battery replacement CHRYSLER VOYAGER 2005 Owner's Manual

(3) Switch ignition ON position.
(4) Connect the clip end of a 12 volt test light to
Pin 13 in door harness connector at the window
switch. Touch the test light probe to Pin 9 and then
to Pin 11.
²If the test light illuminates, the wiring circuit
between the battery and switch is OK.
²If the lamp does not illuminate, first check the
25 amp circuit breaker attached to the electrical dis-
tribution wiring bracket. If the circuit breaker is OK,
then check the 40 amp fuse (#28) in the Integrated
Power Module (IPM). If both components are OK,
then check for a broken wire.
VENT WINDOW MOTOR
DIAGNOSIS AND TESTING
VENT WINDOW MOTOR
If the power vent window motor is receiving proper
current and ground and does not operate proceed
with motor test. Refer to the appropriate wiring
information.
(1) Remove D-pillar trim panel necessary to gain
access to power vent window motor wire connector,
(Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR
TRIM PANEL - REMOVAL) or (Refer to 23 - BODY/
INTERIOR/RIGHT D-PILLAR TRIM PANEL -
REMOVAL).
(2) Disconnect power vent window motor wire con-
nector from body harness.
(3) Using two jumper wires, connect one to a bat-
tery (+) source and the other to a good ground (-).
(4) Connect the Negative (-) jumper probe to one of
the motor connector terminals.
(5) Momentarily touch the Positive (+) jumper
probe to the other motor connector terminal.
When positive probe is connected the motor should
rotate in one direction to either move window open or
closed. If window is all the way open or closed the
motor will grunt and the crank system will flex when
actuated in that one direction.
Reverse jumper probes at the motor connector ter-
minals and window should now move in opposite
direction. If window does not move or grunt, replace
the motor.
If window moved completely open or closed, reverse
the jumper probes and cycle window to the opposite
position to verify full operation.
If motor grunts and does not move, verify that
crank system is not binding.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.(2) Remove D-pillar trim panel. (Refer to 23 -
BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL -
REMOVAL) or (Refer to 23 - BODY/INTERIOR/
RIGHT D-PILLAR TRIM PANEL - REMOVAL).
(3) Disconnect wire connector from power vent
motor.
(4) Using a flat bladed tool, carefully lift the circu-
lar actuator link tab. Remove link from window ball
socket.
(5) Remove bolts holding power vent motor to
D-pillar (Fig. 1).
(6) Remove power vent motor.
INSTALLATION
(1) Obtain new vent window motor.
(2) Snap the actuator link socket onto the quarter
window ball socket. Using a soft rubber mallet, push
the circular link tab flush with link surface.
(3) Install bolts holding power vent motor to D-pil-
lar.
(4) Reconnect wire connector to power vent motor.
(5) Reconnect the battery negative cable.
(6) Cycle quarter window open/close to verify func-
tion.
(7) Install D-pillar trim panel.
WINDOW MOTOR
REMOVAL
The window motor is incorporated into the window
regulator assembly. If the window motor requires
replacement, the window regulator must be replaced.
(Refer to 23 - BODY/DOOR - FRONT/WINDOW
REGULATOR - REMOVAL).
Fig. 1 VENT WINDOW MOTOR
1 - VENT WINDOW MOTOR
2 - WIRE HARNESS CONNECTOR
3 - BOLT
4 - VENT WINDOW
8N - 62 POWER WINDOWSRS
POWER WINDOWS (Continued)

driver and the front seat passenger to the structure
of the instrument panel (Refer to 8 - ELECTRICAL/
RESTRAINTS/KNEE BLOCKER AIRBAG -
DESCRIPTION). The seat belt tensioners remove the
slack from the front seat belts to provide further
assurance that the driver and front seat passenger
are properly positioned and restrained for an airbag
deployment.
When the ORC monitors a problem in any of the
dual front airbag system circuits or components,
including the seat belt tensioners, it stores a Diag-
nostic Trouble Code (DTC) in its memory and sends
an electronic message to the EMIC to turn on the
airbag indicator. Proper testing of the supplemental
restraint system components, the Programmable
Communications Interface (PCI) data bus, the elec-
tronic message inputs to and outputs from the EMIC
or the ORC, as well as the retrieval or erasure of a
DTC from the ORC or the EMIC requires the use of
a scan tool. Refer to the appropriate diagnostic infor-
mation.
OCCUPANT CLASSIFICATION SYSTEM
The Occupant Classification System (OCS) auto-
matically suppresses or enables passenger airbag and
seat belt tensioner operation based upon whether or
not the passenger side front seat is occupied and, if
the seat is occupied, classifies the size of the occu-
pant and whether the seat is occupied by a child
seat.
The OCS has an Occupant Classification Module
(OCM) that monitors inputs from the seat weight
bladder pressure sensor under the passenger side
front seat cushion and from the belt tension sensor
on the passenger side front seat belt lower anchor.
Based upon those inputs the microprocessor within
the OCM classifies the occupant of the passenger
side front seat. The OCM then sends electronic occu-
pant classification messages to the ORC. The micro-
processor and programming of the ORC uses these
occupant classification messages to determine
whether to enable or disable the deployment circuits
for the passenger airbag and seat belt tensioner.
The OCS electrical circuits and components are
continuously monitored by the OCM, and the OCM is
continuously monitored by the ORC. A passenger air-
bag ON/OFF indicator is located in the instrument
panel center stack area. This indicator receives bat-
tery current whenever the ignition switch is in the
ON or START positions, and illuminates only when
the ORC pulls the indicator control circuit to ground.
The indicator illuminates for about seven seconds as
a bulb test each time the ignition switch is turned to
the ON or START positions. Following the bulb test,
the indicator is turned ON or OFF by the ORC based
upon the electronic occupant classification messagesreceived from the OCM. This indicator is illuminated
whenever the passenger airbag and seat belt ten-
sioner operation has been suppressed, and is turned
OFF whenever they are enabled or when the passen-
ger seat is classified as empty.
When the OCM monitors a problem in any of the
OCS circuits or components, it stores a fault code or
DTC in its memory circuit and sends an electronic
message to the ORC. The ORC then sends an elec-
tronic message to the EMIC to turn ON the airbag
indicator. If for any reason the OCM is unable to
classify the occupant it sends an electronic message
to the ORC, and the ORC suppresses passenger air-
bag and seat belt tensioner operation. Proper testing
of the OCS components, the Programmable Commu-
nications Interface (PCI) data bus, the electronic
message inputs to and outputs from the OCM, the
EMIC or the ORC, as well as the retrieval or erasure
of a DTC's, requires the use of a scan tool. Refer to
the appropriate diagnostic information.
WARNING
WARNINGS
Disconnect and isolate the battery negative
cable before beginning any airbag system com-
ponent diagnosis, testing, removal, or installa-
tion procedures. Allow system capacitor to
discharge for two minutes before beginning any
component testing or service. This will disable
the airbag system. Failure to disconnect the
battery negative cable may result in accidental
airbag deployment, personal injury, or death.
Do not place an intact undeployed airbag
face down on a solid surface. The airbag will
propel into the air if accidentally deployed and
may result in personal injury or death.
When carrying or handling an undeployed
airbag, the trim side (face) of the airbag should
be pointing towards the body to minimize pos-
sibility of injury if accidental deployment
occurs. Failure to do this may result in per-
sonal injury or death.
Replace airbag system components with
Mopartreplacement parts. Substitute parts
may appear interchangeable, but internal dif-
ferences may result in inferior occupant protec-
tion. Failure to do so may result in occupant
personal injury or death.
Wear safety glasses, rubber gloves, and long
sleeved clothing when cleaning powder residue
from vehicle after airbag deployment. Sodium
hydroxide powder residue emitted from a
deployed airbag can cause skin irritation.
Flush affected area with cool water if irritation
is experienced. If nasal or throat irritation is
RSRESTRAINTS8O-5
RESTRAINTS (Continued)

experienced, exit the vehicle for fresh air until
the irritation ceases. If irritation continues, see
a physician.
Do not use a replacement airbag that is not in
the original packaging. This may result in
improper deployment, personal injury, or
death.
The factory installed fasteners, screws and
bolts used to fasten airbag components have a
special coating and are specifically designed
for the airbag system. Do not use substitute fas-
teners. Use only original equipment fasteners
listed in the parts catalog when fastener
replacement is required.
During, and following, any child restraint
anchor service, due to impact event or vehicle
repair, carefully inspect all mounting hard-
ware, tether straps, and anchors for proper
installation, operation, or damage. If a child
restraint anchor is found damaged in any way,
the anchor must be replaced. Failure to do this
may result in personal injury or death.
Deployed and nondeployed airbags may or
may not have live pyrotechnic material within
the airbag inflator. Do not dispose of driver/
passenger/seat/curtain/knee blocker airbags or
seat belt tensioners unless you are sure of com-
plete deployment. Refer to the Hazardous Sub-
stance Control System for proper disposal.
Dispose of deployed airbags and tensioners
consistent with state, provincial, local, and fed-
eral regulations.
After any airbag component testing or ser-
vice, do not connect the battery negative cable
(Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM).
Personal injury or death may result if the sys-
tem test is not performed first.
If the vehicle is equipped with the Occupant
Classification System (OCS), do not connect the
battery negative cable before performing the
OCS Verification Test using the scan tool and
the appropriate diagnostic information. Per-
sonal injury or death may result if the system
test is not performed properly.
Never replace both the Occupant Restraint
Controller (ORC) and the Occupant Classifica-
tion Module (OCM) at the same time. If both
require replacement, replace one, then perform
the Airbag System test (Refer to 8 - ELECTRI-
CAL/RESTRAINTS - DIAGNOSIS AND TESTING
- AIRBAG SYSTEM) before replacing the other.
Both the ORC and the OCM store Occupant
Classification System (OCS) calibration data,
which they transfer to one another when one of
them is replaced. If both are replaced at thesame time, an irreversible fault will be set in
both modules and the OCS may malfunction
and cause personal injury or death.
DIAGNOSIS AND TESTING - AIRBAG SYSTEM
(1) With the battery negative remote cable discon-
nected, connect the scan tool to the Data Link Con-
nector (DLC).
(2) Turn the ignition key to the ON position, then
exit vehicle with the scan tool.
(3) After checking that no one is inside the vehicle,
connect the battery negative remote terminal.
(4) Read and record theACTIVEDiagnostic Trou-
ble Code (DTC) data.
(5) Read and record anySTOREDDTC's.
(6) Refer to the proper diagnostic information if
any DTC's are found in Step 4 and Step 5.
(7) If the airbag warning lamp either fails to light,
or goes ON and stays ON, there is a system malfunc-
tion. To test the airbag warning lamp (bulb) opera-
tion in the cluster (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER - DIAGNOSIS AND
TESTING). Refer to the proper diagnostic informa-
tion for any other system problems.
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
AIRBAGS
DEPLOYED AIRBAG
WARNING: The vehicle interior may contain a very
small amount of powder, a by-product of airbag
deployment. This powder can irritate the skin, eyes,
nose and throat. Wear safety glasses, rubber
gloves, and long sleeved clothing when cleaning
any of the powder residue from the vehicle. If you
find that the cleanup is irritating your skin, run cool
water over the affected area. Also, if you experience
nasal or throat irritation, exit the vehicle for fresh
air until the irritation ceases. If irritation continues,
see a physician.
8O - 6 RESTRAINTSRS
RESTRAINTS (Continued)

Service replacement clocksprings are shipped pre-
centered and with a molded plastic shield that snaps
onto the rotor over the release button. The release
button secures the centered clockspring rotor to the
clockspring case and the shield prevents the release
button from being inadvertently depressed during
shipment and handling, but the shield must be
removed from the clockspring after it is installed on
the steering column (Refer to 8 - ELECTRICAL/RE-
STRAINTS/CLOCKSPRING - STANDARD PROCE-
DURE).
The clockspring cannot be repaired. If the clock-
spring is faulty, damaged, or if the driver airbag has
been deployed, the clockspring must be replaced.
OPERATION
The clockspring is a mechanical electrical circuit
component that is used to provide continuous electri-
cal continuity between the fixed instrument panel
wire harness and the electrical components mounted
on or in the rotating steering wheel. The rotating
electrical components include the driver airbag, the
horn switch, the speed control switches, and the
remote radio switches, if the vehicle is so equipped.
The clockspring case is positioned and secured to the
upper steering column housing near the top of the
steering column. The connector receptacles on the
tail of the clockspring case connect the clockspring to
the vehicle electrical system through two connectors
from the instrument panel wire harness.
The clockspring rotor is movable and is keyed by
the tower formation that is molded onto the upper
surface of the rotor hub to an opening that is cast
into the steering wheel armature. Rubber bumper
blocks on either side of the clockspring tower forma-
tion eliminate contact noise between the clockspring
tower and the steering wheel. The lobe of the turn
signal cancel cam on the lower surface of the clock-
spring rotor hub contacts a turn signal cancel actua-
tor of the multi-function switch to provide automatic
turn signal cancellation. The yellow or black-sleeved
pigtail wires on the upper surface of the clockspring
rotor connect the clockspring to the driver airbag,
while a steering wheel wire harness connects the
connector receptacle on the upper surface of the
clockspring rotor to the horn switch and, if the vehi-
cle is so equipped, to the optional speed control
switches and remote radio switches on the steering
wheel.
The clockspring tape has travel limits and can be
damaged by being wound too tightly during full stop-
to-stop steering wheel rotation. To prevent this from
occurring, the clockspring is centered when it is
installed on the steering column. Centering the clock-
spring indexes the clockspring tape to the movable
steering components so that the tape can operatewithin its designed travel limits. However, if the
clockspring is removed from the steering column or if
the steering shaft is disconnected from the steering
gear, the clockspring spool can change position rela-
tive to the movable steering components and must be
re-centered following completion of the service or the
tape may be damaged (Refer to 8 - ELECTRICAL/
RESTRAINTS/CLOCKSPRING - STANDARD PRO-
CEDURE).
Service replacement clocksprings are shipped pre-
centered and with a plastic shield installed over the
clockspring release button. This shield should not be
removed and the release button should not be
depressed until the clockspring has been installed on
the steering column. If the release button is
depressed before the clockspring is installed on a
steering column, the clockspring centering procedure
must be performed (Refer to 8 - ELECTRICAL/RE-
STRAINTS/CLOCKSPRING - STANDARD PROCE-
DURE).
STANDARD PROCEDURE - CLOCKSPRING
CENTERING
If the rotating tape (wire coil) in the clockspring is
not positioned properly with the steering wheel and
the front wheels, the clockspring may fail. The fol-
lowing procedure MUST BE USED to center the
clockspring if it is not known to be properly posi-
tioned, or if the front wheels were moved from the
straight ahead position.
(1) Position steering wheel and front wheels
straight ahead.
(2) Release hood latch and open hood.
(3) Disconnect and isolate the battery negative
cable.
(4) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(5) Remove driver airbag from steering wheel
(Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER
AIRBAG - REMOVAL).
(6) Disconnect wire connectors from back of driver
airbag.
(7) Disconnect the 2±way connector from remote
radio control harness (if equipped).
(8) Disconnect the 4±way harness connector from
the speed control (if equipped)/horn harness to the
clockspring.
(9) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(10) Rotate the clockspring rotor clockwise until
the rotor stops. Do not apply excessive force.
(11) From the end of travel, rotate the rotor two
turns counterclockwise until the wires end up at the
top.
RSRESTRAINTS8O-11
CLOCKSPRING (Continued)

anchor. The OCM then monitors the return voltage
from each of the sensors. The bladder pressure sen-
sor input allows the OCM to determine whether the
passenger front seat is occupied and the relative size
of the occupant by providing a weight-sensing refer-
ence to the load on the seat cushion. The belt tension
sensor provides an additional logic input to the OCM
microprocessor that allows it to distinguish between
the lower seat belt cinch loads of a belted occupant
and the higher loads associated with a belted child
seat.
Pre-programmed decision algorithms and OCS cal-
ibration allow the OCM microprocessor to determine
when the seat cushion load as signaled by the blad-
der pressure sensor and the seat belt cinch load as
signaled by the belt tension sensor indicate that pas-
senger airbag protection is appropriate. When the
programmed conditions are met, the OCM sends the
proper electronic occupant classification messages
over the PCI data bus to the Occupant Restraint
Controller (ORC), and the ORC enables or disables
the deployment circuits for the passenger front sup-
plemental restraints. The ORC also provides a con-
trol output for the Passenger Airbag Disabled (PAD)
indicator in the instrument panel center stack, based
upon the electronic occupant classification messages
it receives from the OCM.
The OCM microprocessor continuously monitors all
of the OCS electrical circuits and components to
determine the system readiness. If the OCM detects
a monitored system fault, it sets an active and stored
Diagnostic Trouble Code (DTC) and sends the appro-
priate electronic messages to the ORC over the PCI
data bus. Then the ORC sets a DTC and sends mes-
sages to control the airbag indicator operation
accordingly. An active fault only remains for the
duration of the fault, or in some cases for the dura-
tion of the current ignition switch cycle, while a
stored fault causes a DTC to be stored in memory by
the OCM and the ORC. For some DTC's, if a fault
does not recur for a number of ignition cycles, the
OCM will automatically erase the stored DTC. For
other internal faults, the stored DTC is latched for-
ever.
The OCM receives battery current from an IPM
high side driver (Run/Start). The OCM receives
ground through a ground circuit of the body wire
harness, which it shares with the ORC. These con-
nections allow the OCM to be operational whenever
the ignition switch is in the Start or ON positions.
To diagnose and test the OCS, use a scan tool and
the appropriate diagnostic information.
REMOVAL
Once any of the original factory-installed compo-
nents except the Occupant Classification Module(OCM) have been replaced with the service replace-
ment package components, the OCM can only be ser-
viced by replacing the entire passenger front seat
cushion unit with another complete service replace-
ment package (Refer to 23 - BODY/SEATS/SEAT
CUSHION - FRONT - REMOVAL).
WARNING: Never replace both the Occupant
Restraint Controller (ORC) and the Occupant Clas-
sification Module (OCM) at the same time. If both
require replacement, replace one, then perform the
Airbag System test (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING - AIRBAG
SYSTEM) before replacing the other. Both the ORC
and the OCM store Occupant Classification System
(OCS) calibration data, which they transfer to one
another when one of them is replaced. If both are
replaced at the same time, an irreversible fault will
be set in both modules and the OCS may malfunc-
tion and result in personal injury or death.
(1) Disconnect and isolate the battery negative
cable.
(2)
WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to
do so may result in accidental airbag deployment,
personal injury or death.
(3) Reach under the front edge of the passenger
side front seat cushion to access and remove the lock
pin from the connector lock tower on the Occupant
Classification Module (OCM) (Fig. 36).
(4) Disconnect the passenger front seat wire har-
ness connector for the OCM.
(5) Remove the two screws that secure the OCM to
the OCM bracket.
(6) Remove the OCM from under the passenger
front seat.
INSTALLATION
WARNING: To avoid personal injury or death on
vehicles equipped with the Occupant Classification
System (OCS), only the Occupant Classification
Module (OCM) and the seat cushion trim may be
serviced separately. All other components of the
passenger front seat cushion must be serviced only
as a complete factory-calibrated, assembled and
tamper-evident service replacement package.
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-
8O - 26 RESTRAINTSRS
OCCUPANT CLASSIFICATION MODULE (Continued)

ger side front seat cushion unit with another com-
plete service replacement package. (Refer to 23 -
BODY/SEATS/SEAT CUSHION - FRONT -
REMOVAL).
WARNING: Never replace both the Occupant
Restraint Controller (ORC) and the Occupant Clas-
sification Module (OCM) at the same time. If both
require replacement, replace one, then perform the
Airbag System test (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING - AIRBAG
SYSTEM) before replacing the other. Both the ORC
and the OCM store Occupant Classification System
(OCS) calibration data, which they transfer to one
another when one of them is replaced. If both are
replaced at the same time, an irreversible fault will
be set in both modules and the OCS may malfunc-
tion may result in personal injury or death.
(1) Carefully position the Occupant Classification
Module (OCM) to the OCM bracket (Fig. 36). When
the OCM is correctly positioned, the connector on the
module will be pointed to right side of the vehicle.
(2) Install the two screws to the OCM. Torque the
screws to 2 N´m (20 in. lbs.).
(3) Connect the seat wire harness connector for the
OCM. Be certain that the latches on the connector
are each fully engaged.(4) Install the lock pin into the connector lock
tower on the OCM.
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
WARNING: Following successful completion of the
Airbag System test procedure, the Occupant Classi-
fication System Verification Test must be done
using a scan tool and the appropriate diagnostic
information.
(5) Verify vehicle and system operation.
(6) Close hood.
OCCUPANT RESTRAINT
CONTROLLER
DESCRIPTION
The Occupant Restraint Controller (ORC) (Fig. 37)
is also sometimes referred to as the Airbag Control
Module (ACM).
Fig. 36 OCM - REMOVE/INSTALL
1 - OCCUPANT CLASSIFICATION MODULE (OCM)
2 - LOCK TOWER
3 - LOCK PIN
4 - CONNECTOR
5 - SCREW (2)
6 - BRACKET
Fig. 37 OCCUPANT RESTRAINT CONTROLLER -
TYPICAL
1 - ORC
2 - ORIENTATION ARROW UPON INSTALLATION
3 - LABEL
4 - ORC ELECTRICAL CONNECTORS
RSRESTRAINTS8O-27
OCCUPANT CLASSIFICATION MODULE (Continued)

restraint system protection in case there is a loss of
battery current supply to the ORC during an impact.
Two sensors are contained within the ORC, an
electronic impact sensor and a safing sensor. The
ORC also monitors inputs from eight remote impact
sensors. Two front impact sensors are located on each
outboard side of the lower radiator support, and
three side impact sensors are located on each side of
the vehicle at the B-pillar, in the lower sliding door
opening in front of the C-pillar, and over the rear
wheel well between the C and D-pillars. The elec-
tronic impact sensors are accelerometers that sense
the rate of vehicle deceleration, which provides veri-
fication of the direction and severity of an impact.
The safing sensor is an electronic accelerometer
sensor within the ORC that provides an additional
logic input to the ORC microprocessor. The safing
sensor is used to verify the need for a supplemental
restraint deployment by detecting impact energy of a
lesser magnitude than that of the primary electronic
impact sensors, and must exceed a safing threshold
in order for the airbags to deploy. Vehicles equipped
with curtain airbags, there is a second safing sensor
within the ORC to provide confirmation to the ORC
microprocessor of side impact forces. This second saf-
ing sensor is a bi-directional unit that detects impact
forces from either side of the vehicle.
Pre-programmed decision algorithms in the ORC
microprocessor determine when the deceleration rate
as signaled by the impact sensors and the safing sen-
sors indicate an impact that is severe enough to
require supplemental restraint system protection
and, based upon the severity of the monitored
impact, determines the level of front airbag deploy-
ment force required for each front seating position.
When the programmed conditions are met, the ORC
sends the proper electrical signals to deploy the dual
multistage front airbags at the programmed force
levels, the front seat belt tensioners and, if the vehi-
cle is so equipped, either curtain airbag. For vehicles
equipped with the OCS, the passenger front airbag
and seat belt tensioner will be deployed by the ORC
only if enabled by the OCM messages (PAD indicator
OFF) at the time of the impact.
To diagnose and test the ORC and all airbag sys-
tem components, use a scan tool and the appropriate
diagnostic information.
REMOVAL
WARNING: Never replace both the Occupant
Restraint Controller (ORC) and the Occupant Clas-
sification Module (OCM) at the same time. If both
require replacement, replace one, then perform the
Airbag System test (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING - AIRBAGSYSTEM) before replacing the other. Both the ORC
and the OCM store Occupant Classification System
(OCS) calibration data, which they transfer to one
another when one of them is replaced. If both are
replaced at the same time, an irreversible fault will
be set in both modules and the OCS may malfunc-
tion and result in personal injury or death.
(1) Disconnect and isolate the battery negative
cable.
(2)
WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to
do so may result in accidental airbag deployment,
personal injury or death.
(3) Remove storage bin from instrument panel
(Refer to 23 - BODY/INSTRUMENT PANEL/STOR-
AGE BIN - REMOVAL).
(4) Remove three bolts holding ORC to floor
bracket (Fig. 39).
(5) Disconnect the wire connectors from the ORC
(Fig. 39).
(6) Remove the ORC from vehicle.
INSTALLATION
WARNING: Do not install ORC if mounting location
is deformed or damaged. This will cause the ORC
to be improperly located and could result in occu-
pant personal injury or death.
WARNING: Use correct screws when installing the
ORC.
Fig. 39 ORC - REMOVE/INSTALL
1 - ORC ELECTRICAL CONNECTORS
2 - ORC
3 - ORC MOUNTING SCREWS
RSRESTRAINTS8O-29
OCCUPANT RESTRAINT CONTROLLER (Continued)

WARNING: Never replace both the Occupant
Restraint Controller (ORC) and the Occupant Clas-
sification Module (OCM) at the same time. If both
require replacement, replace one, then perform the
Airbag System test (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING - AIRBAG
SYSTEM) before replacing the other. Both the ORC
and the OCM store Occupant Classification System
(OCS) calibration data, which they transfer to one
another when one of them is replaced. If both are
replaced at the same time, an irreversible fault will
be set in both modules and the OCS may malfunc-
tion and result in personal injury or death.
(1) Install the ORC into vehicle (Fig. 39).
(2) Connect the wire connector to the ORC (Fig.
39).
(3) Install three bolts holding ORC to floor bracket
(Fig. 39). Torque bolts to 7.3 - 9.6 N´m (65 to 85 in.
lbs.)
(4) Install the storage bin onto the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
STORAGE BIN - INSTALLATION).
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
(5) Verify vehicle and system operation.
(6) Close hood.
PASSENGER AIRBAG
DESCRIPTION
WARNING: Never disassemble the passenger air-
bag. The passenger airbag has no serviceable
parts. If tampered with internally, the airbag could
deploy and result in personal injury or death.
The Passenger Airbag is located beneath the
instrument panel and pad assembly. The airbag is
mounted to the back side of the instrument panel
reinforcement.
The instrument panel top pad is the most visible
part of the passenger airbag system. Located under
the instrument panel top pad are the airbag door, the
passenger airbag cushion and the airbag cushion
supporting components.
The passenger airbag includes a magnesium hous-
ing within which the cushion and inflator are
mounted and sealed.
Following a passenger airbag deployment, the pas-
senger airbag and the instrument panel must bereplaced. The passenger airbag cannot be repaired,
and must be replaced if deployed or damaged in any
way.
OPERATION
The passenger airbag is equipped with two infla-
tors, each with three levels of pressure output. The
inflators seal the hole in the airbag cushion so it can
discharge the gas it produces directly into the cush-
ion when supplied with the proper electrical signal.
Following an airbag deployment, the airbag cushion
quickly deflates by venting this gas through the
cushion material towards the instrument panel.
The passenger airbag is secured with screws to the
instrument panel beneath the instrument panel top
pad and above the glove box opening. The instrument
panel top pad above the glove box opening conceals
the airbag door and a predetermined hinge line
beneath its decorative cover. Upon airbag deploy-
ment, the top pad will bend at the hinge line and the
door will fold back out of the way onto the top of the
instrument panel.
When the front airbag system is deployed, the fol-
lowingMUSTbe replaced:
²Complete Steering Column Assembly.
²Lower Steering Column Coupler.
²Steering Wheel.
²Clock Spring.
²Driver Airbag.
²Passenger Airbag.
²Upper Instrument Panel with Pad.
CARE OF UNDEPLOYED AIRBAGS
Airbags must be stored in their original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag. When carrying or handling an
undeployed airbag, the trim side of the airbag should
be pointing away from the body to minimize possibil-
ity of injury if accidental deployment occurs. Do not
place undeployed airbag face down on a solid surface,
the airbag will propel into the air if accidental
deployment occurs.
REMOVAL
DEPLOYED AIRBAG
(1) Open hood.
(2) Disconnect and isolate the battery negative
cable.
(3)
8O - 30 RESTRAINTSRS
OCCUPANT RESTRAINT CONTROLLER (Continued)

(28) Install two right side nuts at instrument
panel center stack support to floor.
(29) Install two left side nuts at instrument panel
center stack support to floor.
(30) Connect the two wiring connectors to lower
instrument panel cubby bin at bottom of center stack
and install six screws.
(31) Align left side upper A-pillar trim over retain-
ing slots and firmly snap into place.
(32) Install four nuts at brake pedal support
bracket to instrument panel.
(33) Align left A-pillar lower extension trim over
retaining slots and firmly snap into place.
(34) Install knee blocker and retaining screws.
(35) Install Data Link Connector (DLC) into bot-
tom of knee blocker.
(36) Align parking brake lever and snap into place
on knee blocker reinforcement.
(37) Install lower steering column cover and four
retaining screws
(38) Align left cowl panel over retaining slots and
firmly snap into place.
(39) Align left front door sill plate over retaining
slots and firmly snap into place.
(40) Install center console bin between front seats.
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
(41) Close hood.
(42) Verify system and vehicle operation.
PASSENGER AIRBAG
DISABLED INDICATOR
DESCRIPTION
Vehicles equipped with the Occupant Classification
System (OCS) include a Passenger Airbag Disabled
(PAD) indicator (Fig. 40) which is located in the
instrument panel center stack, above the radio. The
PAD indicator is present only in vehicles equipped
with the OCS.The PAD indicator consists of a molded plastic
housing with an integral connector at the back. An
amber Light Emitting Diode (LED) behind the lens
causes the ªPASS AIR BAG OFFº text and icon to
appear silhouetted against an amber field through
the translucent lens when the indicator is illumi-
nated from behind by the LED. The PAD indicator is
available for separate service replacement.
OPERATION
In vehicles equipped with the Occupant Classifica-
tion System (OCS), the Passenger Airbag Disabled
(PAD) indicator gives an indication when the passen-
ger airbag and seat belt tensioner deployment cir-
cuits are disabled by the Occupant Restraint
Controller (ORC). The PAD indicator is controlled by
a transistor within the ORC through a hard wired
output based upon ORC programming and electronic
occupant classification messages received by the ORC
over the Programmable Communications Interface
(PCI) data bus from the Occupant Classification
Module (OCM). The PAD indicator Light Emitting
Diode (LED) is completely controlled by the ORC.
The LED receives a battery current input on the
fused ignition switch output (RUN/START) circuit.
Therefore, the LED will always be OFF when the
ignition switch is in any position except ON or
START. The LED only illuminates when it is pro-
vided a path to ground by the ORC transistor. The
ORC will turn on the PAD indicator for the following
reasons:
²Bulb Test- Each time the ignition switch is
turned to the ON position the PAD indicator is illu-
minated for about six seconds.
²Child Seat Detected Occupant Classifica-
tion Message- Each time the ORC receives a mes-
sage from the OCM indicating a child seat has been
detected in the passenger front seat, the passenger
airbag and seat belt tensioner deployment circuits
are deactivated and the PAD indicator will be illumi-
nated. The indicator remains illuminated until the
ORC receives an occupant classification message
indicating that:
²The passenger front seat is empty.
²The seat is occupied by a load equal to or
greater than a fifth percentile female.
²OR,Until the ignition switch is turned to the
OFF position, whichever of these three occurs first.
²Load Less Than Fifth Percentile Female
Occupant Classification Message- Each time the
ORC receives a message from the OCM indicating
that a load less than a fifth percentile female has
been detected in the passenger front seat, the pas-
senger airbag and seat belt tensioner deployment cir-
cuits are deactivated and the PAD indicator will be
illuminated. The indicator remains illuminated until:
Fig. 40 PASSENGER AIRBAG DISABLED (PAD)
INDICATOR
RSRESTRAINTS8O-33
PASSENGER AIRBAG (Continued)

CABLE
DESCRIPTION
The speed control servo cable is connected between
the speed control vacuum servo diaphragm and the
throttle body control linkage.
OPERATION
This cable causes the throttle control linkage to
open or close the throttle valve in response to move-
ment of the vacuum servo diaphragm.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove speed control cable from throttle cam
by sliding clasp out hole used for throttle cable.
(3) Compress the retaining tabs on the cable and
slide cable out of bracket.
(4) Disconnect electrical connectors and vacuum
hose from servo.
(5) Remove two nuts attaching speed control cable
and mounting bracket to servo.
(6) Pull cable away from servo to expose retaining
clip and remove clip attaching cable to servo.
(7) Remove speed control cable.
INSTALLATION
(1) Slide cable into throttle cable bracket and
engage retaining tabs.
(2) Rotate the throttle cam forward to the wide
open position and install speed control cable clasp.
(3) Rotate the throttle cam forward to the wide
open position and install throttle cable clasp.
(4) Install retaining clip that attaches cable to
servo.
(5) Insert servo studs through holes in the mount-
ing bracket and speed control cable.
(6) Install nuts, tighten to 6.7 N´m (60 in. lbs.).
(7) Connect vacuum hose to servo.
(8) Connect electrical connector.
(9) Install servo and bracket and tighten nuts and
bolt.
(10) Connect negative battery cable.
SERVO
DESCRIPTION
The servo unit consists of a solenoid valve body,
and a vacuum chamber. The solenoid valve body con-
tains three solenoids:
²Vacuum
²Vent
²Dump
The vacuum chamber contains a diaphragm with a
cable attached to control the throttle linkage.
OPERATION
The PCM controls the solenoid valve body. The
solenoid valve body controls the application and
release of vacuum to the diaphragm of the vacuum
servo. The servo unit cannot be repaired and is ser-
viced only as a complete assembly.
Power is supplied to the servo by the PCM through
the brake switch. The PCM controls the ground path
for the vacuum and vent solenoids.
The dump solenoid is energized anytime it receives
power. If power to the dump solenoid is interrupted,
the solenoid dumps vacuum in the servo. This pro-
vides a safety backup to the vent and vacuum sole-
noids.
The vacuum and vent solenoids must be grounded
by the PCM to operate. When the PCM grounds the
vacuum servo solenoid, the solenoid allows vacuum
to enter the servo and pull open the throttle plate
using the cable. When the PCM breaks the ground,
the solenoid closes and no more vacuum is allowed to
enter the servo. The PCM also operates the vent sole-
noid via ground. The vent solenoid opens and closes a
passage to bleed or hold vacuum in the servo as
required.
The PCM cycles the vacuum and vent solenoids to
maintain the set speed, or to accelerate and deceler-
ate the vehicle. To increase throttle opening, the
PCM grounds the vacuum and vent solenoids. To
decrease throttle opening, the PCM removes the
grounds from the vacuum and vent solenoids.
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect the negative battery cable.
(3) Disconnect the throttle and speed control cable
ends from throttle body (Fig. 2).
(4) Depress lock tabs holding speed control and
throttle cable casing to cable mount bracket.
(5) Disconnect vacuum line from speed control
servo that leads to the battery tray/vacuum reservoir.
(6) Remove battery tray/vacuum reservoir, refer to
the Battery section for more information (Fig. 3).
(7) Remove speed control servo and bracket (Fig.
4).
(8) Disconnect wire connector from speed control
servo.
(9) Remove speed control servo.
INSTALLATION
Transfer speed control cable to replacement speed
control servo.
(1) Install retaining clip to cable at servo.
(2) Install 2 nuts at cable to servo and servo
bracket, tighten to 7 N´m (60 ins. lbs.).
(3) Connect electrical connector to servo.
8P - 4 SPEED CONTROLRS