. Retest sys-
tem again.
To further check for a disconnected drain hose:
(1) Remove A-pillar trim, sun visors, and map
lamps/mini console.
(2) Remove sunroof opening trim lace. Refer to
Sunroof Opening Trim Lace.
NOTE: Care must be taken not to fold or kink the
headliner upon removal.
(3) Lower headliner as necessary to gain access to
sunroof housing drain tubes. Refer to Headlining
Removal and Installation for proper procedures.
(4) Repair as necessary.
DRAIN TUBE
REMOVAL
FRONT HOSES
NOTE: Front A-pillars are filled with sound deaden-
ing foam and the front drain tubes are sealed into
the pillars.
(1) Move glass panel to the fully closed position.
(2) Disconnect negative battery cable.
(3) Remove headliner (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL).
(4) Disconnect the drain hose from the sunroof
housing (Fig. 1).
(5) Drain any liquid from hose connection, repair
as necessary.
REAR HOUSING HOSE
(1) Move glass panel to the fully closed position.
(2) Disconnect negative battery cable.
(3) Remove headliner (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL).
(4) Remove third seat or seats from vehicle.
(5) Remove second seat belt lower anchor.
(6) Remove third seat lower anchor.
(7) Remove quarter trim bolster.
(8) Remove trim panel screws.
(9) Remove quarter trim panel
(10) Disconnect the drain hose from the sunroof
housing. (Fig. 1).
(11) Drain any liquid from hose connection, if nec-
essary, and remove tube.
INSTALLATION
FRONT HOSES
(1) Connect the new drain hose to the sunroof
housing and test drainage (Fig. 1).
(2) Install headliner (Refer to 23 - BODY/INTERI-
OR/HEADLINER - INSTALLATION).
(3) Install sunroof opening trim lace.
(4) Connect the control switch wire connector and
install control switch.
23 - 172 SUNROOFRS
SUNROOF (Continued)

(5) Verify sunroof operation and alignment.
REAR HOUSING HOSE
(1) Connect the new drain hose to the sunroof
housing and test drainage (Fig. 1).
(2) Install headliner(Refer to 23 - BODY/INTERI-
OR/HEADLINER - INSTALLATION).
(3) Install sunroof opening trim lace.
(4) Connect the control switch wire connector and
install control switch.
(5) Verify sunroof operation and alignment.
GLASS PANEL
REMOVAL
(1) Move the glass panel to the vent position.
(2) Slide sunshade rearward to the open position.
(3) Remove the glass panel screws (Fig. 1).
(4) Lift off glass panel and remove from vehicle.
INSTALLATION
(1) Position glass panel on to mechanism lift arms.
(2) Start the attaching screws, and hand tighten
(Fig. 1).
(3) Adjust sunroof glass to fit flush with roof
line(Refer to 23 - BODY/SUNROOF/GLASS PANEL -
ADJUSTMENTS).
(4) Verify sunroof operation and alignment.
ADJUSTMENTS
SUNROOF GLASS PANEL ADJUSTMENT
(1) Move the sunshade rearward to the open posi-
tion.
(2) Move the sunroof glass panel to the fully closed
position.
(3) Loosen the forward attaching screws on each
side enough to make the front of the glass to adjust
up or down.
(4) Adjust the front surface of the sunroof glass
panel 0.00 mm to 1.75 mm (0.00 in. to 0.07 in.) below
the top surface of the roof.
(5) Tighten the front glass panel attaching screws
to 3.5 N´m (31 in. lbs.) torque (Fig. 1).
(6) Loosen the rear screws on each side enough to
make the rear adjustment (Fig. 1).
(7) Adjust the rear surface of the sunroof glass
panel 0.00 mm to 1.75 mm (0.03 in. to 0.07 in.) above
the top surface of the roof.
(8) Tighten the rear glass panel attaching screws
to 3.5 N´m (31 in. lbs.) torque (Fig. 1).
(9) Check for proper fit. If not OK, repeat glass
panel adjustment.
SUNROOF ASSEMBLY
REMOVAL
(1) Move glass panel to the fully closed position.
(2) Disconnect battery negative cable.
(3) Remove headliner (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL).
(4) Disconnect the four drain tubes from sunroof
housing (Fig. 1).
(5) Loosen fasteners attaching sunroof assembly
(Fig. 1).
(6) With the aid of a helper, support the sunroof
and remove the fasteners attaching sunroof assembly
to roof panel (Fig. 1).
(7) Remove sunroof from vehicle.
INSTALLATION
(1) Raise sunroof module assembly and guide it
carefully into position.
(2) While supporting the sunroof assembly tighten
the attaching screws (Fig. 1). Tighten to 6 N´m (53
in. lbs.) torque.
(3) Connect the drain tubes to the sunroof (Fig. 1).
(4) Connect battery negative cable.
(5) Test sunroof operation, adjust as necessary(Re-
fer to 23 - BODY/SUNROOF/GLASS PANEL -
ADJUSTMENTS).
(6) Install headliner (Refer to 23 - BODY/INTERI-
OR/HEADLINER - INSTALLATION).
(7) Install sunroof opening trim lace position(Refer
to 23 - BODY/SUNROOF/OPENING TRIM LACE -
INSTALLATION).
SUNSHADE
REMOVAL
(1) Place the sunroof glass panel in the vent posi-
tion.
(2) Remove glass panel (Refer to 23 - BODY/SUN-
ROOF/GLASS PANEL - REMOVAL).
(3) Remove water channel (Fig. 1).
(4) Cycle sunroof motor to the open position.
(5) Move sunshade towards the closed position
stopping three to four inches from the closed position.
(6) Depress the spring feet clips on one side of the
sun shade.
(7) Remove sunshade.
INSTALLATION
(1) Place one side of the sunshade spring feet clips
into the top track U-frame.
(2) Depress the both releasing clips on the other
side to allow them to go into the top track U-frame.
(3) Move sunshade to the open position.
(4) Install water channel (Fig. 1).
RSSUNROOF23 - 173
DRAIN TUBE (Continued)

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
ENGINE COOLING SYSTEM
REQUIREMENTS.......................1
HEATER AND AIR CONDITIONER..........1
MANUAL SINGLE ZONE.................2
MANUAL DUAL ZONE...................2
MANUAL THREE ZONE..................2
AUTOMATIC TEMPERATURE CONTROL....3
OPERATION
HEATER AND AIR CONDITIONER..........4
MANUAL SINGLE ZONE.................4
MANUAL DUAL ZONE...................5
MANUAL THREE ZONE..................5AUTOMATIC TEMPERATURE CONTROL....5
DIAGNOSIS AND TESTING
A/C COOL DOWN TEST.................6
A/C PERFORMANCE TEST...............7
HEATER PERFORMANCE TEST..........10
SPECIFICATIONS
A/C SYSTEM.........................11
CONTROLS - FRONT.....................13
CONTROLS - REAR......................33
DISTRIBUTION - FRONT...................42
DISTRIBUTION - REAR....................56
PLUMBING - FRONT.....................64
PLUMBING - REAR......................98
CABIN HEATER........................113
HEATING & AIR
CONDITIONING
DESCRIPTION
ENGINE COOLING SYSTEM REQUIREMENTS
To maintain the performance level of the heating,
ventilation and air conditioning (HVAC) system, the
engine cooling system must be properly maintained.
The use of a bug screen is not recommended. Any
obstructions in front of the radiator or condenser will
reduce the performance of the air conditioning and
engine cooling systems.
The engine cooling system includes the radiator,
thermostat, radiator hoses and the engine coolant
pump. Refer to Cooling for more information before
opening or attempting any service to the engine cool-
ing system.
HEATER AND AIR CONDITIONER
A manually controlled single zone type heating-air
conditioning system, manually controlled dual zone
type heating-air conditioning system, manually con-
trolled three zone type heating-air conditioning sys-
tem or an automatic controlled three zone type
heating-air conditioning system is available on this
model.
All vehicles are equipped with a common heater,
ventilation and air conditioning (HVAC) housing (Fig.
1). The system combines air conditioning, heating,
and ventilating capabilities in a single unit housingmounted within the passenger compartment under
the instrument panel. The HVAC housing includes:
²Blower motor
²Blower motor resistor block or power module
(depending on application)
²Heater core
²Evaporator coil
²Blend door and actuator
²Mode door and actuator
²Recirculation door and actuator
Based upon the system and mode selected, condi-
tioned air can exit the HVAC housing through one or
Fig. 1 HVAC Housing - LHD Shown, RHD Typical
1 - HVAC HOUSING
2 - BOLT
3 - BRACKET
4 - DASH PANEL
RSHEATING & AIR CONDITIONING24-1

a combination of the three main housing outlets:
defrost, panel or floor. The defrost and panel outlets
are located on the top of the housing and the floor
outlet is located on the bottom of the housing. Once
the conditioned air exits the unit housing, it is fur-
ther directed through molded plastic ducts to the var-
ious outlets in the vehicle interior. These outlets and
their locations are as follows:
²Defroster Outlet- A single large defroster out-
let is located in the center of the instrument panel
top cover, near the base of the windshield.
²Side Window Demister Outlets- There are
two side window demister outlets, one is located at
each outboard end of the instrument panel, near the
A-pillars.
²Panel Outlets- There are five panel outlets in
the instrument panel, one located near each outboard
end of the instrument panel facing the rear of the
vehicle and three located near the top of the instru-
ment panel center bezel.
²Front Floor Outlets- There are two front floor
outlets, one located above each side of the center of
the floor panel near the dash panel.
MANUAL SINGLE ZONE
The manual single zone heating and A/C system
allows one temperature setting for the entire vehicle.
The full range of temperatures that the system can
produce are available by rotating the temperature
control located on the A/C-heater control.
The A/C-heater control and integral computer is
located in the instrument panel and contains:
²a rear window defogger on/off switch. Contains
an LED that illuminates to show when the function
is operational.
²an air recirculation on/off switch. The Recircu-
late button contains an LED that illuminates to show
when the function is in operation.
²an air conditioning on/off switch. The Snowflake
button contains an LED that illuminates to shown
when the function is in operation.
²a rotary knob for fan speed selection and turn-
ing the heater-A/C system off.
²a rotary knob for temperature control of the dis-
charged air.
²a rotary knob for mode control.
MANUAL DUAL ZONE
The manual dual zone heating and A/C system
allows completely independent side-to-side tempera-
ture control of the discharge air.
The A/C-heater control and integral computer is
located in the instrument panel and contains:
²a rear window defogger on/off switch. Contains
an LED that illuminates to show when the function
is operational.²slide controls for completely independent side-to-
side temperature control of the discharged air. The
full range of temperature that the system can pro-
duce in any mode is available on either side of the
vehicle by independently positioning the slide con-
trols on the instrument panel.
²an air recirculation on/off switch. The Recircu-
late button contains an LED that illuminates to show
when the function is in operation.
²an air conditioning on/off switch. The Snowflake
button contains an LED that illuminates to shown
when the function is in operation.
²a rotary knob for fan speed selection and turn-
ing the heater-A/C system off.
²a rotary knob for mode control.
MANUAL THREE ZONE
The fully adjustable manual three zone front and
rear heating and A/C system allows intermediate
seat passengers the ability to regulate air tempera-
ture as well as fan speed and provides floor outlets to
the rear of the right sliding door and overhead out-
lets at each rear outboard seating position. Primary
control for the rear blower is on the front A/C-heater
control. All controls are identified by ISO graphic
symbols.
FRONT CONTROL PANEL
The front A/C-heater control and integral computer
mounted in the instrument panel contains:
²a rear window defogger on/off switch.
²slide controls for completely independent side-to-
side temperature control of the discharge air. The full
range of temperature that the system can produce in
any mode is available on either side of the vehicle by
independently positioning the slide controls on the
instrument panel.
²an air recirculation button. The Recirculate but-
ton contains an LED that illuminates to show when
the function is in operation.
²an air conditioning button that allows the com-
pressor to be turned on/off. The Snowflake button
contains an LED that illuminates to shown when the
function is in operation.
²a rotary knob for front fan speed selection and
turning the heater-A/C system off.
²a rotary knob for rear fan speed selection.
²a rotary knob for mode control.
REAR CONTROL PANEL
The rear A/C-heater control centrally mounted in
the headliner allows intermediate seat passengers to
adjust rear air distribution, temperature and blower
motor speed when the center knob on the front A/C-
heater control is set to the Rear position. The rear
A/C-heater control contains:
24 - 2 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)

²a rotary adjustment knob for temperature.
²a rotary adjustment for fan speed control.
AUTOMATIC TEMPERATURE CONTROL
Two different automatic temperature control (ATC)
heating-A/C systems are available for this model
depending on the market.
The Dual-Zone ATC system allows the driver and
front occupants to each select individual comfort tem-
peratures.
The Three-Zone ATC system allows both the driver
and front occupants and the rear intermediate occu-
pants to select individual comfort temperatures.
NOTE: Individual comfort temperatures are the per-
ceived temperature level at the individual seating
areas, NOT the actual passenger compartment air
temperature.
The ATC system includes a particulate air filter.
The filter element is the same size as the A/C evap-
orator to ensure ample capacity. A door at the base of
the HVAC housing below the glove box provides easy
access to the filter element.
The ATC computer utilizes integrated circuitry and
information carried on the programmable communi-
cations interface (PCI) data bus network to monitor
many sensors and switch inputs throughout the vehi-
cle. In response to those inputs, the internal circuitry
and programming of the ATC computer allow it to
control electronic functions and features of the ATC
system. The inputs to the ATC computer are:
²Vehicle Speed/Engine RPM± The ATC com-
puter monitors engine rpm, vehicle speed and mani-
fold absolute pressure information from the
powertrain control module (PCM).
²Coolant Temperature± ATC computer moni-
tors coolant temperature received from the PCM and
converts it to degrees Fahrenheit.
²Ambient Temperature± ATC computer moni-
tors ambient temperature from the compass mini trip
computer (CMTC) and converts it to degrees Fahren-
heit.
²Engine Miscellaneous Sensor Status±ATC
computer monitors A/C disable information from the
PCM.
²Refrigerant Pressure± ATC computer moni-
tors barometric pressure, intake air temperature,
high side pressure and methanol content as broad-
cast by the PCM.
²Door Ajar Status± The ATC computer moni-
tors driver front door, passenger front door, left rear
door, right rear door and liftgate ajar information, as
identified by the body control module (BCM), to
determine if all in-car temperatures should be main-
tained.²Dimming± The ATC computer monitors dim-
ming status from the BCM to determine the required
level of brightness and will dim accordingly.
²Vehicle Odometer± The ATC computer moni-
tors the vehicle odometer information from the BCM
to prevent flashing the vacuum-flourescent (VF) dig-
ital display icons if the manual motor calibration or
manual cool down tests have failed. Flashing of the
display icons will cease when the vehicle odometer is
greater than 3 miles.
²English/Metric± The ATC computer monitors
the English/Metric information broadcast by the
CMTC. The set temp displays for both the front and
rear control heads will be set accordingly.
²Vehicle Identification Number± The ATC
computer monitors the last eight characters of the
VIN broadcast by the PCM and compares it to the
information stored in EEPROM. If it is different, the
new number will be stored over the old one and a
motor calibration shall be initiated.
²A/C System Information± The ATC computer
will send a message for evaporator temperature too
low, fan blower relay status, evaporator sensor fail-
ure, rear window defogger relay and A/C select.
FRONT CONTROL PANEL
The front A/C-heater control and integral computer
is mounted in the instrument panel and contains:
²a power button which allows the system to be
completely turned off. The display is blank when the
system is off.
²a rocker switch that selects a cool-down rate.
LO-AUTO or HI-AUTO are displayed when the sys-
tem is in automatic operation.
²three rocker switches that select comfort temper-
atures from 15É to 30É C (59É to 85É F), which are
shown in the VF digital display. If the set temp is 15É
C (59É F) and the down button is pressed, the set
temp value will become 13É C (55É F) but the display
will show LO. If the set temp is 29É C (85É F) and the
up button is pressed, the set temp value will become
32É C (90É F) but the display will show HIGH. Tem-
peratures can be displayed in either metric or Fahr-
enheit, which is controlled from the overhead console.
²an air conditioning button that allows the com-
pressor to be turned off. A Snowflake symbol is illu-
minated when air conditioning is on, whether under
manual or automatic control.
²an air recirculation button. A Recirculation sym-
bol appears in the display when the button is
pressed, or when the system exceeds 80 percent recir-
culated air under automatic control due to high air
conditioning demand.
²a rear window defogger on/off switch. A graphic
symbol shows when the defroster is on.
RSHEATING & AIR CONDITIONING24-3
HEATING & AIR CONDITIONING (Continued)