Audiovox CTV-5060 Service manual

1997/1998
Service/Parts
Service
Man
Manual
Version 97/98/99.1.0.Chrysler 4/27/99
1
1997/1998 Chrysler
Service Manual
Table of Contents
1. Table of Contents------------------------------------------2
2. Warranty and Parts Ordering Information -----------3
3. Labor Times -------------------------------------------------13
4. LWB Full Size Van Procedures Low Top------------27
5. LWB Full Size Van Procedures Sport Top ----------34
6. SWB Full Size Van Procedures Low Top -----------42
7. SWB Full Size Van Procedures Sport Top----------48
8. Voyager/Caravan Mini Van Procedures -------------54
9. Pickup Procedures ----------------------------------------58
10. Jeep Procedures -----------------------------------------63
11. Electrical Schematics -----------------------------------70
12. Electrical Trouble Shooting ----------------------------81
13. Graphics Trouble Shooting ----------------------------105
14. Wheel and Tire Trouble Shooting--------------------109
15. Rear Air Trouble Shooting -----------------------------112
16. Power Slider Trouble Shooting and Removal ----136
17. Alarm and Keyless Entry Trouble Shooting -------141
18. Running Boards ------------------------------------------143
2
Table of Contents
Warranty and Parts Ordering Information
Accessories Manufacturer Warranties ------------------------------------------- 8
Chemical Paint Spotting ------------------------------------------------------------- 10
Coverage Provided-------------------------------------------------------------------- 7
Customer assistance ----------------------------------------------------------------- 12
Customer Care ------------------------------------------------------------------------- 4
Limited Original Equipment Manufacturer Warranty ------------------------- 9
Mark III Original Equipment Alterations------------------------------------------ 11
Mark III Warranty Coverage Overview ------------------------------------------- 8
Month/ 36,000 Mile Warranty------------------------------------------------------- 7
Other 97/98 Model Year Warranty Terms--------------------------------------- 11
Paint, Trim, and Appearance Items----------------------------------------------- 10
Procedure for Returning Parts (Warranty Parts) ----------------------------- 5
Procedure for Returning Parts (New Non Warranty Parts) ----------------- 6
Product Display and Protection ---------------------------------------------------- 5
Production Changes ------------------------------------------------------------------ 11
Repair Order Processing Procedures -------------------------------------------- 4
Returned For Credit Parts Procedure (RFC) ----------------------------------- 6
Roadside Assistance ----------------------------------------------------------------- 11
Sheet Metal Coverage---------------------------------------------------------------- 11
Transportation Damage-------------------------------------------------------------- 12
What does your Mark III 97/98 Model Year warranty Cover---------------- 7
What is not Covered ------------------------------------------------------------------ 9
When Does the Warranty Begin--------------------------------------------------- 7
Who is Covered ------------------------------------------------------------------------ 7
3
Warranty Information
1997/1998 Model Year
Should any Mark III conversion require service, the service representative working with
your dealership will need the following information to obtain an authorization number
for repairs. When Mark III parts are required, call the Mark III Customer Care Center
Toll-free number.
Orders placed prior to 3:30 P.M. EST each day will be shipped the following day if it is
a stocked item. items which must be assembled or painted require 2 working days after
order is placed before shipment. Warranty parts are shipped C.O.D./ R.F.C. (return for
credit) or no charge. Non-warranty parts are shipped out C.O.D., plus freight and
handling fee (7%). Please use the following telephone numbers:
Service Representative 1-800-726-8267
FAX 352-351-2321
Prior authorization is not needed if repairs are within the Mark III allowable guidelines
(Refer to the Labor Times Section of the Service Manual)
Have the following information available when contacting your Mark III Service Representative:
1. Last eight (8) digits of VIN (Vehicle Identification Number) or the Mark III Production number
2. Repair Order Number (Labor Authorizations only)
3. Owner's name, address and phone number.
4. Dealer's name, address and phone number.
5. Date of retail purchase
6. Mileage of van or pickup
7. Description of Mark III parts (page and Item Number from Mark III Parts Manual if
available) or OEM parts used.
Note
“CS” in the Mark III Parts Manual represents COLOR SPECIFIC.
8. Itemize defects
9. Itemize labor time per defect and annotate your current shop labor rate.
10. Purchase order is required when ordering warranty or non-warranty parts.
Repair Order Processing Procedures
All warranty repair orders (RO’s) will be approved for payment when the following information has been verified
and approved:
1. Vehicle identification number.
2. Customer name, address and phone number.
3. Date unit was purchased.
4. Current mileage at time unit was repaired.
5. Dealership hourly labor rate.
6. List each repair and an itemized description of what was actually done to correct the problem. Please indicate
“how long” it took to repair.
7. List / describe each part used.
4
NOTE
If a part is purchased locally, you must call a Mark III Service Representative to obtain
prior authorization before locally purchasing the part. This authorization number must
appear on the RO.
Sublet Bills, regardless of the dollar amount, must be attached to and submitted with the RO.
Pre-authorized repairs must have the authorization number clearly on the RO. This will help expedite payment.
NOTE
Mark III DOES NOT PAY FOR ANY MARK - UP CHARGES ON SUBLET BILLS, AND WILL
NOT PAY ANY LABOR CHARGES IN EXCESS OF ITS PUBLISHED FLAT RATE TIMES.
FAILURE TO PROVIDE REQUIRED INFORMATION REQUESTED WILL RESULT IN THE
REPAIR ORDER BEING RETURNED TO THE DEALER AND WILL FURTHER DELAY PAYMENT.
All repair orders must be mailed into the Customer Assistance Center for processing.
Warranty repair work which stays within the allowable labor times (provided in the service manual) will not
require prior authorization from a Mark III customer- assistance representative.
Any warranty repair which will exceed the MarkIII allowable labor times (provided in the service manual) must
recieve prior authorization from a Mark III Customer Assistance Representative.
Note
If prior authorization is not obtained, you will only be reimbursed for the repair at the Mark III
allowable labor time (provided in the service manual) for that repair.
Mark III will not reimburse for: Tax (except New Mexico), Shop supplies, Miscellaneous Materials, Hazardous
waste materials, Parts (supplied by Mark III).
SUBMISSION OF WARRANTY REPAIR ORDERS
To keep abreast of changes in our warranty repair processing / payment procedures, Mark III has established a
(90) ninety day warranty repair cut - off time period, This ninety day period will be for authorized. No
exceptions ! This procedure will help expedite our payment to you.
This procedure eliminates one- time, large packages of repair orders being submitted to Mark III for processing,
the receipt of authorized repair orders in a timely manner will increase Mark III’s processing abilities and expedite
payment to you.
The ninety day cutoff period will be from the invoice date of the repair order versus the date Mark III receives the
repair order. For example: A repair order dated December 1996 (that is the invoiced date on the repair order)
which is received by Mark III in Customer Care Center in April of 1997, would be beyond the 90 day cut- off
period. This claim would not be honored and would be returned to the dealer marked VOID. There will be no
exceptions to this rule!
Product Display and Protection
In order to insure the customer receives the product in good condition, the dealer must see
that units in inventory are adequately protected prior to sale.
Units are to be displayed in a manner that would prevent:
1. Damage to interior components.
2. Damage to fabrics, carpets, drapes, etc... by water or sun fade caused by open windows.
3.Exterior finish damage caused by factory precipitates, storage under trees, etc... Exterior
finish is to be maintained in accordance with appropriate owner’s maintenance instructions.
4. Other damage caused by improper storage.
5. Damage caused by improper storage techniques is considered dealer negligence and will
not be considered for warranty adjustment or reimbursement.
5
Procedure for Returning Parts Warranty Parts
Mark III will credit dealers for the part and freight only on authorized return for credit items.
These parts will be designated on the invoice as “RFC”. Warranty parts sent “No Charge”
cannot be returned UNLESS requested by a service representative.
Returned For Credit Parts Procedure (RFC)
* Mark III has initiated a (RFC) Tagging process to assist you in returning a RFC warranty part.
This procedure will allow us to process your claim more expediently and credit you faster for
your expense of the RFC part.
* This will also help Mark III expedite continuous improvements on our products.
* Return For Credit (RFC) Tag is provided by Mark III when a (RFC) part is sent out. Extras can
be sent through our Customer Care Center. The tag must be filled out completely, and
attached to the part.
* The part, (RFC) Tag, and a copy of our invoice are to be returned together. If any of
these items are missing it will delay the processing of your claim.
* The parts are received in our Return Department and processed daily. If more information is
needed (Example: parts or paperwork missing) you will be notified.
* Multiple items may be packaged in one box.
* Although these items are considered defective, proper packaging must be taken to assure
that these parts are returned in good condition. So we can analyze the root cause.
* Items lost in shipment are the responsibility of the sender. The sender will need to take
appropriate steps with the carrier to retrieve the loss.
* Parts found to be normal wear and tear, customer abuse, lack of maintenance, and/or if no
defect is found, then you will be notified.
* If your claim is denied, you will be given a clear explanation.
* If you wish to have the part back, please advise at this time.
Procedure for Returning Parts New Non-Warranty Parts
All non-warranty parts still in new condition may be returned C.O.D. for the part only.
Freight must be pre-paid. All material must be in new and re-sellable condition (no
defects). A claim number must accompany all parts in order to receive credit. Parts may
only be returned within 90 days from the date ordered. Any special purchase or
special built parts will not be returnable.
6
The 36 Month/ 36,000 Mile Warranty:
•
Under this limited mileage warranty on your Mark III conversion, Mark III warrants
that the authorized dealer will repair, replace or adjust all parts that are found to be
defective in Mark III-supplied materials and workmanship. The defects must occur
under normal use of the vehicle during the warranty coverage period. While Mark III
reserves the right to correct any defect on the conversion package, it is
recommended that you take your vehicle to your MARK III authorized dealer to
ensure your continued satisfaction with the vehicle you purchased.
Coverage Provided
•
Mark III Industries, 36 month/ 36,000 mile limited warranty "bumper to bumper"
coverage.
•
Accessories' Manufacturer
Manufacturer.)
Warranties
(Separate
warranty
provided
by
When does the Warranty Coverage Begin?
•
The Mark III 36 month/36,000 mile limited mileage warranty begins on your vehicle's
warranty start date which is the earlier of (1) the date you take delivery of your new
vehicle, or (2) the date the vehicle was first put into service (for example, as a
dealer "DEMO" or as a company vehicle.)
Who is covered?
•
The current Mark III owner for the duration of the original warranty.
What Does Your Mark III Warranty Cover?
•
All vehicle conversion items are covered. This coverage includes cost of all parts
and labor needed to repair any items that are defective in materials or workmanship.
You will not be charged for these warranty repairs.
•
Note: See exceptions under items not covered.
7
Mark III Warranty Coverage Overview:
The 97/98 Mark III conversion warranty coverage’s and exclusions are listed below. For
more details, refer to the “Limited 3 Year/ 36,000 Mile Warranty."
Warranty Items Covered
Component
Warranty Coverage
Carpet
Defects in material; fading; seams separating.
Upholstery
Flaws or defects in fabric; seams coming apart;
abnormal wear patterns.
Wood
Cracked or split.
Exterior Paint
Cracked; flaking; fading.
Fiberglass
Structural defects.
Vinyl Graphics
Peeling or fading due to manufacturing or installation.
Seat Frames
Structural defects.
Rear Air Conditioner and Component failure.
Heater
Corrosion
Conversion related.
Seat Belts
The front seat belts are factory. Mid seat and sofa belts
are covered against tearing or breakage.
Custom Wheels
Structural Defects.
Warranty Items Not Covered
Component
Warranty Exclusion
Carpet
Stains; normal wear.
Upholstery
Stains; normal wear.
Wood
Scratches; chips.
Exterior Paint
Road hazard, paint chips; scratches.
Vinyl Graphics
Peeling or fading due to harsh chemicals to remove wax
or tar.
Rear Air Conditioner and Lack of normal maintenance.
Heater
Light Bulbs
Except for those noted at delivery.
Corrosion
Surface.
Custom Wheels
Normal wear and tear; problems due to improper
maintenance or if improper cleaning agents are used.
Wheel alignment, torquing and balancing are not
covered by this warranty
Accessories Manufacturer Warranties:
• Many accessories installed on Mark III conversions have separate warranties
offered by the accessory manufacturer. Written warranties by manufacturers of
these products are provided with each new conversion. The items include, but are
not limited to Television, CD Player, Headphone Systems, Rear Air Conditioner
Systems, Fabrics, and Tires.
8
Limited Original Equipment Manufacturer Warranty:
• Your chassis Manufacturer Warranty covers automotive chassis, engine, drive train
and other items that have been produced by the original equipment manufacturers.
For details on your OEM Warranty refer to your factory Warranty Book.
What is not covered?
• Damage caused by lack of maintenance or any liquid not recommended in the
owner's manuals. Mark III recommends that you keep all receipts and make them
available if questions arise about maintenance.
•
Damages to your vehicle that results from fire, accident, theft, vandalism, riot,
explosion, or objects striking the vehicle.
•
Misuse of the vehicle, driving over curbs, overloading, racing, or other competition.
•
Damage that results from alteration to the vehicle, or misusing the conversion
package. In addition any alterations to the odometer will result in the voiding of the
warranty coverage.
•
Deterioration due to use and exposure are not covered by the warranty. The
instructions in the owner's manual regarding the care of paint, trim, upholstery,
glass and other appearance items should be followed closely.
•
Removal of conversion parts to repair defective Original Equipment Manufacturer
parts.
•
"Incidental or Consequential Damages" connected with the failure of your vehicle
under warranty. Such damages include but are not limited to, lost time;
inconvenience; the loss of the use of your vehicle; the cost of rental cars; gasoline;
telephone expenses; travel or lodging; the loss of personal or commercial property;
the loss of revenue; etc. as allowed by state law.
•
Mark III does not warranty the automotive chassis.
•
The repair or replacement of items such as soft trim, interior trim, and other
appearance items manufactured and installed by Mark III is confined to cases where
the item is defective and not to cases involving wear, neglect or accident.
•
Imperfections in body trim paint; exterior moldings and/or vinyl graphics applied by
Mark III are normally apparent during new vehicle inspection by the dealer and/or
retail customer and are to be corrected then. For your protection, we suggest that if
you find any Mark III-related paint or appearance defects, report them to your dealer
immediately, as normal wear and tear due to use and exposure is not covered by
this warranty.
•
Mark III does not cover any and all parts supplied with the automotive chassis by
the chassis manufacturer. These include, but are not limited to, engine, frame,
transmission, factory air conditioner and heater, axles, brakes, suspensions, tires,
batteries, exterior paint defects, and factory body defects (weld marks, minor factory
defects, etc.). Consult the chassis manufacturer’s warranty regarding these items.
9
Items Not Covered Continued:
• Custom wheels are warranted for three (3) years or thirty-six thousand (36,000)
miles in cases of structural defects. Normal wear and tear due to use and exposure
or other problems due to improper maintenance or improper torquing of the wheels
are not covered by this warranty. Retorquing of wheels per Mark III Owner’s Manual
Wheel Maintenance is considered Normal Maintenance and is not covered by this
warranty (See Mark III Owner’s Manual Wheel Maintenance.)
• This warranty does not cover alterations or equipment added to the Mark III
conversion or chassis by the dealer or other sources or problems with other
components related to such alterations or additions.
• The cost of repairing damage caused by environment factors or "Acts of God."
"Environmental factors" include but are not limited to such things as airborne
fallout, chemicals, tree saps, salt, ocean spray and road hazards. "Acts of God"
includes, but are not limited to, such things as hail storms, wind storms, tornado’s,
sand storms, lightning, floods, hurricanes, earthquakes, the application of
chemicals or sealants subsequent to manufacture, etc., is not covered. See
Chemical Paint Spotting.
• Any part that was replaced under warranty will be covered for the duration of the
original conversion warranty only.
• The tire manufacturer warrants tires. The tire warranty is included with your
Mark III package.
• Maintenance - Normal Maintenance such as those detailed in the Factory Owner’s
manual and the Mark III Owner’s Manual are not covered and are the owner’s
expense. Also, items requiring replacement or repair from routine wear, use, and
exposure are not covered.
Chemical Paint Spotting:
•
Some weather and atmospheric conditions can create chemical fallout. Air borne
pollutants can fall and may damage painted surfaces on your vehicle. This damage
can take many forms, including blotching/ringlet shaped discoloration’s and small
irregular dark spots etched into the painted surfaces. Chemical paint spotting is not
covered by warranty.
Interior/ Exterior Paint, Trim, and Appearance Items:
•
Defects in paint, trim, upholstery or other appearance items are normally corrected
during new vehicle inspections. If you find any paint or appearance concerns
advise your dealership as soon as possible. Deterioration due to use and exposure
are not covered by the warranty. The instructions in the owner's manual regarding
the care of paint, trim, upholstery, glass and other appearance items should be
followed closely.
* Note:
Cosmetic or surface corrosion (resulting from stone chips, scratches in the
paint, for example) is not included in the Paint, Trim, and Appearance Items
coverage.
10
Mark III Original Equipment Alterations:
•
This warranty does not cover any damage or failure resulting from modification or
alteration to the Mark III conversion equipment, as manufactured or assembled by
Mark III industries.
Production Changes:
•
Mark III Industries reserves the right to make changes in vehicles built or sold by
them at any time without incurring any obligation to make the same or similar
changes on vehicles previously built or sold by Mark III Industries.
Roadside Assistance:
•
For Roadside Assistance programs. Refer to your factory owner’s manual.
Sheet Metal Coverage:
•
Corrosion: Body sheet metal panels are covered against rust for 3 years or 36,000
miles, whichever comes first.
* Note:
Cosmetic or surface corrosion (resulting from stone chips, scratches in the paint,
for example) is not included in the sheet metal coverage.
Other Warranty Terms:
•
•
This warranty gives you specific legal rights in addition to other legal rights that vary
from state to state.
Mark III Industries does not authorize any person, dealer, and/or other entity to create
for it any other obligation or liability with your Mark III Conversion vehicles.
• Any implied warranty of merchantability or fitness for a particular
purpose applicable to this vehicle is limited in duration to the
duration of the written warranty. Performance of repairs and needed
adjustments is the exclusive remedy under this written warranty or
an implied warranty. Mark III Industries shall not be liable for
incidental or consequential damages (such as, but not limited to, loss
wages or vehicle rental expenses) resulting from breech of this
written warranty or any implied warranty *
* Some states do not allow limitations on how long an implied warranty will last or the
exclusion or limitation of incidental or consequential damages, so the above limitation or
exclusions may not apply to you.
11
Customer Assistance:
Your complete satisfaction is important to your dealer and Mark III. Mark III will assist
you in resolving any misunderstanding or conversion-related problem if you have already tried to have your concerns addressed by your dealer. If any concern has not
been resolved, despite the best intentions of all concerned, the following steps should
be taken:
1. Contact a member of your dealership management. Most complaints are quickly
resolved at this level.
2. If it appears the dealership management cannot resolve your problem, contact
Mark III’s Customer Care Center by calling 1-800-726-8267.
3. Please have the following information available to give our customer assistance
representative.
• Your name, addresses, and telephone number.
• Mark III production number. (This is available on the manufacturing label attached
to the driver’s doorpost.)
• Delivery date and current mileage.
• Nature of problem/ history of repairs.
When contacting Mark III for assistance, please remember that our initial effort will be
to give your dealer all possible assistance in resolving your problem, using the
dealer’s facilities, equipment and personnel.
If you are still not satisfied after trying steps 1 through 3, please contact Mark III Customer Care Center by writing:
Attn.: Customer Care Center
Mark III Industries
PO Box 2525
Ocala, Florida, 34478
We will review your case and contact you with the outcome of our review.
Transportation Damage
If you find damage, vandalism or missing items, upon delivery of a unit perform the following immediately:
Attention:
Damage Must Be Noted On A Mark Iii Inspection Sheet:
* Note
Driver and a dealer representative must sign (all sheets.)
Photos may be required on bumper damage and dents
Tax-exempt on labor we do not pay G.O.G.
Please Follow Procedures Listed Below
1. Call transport claims within 72 hours of delivery.
2. Fax estimate (352-732-0071) and inspection sheet (noting all damage).
(All claims must be reviewed)
3. Call for authorization number on repair order and fax to 1-352-351-2321.
4. Approved repairs can be done.
5. We can not issue payment from an estimate we need your official repair order
12
Table of Contents
1997/1998 Chrysler Labor Times
1.
2.
3.
4.
5.
6.
Caravan/Voyager ---------------------------------------------------------------- 20
Jeep Grand Cherokee ---------------------------------------------------------- 24
Ram Pickup/ Dakota ------------------------------------------------------------ 23
Ram Van LWB-------------------------------------------------------------------- 17
Ram Van SWB ------------------------------------------------------------------- 14
Rear Air ----------------------------------------------------------------------------- 26
13
1997/1998 Chrysler
Ram Van SWB
Labor Times
HT - High Top
LT - Low Top
CFA - Call For Authorization
Item
R&R
A
A/C Return Grill
A/C Blower Motor and/or wheel
A/C Discharge Hose (H.P.)
A/C Fuse
A/C Louver/ Vent
Antenna, Styrofoam (LT)
Antenna, Foil (HT)
Antenna, Balm
Air Compressor
Ashtray
0.2
1.5
1.0
0.1
0.1
1.5
2.0
0.5
0.4
0.1
B
C
Carpet
Carpet Mats
Carpet Protector, Rear Cargo
CD Player, (Main Unit)
CD Player, FM Modulator and/or Cable
CD Player Frame
Center Beam, Wood Insert
Center Beam Molded Plastic Complete
Clothes Hook, Fold down (HT)
Console, Floor (TV) (Van)
Console, Overhead (van)
Cup Holder, Folding
Cup Holder, Temp. Controlled
CFA
0.2
0.1
1.0
1.0
0.1
0.3
1.0
0.2
1.0
0.3
0.2
1.0
D
Door, TV (Repair Kit)
Door, Smart Fuse Block
Door, Storage
0.1
0.2
0.2
E
Engine Cover
Electrical
1.0
CFA
F
Face Plate, Complete
Face Plate, Right Side (HT)
Face Plate, Left Side (HT)
Flash Light
Fuse
0.8
0.3
0.3
0.2
0.1
G
Game Ready Control Panel
Gimp. Door
Graphics
0.2
0.3
CFA
14
HT - High Top
LT - Low Top
CFA - Call For Authorization
H
Handle, Pull
Headboard (LT)
Headboard (HT)
Head Board Wood Trim
Headliner (LT)
Headliner (HT)
Headphone, Jack
Head Phone
0.3
1.5
2.0
0.2
1.5
2.0
0.2
0.1
I
J
Jack Kit
0.5
K
L
Light, Map
Light, Step Well
Light, Center Beam
Light, Valance
0.3
0.2
0.3
0.5
M
N
O
P
Panel, Door (Front)
Panel, Door (Side or Rear)
Panel, Speaker (Rear Wall)
0.5
0.5
1.0
Q
R
Radio, Deluxe Wall
Running Board, Fiberglass, each
Running Board, Aluminum, each
Running Board Bracket
0.5
1.0
0.75
0.5
S
Seat Cover. Front & Mid
Seat Cover Sofa Back
Seat Cover Sofa Bottom
Seat, Arm Rest
Seat, Arm Rest Covers
Seat, Front & Mid, W/O Ped
Seat, Front & Mid With Ped
Seat, Removable with Shrouds
Shades
Sill, Window
Smart Fuse Block
Storage Comp. Rear Wall, each
Sofa/Bed (Complete Unit)
Sofa Back (Plastic)
Sofa Motor
Sofa Controller (Intellitec)
1.0
1.0
1.0
0.2
0.3
0.5
0.75
1.0
0.2
0.2
0.2
0.2
1.0
0.2
0.4
0.2
15
HT - High Top
LT - Low Top
CFA - Call For Authorization
Sofa Frame Replacement
Sofa Foot Rest
Sofa Arm rest
Sofa Arm Rest Cover
Sofa Head Rest
Sofa Head Rest Cover
Speaker, Grill
Speaker, TV
Speaker, Radio
Sport Top Upper Wall
Step Plate
1.5
0.4
0.2
0.3
0.3
0.4
0.2
0.2
0.2
1.0
0.2
T
Trash Bin
TV, (LT)
TV, (HT)
TV Remote
TV Frame
0.1
0.3
0.5
0.1
0.2
U
V
Valance
Visor
VCP (LT)
VCP (HT)
VCP Frame (HT)
0.4
0.
0.3
0.5
0.2
W
Wall, Deluxe, LX
Wall, deluxe, LE, STD.
Wall, Driver Side
Wall, Passenger Side
Wheel
Window Shroud (Plastic)
Window W/ Ring
Window Ring
Window Frame (Wood)
1.0
0.75
CFA
CFA
0.4
0.5
1.0
1.5
1.0
16
1997/1998 Chrysler
Ram Van LWB
Labor Times
HT - High Top
LT - Low Top
CFA - Call For Authorization
Item
R&R
A
A/C Return Grill
A/C Blower Motor and/or wheel
A/C Discharge Hose (H.P.)
A/C Fuse
A/C Louver/ Vent
Antenna, Styrofoam (LT)
Antenna, Foil (HT)
Antenna, Balm
Air Compressor
Ashtray
0.1
1.5
1.0
0.1
0.2
1.5
2.0
0.5
0.4
0.1
B
C
Carpet
Carpet Mats
Carpet Protector, Rear Cargo
CD Player, (Main Unit)
CD Player, FM Modulator and/or Cable
CD Player Frame
Center Beam, Wood Insert
Center Beam Molded Plastic Complete
Clothes Hook, Fold down (HT)
Console, Floor (TV) (Van)
Console, Overhead (van)
Cup Holder, Folding
Cup Holder, Temp. Controlled
CFA
0.2
0.1
1.0
1.0
0.1
0.2
1.0
0.2
1.0
0.4
0.2
1.0
D
Door, TV (Repair Kit)
Door, Smart Fuse Block
Door, Storage (All)
0.2
0.2
1.0
E
Engine Cover
Electrical
1.0
CFA
F
Face Plate, Complete
Face Plate, Right Side (HT)
Face Plate, Left Side (HT)
Flash Light
Fuse
0.6
0.3
0.3
0.2
0.1
G
Game Ready Control Panel
Gimp. Door
Graphics
0.2
0.3
CFA
17
HT - High Top
LT - Low Top
CFA - Call For Authorization
H
Handle, Pull
Headboard (LT)
Headboard (HT)
Head Board Wood Trim
Headliner (LT)
Headliner (HT)
Headphone, Jack
Head Phone
0.2
1.5
2.0
0.2
1.5
2.0
0.2
0.1
I
J
Jack Kit
0.5
K
L
Light, Map
Light, Step Well
Light, Center Beam
Light, Valance
0.3
0.2
0.3
0.3
M
N
O
P
Panel, Door (Front)
Panel, Door (Side or Rear)
Panel, Speaker (Rear Wall)
0.5
0.5
1.0
Q
R
Radio, Deluxe Wall
Running Board, Fiberglass, each
Running Board, Aluminum, each
Running Board Bracket
0.5
1.0
0.75
0.5
S
Seat Cover. Front & Mid
Seat Cover Sofa Back
Seat Cover Sofa Bottom
Seat, Arm Rest
Seat, Arm Rest Covers
Seat, Front & Mid, W/O Ped
Seat, Front & Mid With Ped
Seat, Removable with Shrouds
Shades
Sill, Window
Smart Fuse Block
Storage Comp. Rear Wall, each
Sofa/Bed (Complete Unit)
Sofa Back (Plastic)
Sofa Motor
Sofa Controller (Intellitec)
10
1.0
1.0
0.2
0.3
0.5
0.75
1.0
0.2
0.2
0.2
0.3
1.0
0.2
0.4
0.2
18
HT - High Top
LT - Low Top
CFA - Call For Authorization
Sofa Frame Replacement
Sofa Foot Rest
Sofa Arm rest
Sofa Arm Rest Cover
Sofa Head Rest
Sofa Head Rest Cover
Speaker, Grill
Speaker, TV
Speaker, Radio
Sport Top Upper Wall
Step Plate
1.2
0.4
0.2
0.3
0.3
0.4
0.1
0.1
0.2
1.0
0.3
T
Trash Bin
TV, (LT)
TV, (HT)
TV Remote
TV Frame
0.1
0.3
0.5
0.2
0.2
U
V
Valance
Visor
VCP (LT)
VCP (HT)
VCP Frame (HT)
0.4
0.4
0.3
0.4
0.2
W
Wall, Deluxe, LX
Wall, deluxe, LE, STD.
Wall, Driver Side
Wall, Passenger Side
Wheel
Window Shroud (Plastic)
Window W/ Ring
Window Ring
Window Frame (Wood)
1.0
0.75
2.0
2.0
0.4
0.5
1.0
1.0
1.0
19
1997/1998 Chrysler
Caravan/ Voyager
Labor Times
HT - High Top
LT - Low Top
CFA - Call For Authorization
Item
R&R
A
B
C
Carpet
Carpet Mats
CD Player, (Main Unit)
CD Player, FM Modulator and/or Cable
CD Player Frame
Center Beam , Complete
Console, Floor (TV)
Console, Overhead
CFA
0.1
1.0
1.0
0.1
0.5
0.4
0.3
D
Door, TV (Repair Kit)
0.2
E
Electrical
CFA
F
Face Plate, Complete
Flash Light
Fuse
0.5
0.1
0.1
G
Game Ready Control Panel
Gimp. Door
Graphics
0.2
0.3
CFA
H
Handle, Pull
Headboard (LT)
Headboard (HT)
Head Board Wood Trim
Headliner (LT)
Headliner (HT)
Headphone, Jack
Head Phone
0.3
1.5
2.0
0.2
1.5
2.0
0.2
0.1
I
J
K
20
HT - High Top
LT - Low Top
CFA - Call For Authorization
L
Light, Map
Light, Center Beam
Light, Valance
0.2
0.3
0.2
M
N
O
P
Panel, Door (Front)
Panel, Door (Side or Rear)
Panel, Speaker (Rear Wall)
0.5
0.5
1.0
Q
R
Running Board, Fiberglass, each
1.0
S
Seat Cover. Front & Mid
Seat Cover Sofa Back
Seat Cover Sofa Bottom
Seat, Arm Rest
Seat, Arm Rest Covers
Seat, Front & Mid With Ped
Sofa/Bed (Complete Unit)
Sofa Arm rest
Sofa Arm Rest Cover
Sofa Head Rest
Sofa Head Rest Cover
Speaker, Grill
Speaker, TV
Speaker, Radio
Sport Top Upper Wall
0.75
1.0 + FACTORY
1.0 + FACTORY
0.2 + FACTORY
0.3 + FACTORY
0.75 + FACTORY
1.0 + FACTORY
0.3 + FACTORY
0.4 + FACTORY
0.4 + FACTORY
0.5
0.1
0.3
0.3
1.0
21
HT - High Top
LT - Low Top
CFA - Call For Authorization
T
TV, (LT)
TV, (HT)
TV Remote
0.3
0.5
0.1
U
V
Valance
Visor
VCP (LT)
VCP (HT)
0.2
0.3
0.3
0.3
W
Wheel
0.4
22
1997/1998 Chrysler
Ram and Dakota Pickups
Labor Times
CFA – Call For Authorization
Item
R&R
A
B
Bug Shield
0.3
C
CD Player, (Main Unit)
CD Player, FM Modulator and/or Cable
Console Overhead
0.3
1.0
0.3
D
E
Electrical
CFA
F
Fuse
0.1
G
Graphics
CFA
H
I
J
K
L
Light, Auxiliary (Fog)
Light, Map
0.2
0.2
M
N
O
P
Q
R
Running Board, Fiberglass, each
Running Board Bracket
1.0
0.2
S
Seat Cover
Seat, Arm Rest
Seat, Arm Rest Covers
Step Tube
1.0
0.2
0.2
0.4
T
U
V
W
Wheel
0.4
23
1997/1998 Chrysler
JEEP GRAND CHEROKEE
Labor Times
CFA - Call For Authorization
Item
R&R
A
Air Compressor
Antenna, Antenna (Center Mount)
Antenna, Antenna (Left Mount)
Antenna, TV
0.3
7.7
6.2
6.2
B
“B” Pillar Upper Shroud
Box, Rear Storage (replace box)
Box, Rear Storage (replace components)
Brush Guard, Front
Brush Guard, Tail Light
0.2
2.2
2.2
1.2
0.3
C
Carpet Protector, Rear Cargo
CD Player, (Main Unit)
CD Player, FM Modulator and/or Cable
CD Player Remote (wired)
“C” Pillar Shrouds, Upper
Console, Overhead, Front
Console, Overhead, Rear
0.1
1.0
6.2
0.4
0.2
0.3
0.3
D
Dash Wood Kit Per Piece
Door Wood Kit Per Piece
0.2
0.2
E
Electrical
Exterior Logo on Door
CFA
0.2
F
Fuse Block
0.5
G
Game Ready Control Panel
GPS Telepath
Graphics
Grill, Front
0.2
0.5
CFA
0.4
H
Handle, Pull
Hatch (Rear Door) Shroud L & R
Hatch (Rear Door) Shroud Upper
Hatch (Rear Door) Step Plate
Head Phone
Headliner
Headphone, Jack
0.2
0.2
0.2
0.3
0.1
6.0
0.1
I
J
K
24
CFA - Call For Authorization
L
Light, Fog (PIAA)
0.5
M
N
Noise Choke
CFA
O
P
Panel, Door Front
Panel, Door (Side or Rear)
Panel Speaker (Rear Wall)
0.3
0.3
0.1
Q
R
Rear Box
Roof Rack
0.5
1.0
S
Seat Belt
Seat Cover. Front & Rear
Seat, Front and Rear W/O Ped
Seat, Front and Rear with Ped
Speaker Grill
Speaker, TV
Step Tube
Sun Roof Electric
Sun Roof Manual
Sun Roof Switch
0.4
0.8
0.3
0.6
0.1
0.2
0.5
CFA
CFA
0.2
T
Tire Carrier Assembly
TV Amplifier
TV Base (Wood)
TV Remote
TV Removal
TV Speaker Switch
3.0
0.5
0.2
0.1
0.5
0.2
U
V
VCP
Visor
1.0
0.2
W
Wheel
Window, Sport Top (Clear)
Window, Sport Top (Smoked)
Window, Sport Top Shroud
.4
CFA
CFA
.2
25
1997/1998
Rear Air and Heat
Labor Times
CFA - Call For Authorization
Item
R&R
Pressurize, diagnose, leak test, drain,
evacuate, charge, recover – Note 1
Cooling system diagnose – Note 1
A/C system diagnose – Note 1
Power Pack – replace (includes diagnose,
leak test, drain, etc.)
Core - replace
Blower - replace
Relay - replace
Resistor - replace
Wiring - repair
Fuse – Replace (includes system check)
Switch - replace
Expansion Valve - replace
Water Valve - replace
Heater Hose Wye – replace (one or more)
Hose clamp – replace (one or more)
Heater hose – repair (each)
Refrigerant hose – replace (one or more)
Ford and Dodge
Refrigerant hose – Suction Hose - replace
Astro/ Safari
Refrigerant hose – Liquid Hose - replace
Astro/ Safari
Refrigerant hose – Suction Hose - replace
GMT-600
Refrigerant hose – Liquid Hose - replace
GMT-600
Refrigerant hose – repair (each)
Fitting – replace or repair (each)
1.0
0.5
0.5
2.0
1.2
0.5
0.5
0.5
0.8
0.5
0.5
0.5
0.5
0.6
0.5
0.5
1.5
2.5
2.0
2.0
2.0
0.5
0.8
Note1 – can be used in addition to other operations
26
LWB Full-Size Van Procedures
Table of Contents
Dodge LWB
Low Top
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Carpet ------------------------------------------------------------------------------- 28
Center Beam, Molded Plastic------------------------------------------------- 28
Door Panel, Cargo Doors Rear ---------------------------------------------- 28
Door Panel, Passenger & Driver Front ------------------------------------- 28
Door Panel, Side Cargo, Front ----------------------------------------------- 29
Door Panel, Side Cargo, Rear------------------------------------------------ 29
Head Board------------------------------------------------------------------------ 29
Headliner --------------------------------------------------------------------------- 29
Panel, Speaker, Rear ----------------------------------------------------------- 29
Seat Belt Driver Side ---------------------------------------------------------- 30
Seat Belt Sofa Lap ------------------------------------------------------------- 30
Seat Belt, Center and Rear -------------------------------------------------- 30
Shade, Cargo door Side and Rear ---------------------------------------- 30
Shade, Vista Bay Windows-------------------------------------------------- 30
Shroud, Rear Cargo Doors -------------------------------------------------- 30
Shroud, Side Cargo Doors--------------------------------------------------- 30
Sofa Motor Control Module -------------------------------------------------- 31
Sofa Motor------------------------------------------------------------------------ 31
Torque Specification----------------------------------------------------------- 32
TV ---------------------------------------------------------------------------------- 31
TV Console ---------------------------------------------------------------------- 31
Valance --------------------------------------------------------------------------- 31
VCP ------------------------------------------------------------------------------- 31
Wall, Deluxe --------------------------------------------------------------------- 32
Wall, Driver ---------------------------------------------------------------------- 32
Wall, Passenger ---------------------------------------------------------------- 32
Window Ring Driver Side ---------------------------------------------------- 33
Window Ring Passenger Side ---------------------------------------------- 33
Window, Vista Bay ------------------------------------------------------------- 33
27
1997/1998 Dodge LWB
Low Top
Carpet
1. Remove all seating.
2. Remove Engine cover.
3. Remove all door step plates.
4. Remove all window sill wood.
5. Remove 2 screws in window frame that were exposed after sill removal.
6. Remove deluxe wall (refer to procedure) if equipped.
7. Remove both rear storage cabinets installed in walls, if equipped.
8. Remove sofa control module.
9. Remove jack and jack handle, remove jack base plate.
10. Remove all seat belt anchor bolts secured at floor.
11. Remove TV console if equipped.
12. Beginning at rear cargo doors grasp carpet and lift upward removing carpet from
flooring, moving toward the front of the van roll carpet as it is freed. If you encounter
difficulty with carpet that is wedged under the walls gently grasp the bottom of the
wall and the window frame and pull outward. This will lift the wall away from the
carpeting allowing you to pull it free, * Note carpet is stapled along the edges of the
rear fender wells and will require extra effort to release. Ensure that all staples are
removed prior to installing the new carpet.
Center Beam, Molded Plastic
1.
2.
3.
4.
5.
6.
Remove map light cover and unscrew housing. Remove map lights.
Remove exposed screws.
Remove screws from center wood insert.
Remove exposed screws from molded plastic center beam, lower center beam.
Disconnect electrical connector and remove center beam.
If vehicle is equipped with rear air unscrew the outer male from the inner female
outlet.
Door Panel, Passenger & Driver Front
1. Remove factory door handle.
2. Grasp insert on upper door panel and pull outward until retainers are free from door,
disconnect electrical connector.
3. Remove exposed screws.
4. Remove retainer screw from bottom front corner of door panel (exposed).
5. Grasp door panel at top edge and pull outward and pull upward to free.
6. Bottom door panel, grasp edges of panel and pull outward until retainers are free.
Door Panel, Cargo Doors, Rear
1. Remove door handle bezel (2) screws, passenger side.
2. Grasp edge of door panel at top and pull outward until you feel retainers are free.
3. Continue this motion all around panel to complete process.
28
Door Panel, Cargo Door, Side (Front)
1.
2.
3.
4.
5.
6.
Remove caps from pull handle by unsnapping.
Remove exposed screws, remove handle.
Remove screws from molded mag rack/ cup holder, if equipped.
Remove fold down cup holder screws, if equipped.
Remove factory door handle bezel.
Grasp edge of door panel at top and pull outward until retainers are free. Continue
this motion all around panel to complete process.
Door Panel, Cargo Door, Side (Rear)
1. Remove caps from pull handle by unsnapping.
2. Remove 4 exposed screws, remove handle.
3. Grasp edge of door panel at top and pull outward until retainers are free. Continue
this motion all around panel to complete process.
Head Board
1. Remove map light cover and unscrew housing. Remove map lights.
2. Unsnap faceplate switch cover, this exposes 4 screws, and remove. Pull straight
back on switch plate and disconnect 3 plug in connectors, if equipped.
3. Remove headboard wood trim piece.
4. Reach through hole where switch assembly was, grasp and pull straight back until
headboard clips are free from factory lip in roof.
5. Tilt rear of headboard down and pull rearward until free.
Headliner
1. Remove map light covers and unscrew housing. Remove lights from center beam.
2. Remove center beam per procedures.
3. Remove rear map light covers and unscrew housings located in headliner. Remove
lights from center beam.
4. Remove valances per procedures.
5. Remove headboard (refer to procedure).
6. Remove screws from headliner, located where center beam was.
7. Slide forward until rear cleats release from factory roof lip.
8. Remove headliner.
Panel, Speaker, Rear
1. Remove rear storage cabinets in passenger sidewall, if equipped.
2. Using razor knife cut fabric along door edge, pull fabric loose to expose screws.
3. Remove screws.
29
Seat Belt, Center and Rear
1.
2.
3.
4.
5.
Remove screws from valance wood trim, pull out and disconnect plug in connector.
Remove valance.
Remove wall per procedures.
Remove seat belt plastic insert from wall.
Remove 2 nuts from seat belt retainer
* (Critical items ensure when reinstalling seat belt that these 2 nuts are
torqued to 6 to 8 foot lbs.).
6. Pull back seat belt boot located on floor which will expose seat belt anchor bolt,
remove
* (Critical items ensure when reinstalling seat belt anchor bolt that it is
torqued to 22 to 28 foot lbs.).
Seat Belt Driver
1. Remove valance wood trim.
2. Remove seatbelt.
Seat Belt Sofa Lap
1. Peel back seat belt boot cover exposing mounting bolt, remove bolt.
2. Pull seat belt through elastic retaining loop in sofa remove.
* (Critical item seat belt mounting bolt must be torqued when reinstalling 22
to 30 foot pounds)
Shade Cargo Door, Side And Rear
1. Locate shade retainer clips behind shade and using thumb press down on bottom
clip and pull out on shade until it releases from clip.
2. Grasp shade string at bottom where grommet enters into door shroud and pull outward until string grommet releases from hole, repeat procedure for other string.
Shade, Vista Bay Windows
1. Remove 3 screws attaching shade to top of window.
2. Remove screw from shade string tensioners located at bottom of window.
Shroud, Rear Cargo Doors
1.
2.
3.
4.
5.
Remove window shade; refer to shade removal procedure.
Remove door panel; refer to door panel removal procedure.
Remove screws.
Remove screws from factory window latch.
Grasp shroud and pull outward to remove.
Shroud, Side Cargo Doors
1.
2.
3.
4.
5.
6.
Remove window shade; refer to shade removal procedure.
Remove door panel; refer to door panel removal procedure.
Remove screws.
Remove screws from factory window latch.
Remove door lock knob by unscrewing and pulling up.
Grasp shroud and pull outward to remove.
30
Sofa Motor
1. Remove sofa motor shroud.
2. Remove right side bolt from sofa frame attaching bracket to motor. (This releases
bracket).
3. Remove 5/16" nuts from end of sofa motor on both sides.
4. Unplug power wires from control module.
5. Grasp and pull drive cable loose from motor.
6. Remove sofa motor.
Sofa Motor Control Module
1. Unplug 2 connectors from module
2. Remove screws from base
TV
1.
2.
3.
4.
5.
Grasp edges and pull forward.
Disconnect RCA cable from video in and audio in (color-coded).
Remove coax cable.
Remove external speaker connection.
Remove DC power input cable.
TV Console
1.
2.
3.
4.
Remove VCP (refer to VCP removal procedure).
Remove TV (refer to TV removal procedure).
Remove 2 screws in L bracket located inside frame attached to floor.
Grasp console and lift upward while guiding VCP and TV wires through opening in
rear of console.
Valance
1.
2.
3.
4.
5.
6.
7.
Remove shades per procedure.
Remove screws that were exposed upon shade removal.
Remove valance wood trim.
Remove exposed pod screws.
Remove screws inside valance cutouts.
Untuck material from front and rear of valance to expose screws.
Remove screws from front and rear valances and lower valances.
VCP
1. Remove TV (refer to TV removal procedure).
2. Remove 2 screws attaching VCP bracket from underneath (Top of edge of console
where TV was removed from).
3. Grasp VCP by edge pull straight back until out of console.
4. Disconnect RCA jacks and power wire.
31
Wall, Deluxe
1. Open smart block fuse door. Disconnect smart block harness from smart block (3
connectors). Re-position harnesses through cut out in compartment.
2. Remove hidden screws from behind fuse block.
3. Remove screws from windowsill plate and remove.
4. Reach through opening in windowsill and disconnect connector from rear of CD
player and/or rear radio (if equipped).
5. Grasp CD player/ rear radio and remove (if equipped).
6. Remove rear screw from top of deluxe-wall sill, untuck fabric from rear corner and
remove hidden screw.
7. Untuck fabric at front of deluxe wall and remove hidden screw under fabric,
* (Untuck fabric by placing putty knife under edge and prying gently out, grasp fabric to expose screw).
8. Lift straight up on deluxe-wall approximately 2” to release from cleat. Continue lifting
upward and remove.
Wall, Driver Side
1. Remove driver center seat.
2. Remove sofa.
3. Peel back wall fabric from driver doorpost and expose-hidden screws, remove all
screws.
4. Remove video game center control plate, if equipped.
5. Remove rear speaker.
6. Remove Deluxe wall, refer to procedure.
7. Remove rear storage cabinet, refer to rear storage cabinet removal procedure).
8. Remove valance, see procedure.
9. Remove shades driver side front and rear, (Refer to procedure).
10. Remove window sill top plates front and rear windows, remove counter sunk screws
and pull straight outward on top plate.
11. Remove screws located on the inside top of the window frame.
12. Remove screws from bottom window frame (this releases wall).
13. Grasp wall at gas fill mid lower wall and pull down as you are pulling the bottom of
wall outward slide toward front of van until released from behind speaker panel.
Remove wall out through rear cargo doors.
Wall, Passenger
1. Slide passenger center seat all the way forward or remove if it has the removable
seat option.
2. Remove rear speaker.
3. Remove rear cabinet.
4. Remove DC outlet (refer to DC outlet removal procedure).
5. Place sofa in the flat position. Remove Sofa switch.
6. At the Side cargo rear door, peel back wall fabric at edges this exposes hidden
screws, remove all screws.
7. Remove windowsill top plate. Remove 2 screws that are now exposed in windowsill.
8. Remove valance, see procedure.
9. Untuck at side cargo post, exposing screws, remove screws.
10. Grasp front of wall and pull out until rear releases from behind the rear speaker
panel.
11. Tilt top inward and lower over the sofa.
12. Remove through rear cargo doors.
32
Window Ring Driver Side
1. Remove bottom windowsill.
2. Remove valance per procedures.
3. Repeat the above procedure for the 2nd vista bay window.
* Note
It is critical that the wall is loose at both window-mounting points.
4. At driver door peel back fabric on wall, this will expose screws. Remove screws.
5. Remove driver front factory seat belt shroud.
6. Remove driver center seat belt retainer if removal is for the rear window.
7. Pull bottom of wall away from window ring.
8. Lift fabric off from bottom of ring exposing screws, remove screws.
9. Grasp ring and slide upward until top of ring comes out from behind wall at the top.
10. Grasp top and bottom of ring and bend inward toward center of van, pull outward
the removal is complete.
* Note
Caution this ring in step 10 is made of wood and will break if bent to sharply.
Window Ring Passenger Side
1.
2.
3.
4.
5.
6.
7.
Remove bottom windowsill.
Remove valance per procedures.
Remove screws from window frame which, were under windowsill.
Peel back fabric at cargo door edge of wall, this will expose screws, remove screws.
Pull bottom of wall away from window ring.
Lift fabric off from bottom of ring exposing screws, remove screws.
Grasp ring and slide forward until ring comes out from behind wall at the front.
Window, Vista Bay
* Note This is a two-person operation.
1. Remove cloth covered window ring (refer to window ring removal procedure) this
will expose all metal window frame mounting screws.
2. Secure window to ensure it will not fall during the following removal step.
3. Remove all #8 x 3/4" screws around the perimeter of the metal window frame.
4. Grasp window at the top and bottom, pull outward and set down.
Torque Specifications
1.
2.
3.
4.
5.
6.
7.
8.
9.
Captain’s Chair to Slider ------------------------------- 16-21 FT LB
Pedestal to Floor ----------------------------------------- 22-30 FT LB
Removable Seat Plate to Floor ----------------------- 22-30 FT LB
Seatbelt Retractor to Bracket (Dodge SWB) ------ 6-8 FT LB
Seatbelt Retractor to Floor ---------------------------- 22-30 FT LB
Seatbelt Retractor to Wall ----------------------------- 22-30 FT LB
Slider to Pedestal ---------------------------------------- 24-29 FT LB
Sofa to Floor ---------------------------------------------- 22-30 FT LB
Wheel------------------------------------------------------- 85 FT LB
33
LWB Full-Size Van Procedures
Table of Contents
Dodge LWB
SPORT Top
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Carpet ------------------------------------------------------------------------------- 35
Center Beam, Molded Plastic------------------------------------------------- 35
Door Panel, Cargo Doors Rear ---------------------------------------------- 36
Door Panel, Passenger & Driver Front ------------------------------------- 35
Door Panel, Side Cargo, Front ----------------------------------------------- 36
Door Panel, Side Cargo, Rear------------------------------------------------ 36
Faceplates ------------------------------------------------------------------------- 36
Head Board------------------------------------------------------------------------ 36
Headliner --------------------------------------------------------------------------- 37
Panel, Speaker, Rear --------------------------------------------------------- 37
Rear Box-------------------------------------------------------------------------- 37
Seat Belt Driver Side ---------------------------------------------------------- 38
Seat Belt Sofa Lap ------------------------------------------------------------- 38
Seat Belt, Center and Rear -------------------------------------------------- 37
Shade, Cargo Door Side And Rear---------------------------------------- 38
Shade, Vista Bay Windows-------------------------------------------------- 38
Shroud Cargo Doors, Rear Cargo Doors -------------------------------- 38
Shroud Cargo Doors, Side Cargo Doors--------------------------------- 38
Sofa Motor Control Module -------------------------------------------------- 39
Sofa Motor------------------------------------------------------------------------ 38
Torque Specification----------------------------------------------------------- 41
TV ---------------------------------------------------------------------------------- 39
Valance --------------------------------------------------------------------------- 35
VCP ------------------------------------------------------------------------------- 39
Wall, Deluxe --------------------------------------------------------------------- 39
Wall, Driver ---------------------------------------------------------------------- 40
Wall, Passenger ---------------------------------------------------------------- 40
Wall, Upper Sport Top Driver ----------------------------------------------- 40
Wall, Upper Sport Top Passenger----------------------------------------- 40
Window Ring Driver Side ---------------------------------------------------- 40
Window Ring Passenger Side ---------------------------------------------- 41
Window, Vista Bay ------------------------------------------------------------- 41
34
1997/1998 Dodge LWB
Sport Top
Valance
1.
2.
3.
4.
5.
Remove wood trim.
Untuck fabric at front of valance (driver side) and remove hidden screw.
Remove shades per procedure.
Remove screws located inside wood trim cutout which secures valance to headliner
Lower valance, disconnect harness and remove valance.
Carpet
1. Remove all seating.
2. Remove Engine cover.
3. Remove all door step plates.
4. Remove all window sill wood.
5. Remove 2 screws in window frame that were exposed after sill removal.
6. Remove deluxe wall (refer to procedure) if equipped.
7. Remove both rear storage cabinets installed in walls, if equipped.
8. Remove sofa control module per procedure.
9. Remove deluxe wall per procedure.
10. Remove Cellular phone box.
11. Remove jack and jack handle, remove jack base plate.
12. Remove all seat belt anchor bolts secured at floor.
13. Beginning at rear cargo doors grasp carpet and lift upward removing carpet from
flooring, moving toward the front of the van roll carpet as it is freed. If you encounter
difficulty with carpet that is wedged under the walls gently grasp the bottom of the
wall and the window frame and pull outward. This will lift the wall away from the
carpeting allowing you to pull it free (note carpet is stapled along the edges of the
rear fender wells and will require extra effort to release. Ensure that all staples are
removed prior to installing the new carpet.
Center Beam, Molded Plastic
1. Remove front and rear maps lights covers and remove screws from housing.
Remove map lights.
2. Remove exposed screws.
3. Remove screws from center wood insert and remove insert.
4. Remove exposed screws from molded plastic center beam, lower center beam.
5. Disconnect electrical connector and remove center beam.
6. If vehicle is equipped with rear air unscrew the outer male from the inner female
outlet.
Door Panel Passenger & Driver Front
1. Remove factory door handle.
2. Grasp insert on upper door panel and pull outward until retainers are free from door,
disconnect electrical connector. Remove exposed screws.
3. Remove retainer screw from bottom front corner of door panel (exposed).
4. Grasp door panel at top edge and pull outward and pull upward to free.
5. Bottom door panel, grasp edges of panel and pull outward until retainers are free.
35
Cargo Doors Rear
1. Remove door handle bezel (2) screws, passenger side.
2. Grasp edge of door panel at top and pull outward until you feel retainers are free
Continue this motion all around panel to complete process.
Cargo Door, Side, Front
1.
2.
3.
4.
5.
6.
Remove caps from pull handle by unsnapping.
Remove exposed screws, remove handle.
Remove screws from molded mag rack/ cup holder, if equipped.
Remove fold down cup holder screws, if equipped.
Remove factory door handle bezel.
Grasp edge of door panel at top and pull outward until retainers are free. Continue
this motion all around panel to complete process.
Cargo Door, Side, Rear
1. Remove caps from pull handle by unsnapping.
2. Remove 4 exposed screws, remove handle.
3. Grasp edge of door panel at top and pull outward until retainers are free. Continue
this motion all around panel to complete process.
Faceplates
Remove VCP Faceplate:
1. Remove VCP trim ring.
2. Remove faceplate screws and remove faceplate.
Remove Storage Box Faceplate:
3. Open storage compartment door and remove faceplate screws.
4. Remove faceplate.
Removal of TV Lower Trim Piece:
5. Remove TV Lower Trim Piece Screws.
6. Remove TV Lower Trim Piece.
Head Board
1. Remove 2 exposed screws from VCP trim ring, remove ring. (Exposes 2 screws in
face plate remove).
2. Grasp faceplate and pull outward until mating edge along TV is clear, slide toward
center of van to remove.
3. Open storage compartment door exposing 2 screws, remove.
4. Grasp frame and pull outward until mating edges along TV is clear, slide toward
center of van to remove.
5. Remove 2 screws from strip under TV, remove strip (exposes TV mounting screws
in L brackets (3) brackets one in the front, one on each side).
6. Remove screws from brackets.
7. Grasp TV and pull outward until connections are exposed.
8. Disconnect all connections, remove TV.
9. Remove VCP (refer to VCP removal procedure).
10. Remove 4 screws located in plywood backer 2 for each box (attaches boxes to
backer) push boxes onto factory roof.
11. Remove map lights.
12. Remove switch plate.
36
* Note
Headboard and backer are loose at this point and will fall if not supported.
13. Remove 4 screws from bottom edge of faceplate backer.
14. Push top of faceplate toward front of van, allow to sit on storage and VCP boxes.
15. Pull rearward on headboard while tilting downward and remove.
Headliner
1.
2.
3.
4.
5.
6.
7.
8.
Lower sofa to the flat position.
Remove center beam (refer to procedure).
Remove headboard (refer to headboard removal procedure).
Remove valances (refer to procedure).
Remove Sport Top Wall (Refer to Upper Sport Top Wall removal procedure).
Remove rear box (refer to procedure).
Remove retaining screws remaining in headliner at center.
Slide headliner forward to clear rear roof, lower rear section, slide out through rear
cargo doors.
Panel, Speaker, Rear
1. Remove rear storage cabinets in passenger sidewall, if equipped.
2. Using razor knife cut fabric along door edge, pull fabric loose to expose screws.
3. Remove screws.
Rear Box
1.
2.
3.
4.
5.
6.
7.
8.
Remove and disconnect speakers.
Remove 2 screws from rear storage box frame.
Remove 2 screws from storage box, push in box and allow to sit on rear roof.
Remove screws from each rear window valance wood trim.
Remove 3” retainer screws from inside of clothes hanger (1 at each end).
Remove screws from L brackets connecting box to roof.
Push forward and lower.
Remove box out through rear cargo doors.
Seat Belt, Center and Rear
1.
2.
3.
4.
5.
Remove screws from valance wood trim, pull out and disconnect plug in connector.
Remove valance.
Remove wall.
Remove plastic seat belt insert from wall.
Remove 2 nuts from seat belt retainer
* (Critical items ensure when reinstalling seat belt that these 2 nuts are
torqued to 6 to 8 foot lbs.).
6. Pull back seat belt boot located on floor which will expose seat belt anchor bolt,
remove
* (Critical items ensure when reinstalling seat belt anchor bolt that it is
torqued to 22 to 28 foot lbs.).
37
Seat Belt, Driver
1. Remove valance from Sport Top Wall (will expose tack screw).
2. Remove retaining bolt.
(Critical item seat belt mounting bolt must be torqued when reinstalling 22 to 30
foot pounds).
Seat Belt Sofa Lap
1. Peel back seat belt boot cover exposing mounting bolt, remove bolt.
2. Pull seat belt through elastic retaining loop in sofa remove.
* (Critical item seat belt mounting bolt must be torqued when reinstalling 22
to 30 foot pounds)
Shade Cargo Door, Side And Rear
1. Locate shade retainer clips behind shade and using thumb press down on bottom
clip and pull out on shade until it releases from clip.
2. Grasp shade string at bottom where grommet enters into door shroud and pull outward until string grommet releases from hole, repeat procedure for other string.
Shade, Vista Bay Windows
1. Remove 3 screws attaching shade to top of window.
2. Remove screw from shade string tensioners located at bottom of window.
Shroud, Rear Cargo Doors
1.
2.
3.
4.
5.
Remove window shade; refer to cargo door shade removal procedure.
Remove door panel; refer to door panel removal procedure.
Remove screws.
Remove screws from factory window latch.
Grasp shroud and pull outward to remove.
Shroud, Side Cargo Doors
1.
2.
3.
4.
5.
6.
Remove window shade; refer to cargo door shade removal procedure.
Remove door panel; refer to door panel removal procedure.
Remove screws.
Remove screws from factory window latch.
Remove door lock knob by unscrewing and pulling up.
Grasp shroud and pull outward to remove.
Sofa Motor
1. Remove sofa motor shroud.
2. Remove right side bolt from sofa frame attaching bracket to motor. (This releases
bracket).
3. Remove 5/16" nuts from end of sofa motor on both sides.
4. Unplug power wires from control module.
5. Grasp and pull drive cable loose from motor.
6. Remove sofa motor.
38
Sofa Motor Control Module
1. Unplug 2 connectors from module
2. Remove screws from base
TV
1. Remove VCP Faceplate:
Remove VCP trim ring.
Remove faceplate screws and remove faceplate.
2. Remove Storage Box Faceplate:
Open storage compartment door and remove faceplate screws.
Remove faceplate.
3. Removal of TV Lower Trim Piece:
Remove TV Lower Trim Piece Screws.
Remove TV Lower Trim Piece.
4. Remove screws from TV brackets.
5. Grasp TV and pull outward until connections are exposed.
6. Disconnect all connections, remove TV.
VCP
1. Remove VCP Faceplate:
Remove VCP trim ring.
Remove faceplate screws and remove faceplate.
2. Remove screws from VCP brackets.
3. Grasp VCP and pull outward until connections are exposed.
4. Disconnect all connections, remove VCP.
Wall, Deluxe
1. Open smart block fuse door. Disconnect smart block harness from smart block. Reposition harnesses through cut out in compartment.
2. Remove hidden screws behind fuse block.
3. Remove screws from windowsill plate and remove.
4. Reach through opening in windowsill and disconnect connector from rear of CD
player and/or rear radio (if equipped).
5. Grasp CD player/ rear radio and remove (if equipped).
6. Remove rear screw from top of deluxe-wall sill, untuck fabric from rear corner and
remove hidden screw.
7. Untuck fabric at front of deluxe wall and remove hidden screw under fabric,
* (Untuck fabric by placing putty knife under edge and prying gently out, grasp fabric to expose screw).
8. Lift straight up on deluxe-wall approximately 2” to release from cleat. Continue lifting
upward and remove.
39
Wall, Driver
1. Remove 6 exterior screws from upper wall wood trim, pull straight back and disconnect wires.
2. Remove sheer (3 screws at top) lower sheer down and rest on window ledge.
3. Remove screw from seat belt pod tab.
4. Remove 3 upper interior screws from top of Sport Top Wall through opening created
with removal of valance trim.
5. Remove 2 tack screws from bottom of Sport Top Wall.
Wall, Passenger
1. Remove 4 exterior screws from Upper wall wood trim, pull straight back and disconnect wires.
2. Remove shade (3 screws at top) lower shade down and rest on window ledge.
3. Remove screw from center seat belt pod tab.
4. Remove 2 upper interior screws from top of Sport Top Wall through opening created
with removal of valance.
5. Remove rear seat belt pod (1 hidden screw located 1" down from top under fabric at
center) remove 1 screw from pod tab remove pod.
6. Remove 2 tack screws from bottom of Sport Top Wall, located in top of window
frame.
7. Remove Sport Top Wall by sliding rearward until it comes out from under center
pod, now pull straight back to yourself.
Wall, Upper Sport Top, Driver Side
1.
2.
3.
4.
5.
6.
Remove applicable valance wood.
Remove storage box by removing external screws, grasp and pull up and out.
Remove 4 screws from bottom edge under valance.
Remove rear box per procedure.
Remove upper Wall wood trim.
Tilt bottom outward to access 5-L brackets, remove screws from brackets (located at
top of Sport Top Wall. These attach the Sport Top Wall to headliner).
Wall, Upper Sport Top, Passenger Side
1.
2.
3.
4.
5.
6.
Remove applicable valance wood.
Remove storage box by removing external screws, grasp and pull up and out.
Remove 4 screws from bottom edge under valance.
Remove rear box per procedure.
Remove Upper Wall wood trim.
Tilt bottom outward to access 5L brackets, remove rear box screws from brackets
(located at top of Sport Top Wall. These attach the Sport Top Wall to the headliner.)
Window Ring Removal Driver Side
1. Remove bottom windowsill.
2. Remove valance per procedures.
3. Repeat the above procedure for the 2nd vista bay window.
* Note
4.
5.
6.
7.
It is critical that the wall is loose at both window-mounting points.
At driver door peel back fabric on wall, this will expose screws. Remove screws.
Remove driver front factory seat belt shroud.
Remove driver center seat belt retainer if removal is for the rear window.
Pull bottom of wall away from window ring.
40
8. Lift fabric off from bottom of ring exposing screws, remove screws. Slide ring around
to expose all screws in window retainer clamp.
9. Grasp ring and slide upward until top of ring comes out from behind wall at the top.
10. Grasp top and bottom of ring and bend inward toward center of van, pull outward
the removal is complete.
* Note
Caution this ring in step 10 is made of wood and will break if bent to sharply.
Window Ring Removal Passenger Side
1.
2.
3.
4.
Remove bottom windowsill.
Remove valance per procedures.
Remove screws from window frame which, were under windowsill.
Peel back fabric at cargo door edge of wall, this will expose screws, remove screws.
Slide ring around to expose screws in window retainer clamp.
5. Pull bottom of wall away from window ring.
6. Lift fabric off from bottom of ring exposing screws, remove screws.
7. Grasp ring and slide forward until ring comes out from behind wall at the front.
* Note
Caution this ring in step 13 is made of wood and will break if bent to sharply.
Window, Vista Bay
* Note
This is a two-person operation.
1. Loosen cloth covered window ring (refer to window ring removal procedure step 8)
this will expose all metal window frame mounting screws.
2. Secure window to ensure it will not fall during the following removal step.
3. Remove all #8 x 3/4" screws around the perimeter of the metal window frame.
4. Grasp window at the top and bottom, pull outward and set down.
Torque Specifications
1.
2.
3.
4.
5.
6.
7.
8.
9.
Captain’s Chair to Slide -------------------------------- 16-21 FT LB
Pedestal to Floor ----------------------------------------- 22-30 FT LB
Removable Seat Plate to Floor ----------------------- 22-30 FT LB
Slider to Pedestal ---------------------------------------- 24-29 FT LB
Sofa to Floor ---------------------------------------------- 22-30 FT LB
Seatbelt Retractor to Floor ---------------------------- 22-30 FT LB
Seatbelt Retractor to Bracket (Dodge SWB) ------ 6-8 FT LB
Seatbelt Retractor to Wall ----------------------------- 22-30 FT LB
Wheel------------------------------------------------------- 85 FT LB
41
SWB Full-Size Van Procedures
Table of Contents
Dodge SWB
Low Top
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Carpet ------------------------------------------------------------------------------- 43
Center Beam ---------------------------------------------------------------------- 43
Door Panel, Passenger & Driver Front ------------------------------------- 43
Door Panel, Rear Cargo Doors ---------------------------------------------- 43
Door Panel, Side Cargo Door, Front---------------------------------------- 43
Door Panel, Side Cargo Door, Rear ---------------------------------------- 44
Head Board------------------------------------------------------------------------ 44
Headliner --------------------------------------------------------------------------- 44
Panel Speaker, Rear------------------------------------------------------------ 44
Seat Belt, Mid Seats and Sofa---------------------------------------------- 44
Shade Removal, Vista Bay Windows ------------------------------------- 45
Shroud Cargo Doors, Rear Cargo Doors -------------------------------- 45
Shroud Cargo Doors, Side Cargo Doors --------------------------------- 45
Shroud, Vista Bay Window -------------------------------------------------- 45
Soffit, Driver Side--------------------------------------------------------------- 46
Soffit, Passenger Front ------------------------------------------------------- 45
Soffit, Passenger Rear-------------------------------------------------------- 45
Torque Specifications --------------------------------------------------------- 47
TV Console ---------------------------------------------------------------------- 46
Wall, Driver Side --------------------------------------------------------------- 46
Wall, Passenger ---------------------------------------------------------------- 46
Window, Vista Bay ------------------------------------------------------------- 46
42
1997/1998 Dodge SWB
Low Top
Carpet
1.
2.
3.
4.
5.
6.
7.
8.
9.
Remove all seating.
Remove jack and jack handle, remove jack base plate 4 screws.
Remove all door step plates.
Remove all seat belt anchor bolts secured at floor (refer to seat belt removal
procedure).
Remove screws holding the bottom of the window shrouds.
Remove shade string grommets.
Remove TV Console per procedure, if equipped.
Remove engine cover by removing the screws located in the upper storage
compartment and the clips located on the sides of the engine cover.
Beginning at rear cargo doors grasp carpet and lift upward removing carpet from
flooring, moving toward the front of the van roll carpet as it is freed. If you encounter
difficulty with carpet that is wedged under the walls gently grasp the bottom of the
wall and the window frame and pull outward. This will lift the wall away from the
carpeting allowing you to pull it free. *Note carpet is stapled along the edges of the
rear fender wells and will require extra effort to release. Ensure that all staples are
removed prior to installing the new carpet.
Center Light Beam
1. Remove exposed screws.
2. Disconnect electrical connector and remove center beam.
Door Panel, Passenger & Driver Front
1.
2.
3.
4.
5.
6.
Remove factory armrest assembly and power window and door lock assembly.
Remove the retainer screw from the bottom front corner of door panel. (Exposed).
Remove retainer screw from bottom front corner of door panel (exposed).
Grasp top door panel inserts at top edge and pull outward to free.
Remove exposed screw.
Bottom door panel, grasp edges of panel and pull outward until retainers are free.
Door Panel, Rear Cargo Doors
1. Remove door handle bezel (2) screws, (passenger side).
2. Grasp edge of door panel at top and pull outward until you feel retainers snap out
from its retainer. Continue this motion all around panel to complete process.
Door Panel, Side Cargo Door, Front
1.
2.
3.
4.
5.
Remove caps from pull handle by unsnapping.
Remove 4 exposed screws, remove handle.
Remove factory door handle bezel (2) screws.
Remove fold down cup holder (4) screws if equipped.
Grasp edge of door panel at top and pull outward until you feel retainers snap out
from its retainer. Continue this motion all around panel to complete process.
43
Door Panel, Side Cargo Door, Rear
1.
2.
3.
4.
Remove caps from pull handle by unsnapping.
Remove 4 exposed screws, remove handle.
Remove 4 screws from frame around molded insert.
Grasp edge of door panel at top and pull outward until you feel retainers snap out
from its retainer. Continue this motion all around panel to complete process.
Head Board
1. Remove map lights (2), unsnap cover this exposes 2 screws, remove. Pull down on
light and disconnect wiring.
2. Drop the top of the Soffits by doing the following: Remove soffit wood trim (both
sides). Untuck the fabric at the front and rear of the driver’s side soffit and remove
the exposed screw. Pull the top of the soffit to release the top from the j-rail.
Remove the soffit over the passenger’s side cargo doors by untucking the fabric at
the front of the soffit and remove the exposed screw.
3. Remove buttons, remove exposed screws.
4. Reach through hole where map light was, grasp and pull straight back until
headboard clips are free from factory lip in roof.
5. Tilt rear of headboard down and pull rearward until free.
Headliner
1. Remove headboard (per procedures).
2. Drop the top of the Soffits by doing the following: Remove Upper sport top wall
wood trim (both sides). Untuck the fabric at the front and rear of the driver’s side
soffit and remove the exposed screw. Pull the top of the soffit to release the top from
the j-rail. Remove the soffit over the passenger’s side cargo doors by untucking the
fabric at the front of the soffit and remove the exposed screw. Untuck the fabric on
the front and rear of the rear soffit and remove the exposed screws. Pull at the top
of the Soffits and let hang.
3. Remove screws from center light beam pull down unplug wires at lights
4. Remove rear map light located in headliner, unsnap cover exposes 2 screws,
remove, pull down on light and disconnect plug in, remove screw that is under the
fabric 1” to the front of the map light.
5. Remove 4 tack screws from headliner, located where center beam was.
6. Slide forward until rear cleats release from factory roof lip.
7. Lower down and remove through the rear doors.
Panel Speaker, Rear
1. Remove speakers.
2. Remove rear door gimp as required pulling fabric loose on speaker panel.
3. Remove all exposed screws and remove speaker panel.
Seat Belts, Mid Seats And Sofa
1. Drop the top of the Soffits by doing the following (left or right side): Remove soffit
wood trim (either side). Untuck the fabric at the front and rear of the driver soffit and
remove the exposed screw. Pull the top of the soffit to release the top from the j-rail.
Remove the soffit over the passenger’s side cargo doors by untucking the fabric at
the front of the soffit and remove the exposed screw. Untuck the fabric on the front
and rear of the rear soffit and remove the exposed screws. Pull at the top of the
Soffits and let hang.
2. Remove seat belt bolt
44
*
(Critical items ensure when reinstalling seat belt that these 2 nuts are
torqued to 6 to 8 foot lbs.).
3. Pull back seat belt boot located on floor which will expose seat belt anchor bolt,
remove
* (Critical items ensure when reinstalling seat belt anchor bolt that it is
torqued to 22 to 28 foot lbs.).
Shade Removal
1. Remove screws attaching shade to top of window.
2. Remove shade string grommet located at bottom of window.
Shroud Cargo Doors, Rear Cargo Doors
1. Remove window shade; refer to shade removal procedure.
2. Remove screws.
3. Remove screws from factory window latch (ensure that you position your other hand
inside the doorframe under the latch to catch the plate).
4. Grasp shroud and pull up and out to remove.
Shroud, Vista Bay Window
1. Remove shade, see procedure.
2. Remove screws attaching shroud to wall.
Shroud Cargo Doors, Side Cargo Doors
1. Remove window shade; refer to shade removal procedure.
2. Remove screws.
3. Remove screws from factory window latch (ensure that you position your other hand
inside the doorframe under the latch to catch the plate).
4. Remove door lock knob by unscrewing and pulling up.
5. Grasp shroud and pull up and out to remove.
Soffit, Passenger Side, Front
1. Remove Map Light cover and remove exposed screws. Lower light, disconnect harness.
2. Untuck the fabric at the front of the soffit to expose the hidden screw. Remove
screw.
3. Pull the top of the soffit to release the top from the J-channel.
4. Remove the exposed screws.
Soffit, Passenger Side, Rear
1. Remove the shade (see procedure).
2. Remove the exposed screws.
3. Remove Map Light cover and remove exposed screws. Lower light, disconnect harness
4. Untuck the fabric at the front and rear of the soffit to expose the hidden screws.
Remove the screws.
5. Pull the top of the soffit to release the soffit from the J-channel.
6. Remove the seat belt retainer bolt and thread the seat belt through the seat belt
cutout. Remove the exposed screws.
45
Soffit, Driver Side
1. Remove shade (see procedure).
2. Remove the exposed screws.
3. Remove the Map lights cover and remove exposed screws. Lower light and disconnect.
4. Untuck the fabric at the front of the soffit to expose the hidden screw. Remove
screw.
5. Pull the top of the soffit to release the top from the J-channel.
6. Remove the seat belt retainer bolt and thread the seat belt through the seat belt
cutout.
7. Remove the exposed screws.
TV Console
1. Grasp edges of TV, pull out and disconnect.
2. Grasp edges of VCP, lift out and disconnect.
3. Remove screws connecting L-bracket to floor and remove TV console.
Wall, Driver Side
1. Remove the mid seat.
2. Remove the sofa.
3. Peel back wall fabric from driver doorpost and expose-hidden screws, remove all
screws.
4. Remove shrouds driver side front and rear, (Refer to shroud removal procedure).
5. Remove Driver side soffit. (See soffit procedure).
6. Grasp wall at gas fill mid lower wall and pull down as you are pulling the bottom of
wall outward slide toward front of van until released from behind speaker panel.
7. Remove wall out through rear cargo doors.
Wall, Passenger
1. Push the mid seat forward.
2. Lay the sofa in the flat position.
3. Peel back wall fabric from cargo doorpost and expose-hidden screws, remove all
screws.
4. Remove window shroud (Refer to shroud removal procedure).
5. Remove side soffit. (See soffit procedure).
6. Grasp wall at gas fill mid lower wall and pull down as you are pulling the bottom of
wall outward slide toward front of van until released from behind speaker panel.
7. Remove wall out through rear cargo doors.
Window, Vista Bay
* Note
This is a 2-person operation
1. Remove window shroud (per procedures).
2. Remove all screws around the perimeter of the metal window frame.
3. Exit vehicle and go to outside of window and grasp at the top and bottom, pull
outward and set down.
46
Torque Specifications
1.
2.
3.
4.
5.
6.
7.
8.
9.
Captain’s Chair to Slide -------------------------------- 16-21 FT LB
Pedestal to Floor ----------------------------------------- 22-30 FT LB
Removable Seat Plate to Floor ----------------------- 22-30 FT LB
Slider to Pedestal ---------------------------------------- 24-29 FT LB
Sofa to Floor ---------------------------------------------- 22-30 FT LB
Seatbelt Retractor to Floor ---------------------------- 22-30 FT LB
Seatbelt Retractor to Bracket (Dodge SWB) ------ 6-8 FT LB
Seatbelt Retractor to Wall ----------------------------- 22-30 FT LB
Wheel------------------------------------------------------- 85 FT LB
47
SWB Full-Size Van Procedures
Table of Contents
Dodge SWB
SPORT Top
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Carpet ------------------------------------------------------------------------------- 49
Center Beam ---------------------------------------------------------------------- 49
Door Panel, Passenger & Driver Front ------------------------------------- 49
Door Panel, Rear Cargo Doors ---------------------------------------------- 49
Door Panel, Side Cargo Door, Front---------------------------------------- 49
Door Panel, Side Cargo Door, Rear ---------------------------------------- 50
Faceplate--------------------------------------------------------------------------- 50
Head Board------------------------------------------------------------------------ 50
Headliner --------------------------------------------------------------------------- 50
Panel Speaker, Rear ---------------------------------------------------------- 50
Rear Box-------------------------------------------------------------------------- 50
Seat Belt, Mid Seats And Sofa --------------------------------------------- 51
Shade Removal, Vista Bay Windows ------------------------------------- 51
Shroud Cargo Doors, Rear Cargo Doors -------------------------------- 51
Shroud Cargo Doors, Side Cargo Doors --------------------------------- 51
Shroud, Vista Bay Window--------------------------------------------------- 51
Soffit, Driver---------------------------------------------------------------------- 52
Soffit, Passenger Front ------------------------------------------------------- 51
Soffit, Passenger Rear-------------------------------------------------------- 52
Torque Specifications --------------------------------------------------------- 53
TV ---------------------------------------------------------------------------------- 52
VCP -------------------------------------------------------------------------------- 52
Wall, Driver Side --------------------------------------------------------------- 52
Wall, Passenger ---------------------------------------------------------------- 52
Wall, Upper Sport Top -------------------------------------------------------- 53
Window, Vista Bay ------------------------------------------------------------- 53
48
1997/1998 Dodge SWB
Sport Top
Carpet
1.
2.
3.
4.
5.
6.
7.
8.
Remove all seating.
Remove jack and jack handle, remove jack base plate 4 screws.
Remove all door step plates.
Remove all seat belt anchor bolts secured at floor (refer to seat belt removal
procedure).
Remove lower window shrouds screws.
Remove shade string grommets.
Remove engine cover by removing the screws located in the upper storage
compartment and the clips located on the sides of the engine cover.
Beginning at rear cargo doors grasp carpet and lift upward removing carpet from
flooring, moving toward the front of the van roll carpet as it is freed. If you encounter
difficulty with carpet that is wedged under the walls gently grasp the bottom of the
wall and the window frame and pull outward. This will lift the wall away from the
carpeting allowing you to pull it free. Note carpet is stapled along the edges of the
rear fender wells and will require extra effort to release. Ensure that all staples are
removed prior to installing the new carpet.
Center Light Beam
1. Remove exposed screws.
2. Disconnect electrical connector and remove center beam.
Door Panel, Passenger & Driver Front
1.
2.
3.
4.
5.
Remove factory armrest assembly and power window and door lock assembly.
Remove the retainer screw from the bottom front corner of door panel (exposed).
Grasp top door panel inserts at top edge and pull outward to free.
Remove screws exposed after performing step 3.
Bottom door panel, grasp edges of panel and pull outward until retainers are free.
Door Panel, Rear Cargo Doors
1. Remove door handle bezel (2) screws, (passenger side).
2. Grasp edge of door panel at top and pull outward until you feel retainers snap out
from its retainer. Continue this motion all around panel to complete process.
Door Panel, Side Cargo Door, Front
1.
2.
3.
4.
5.
Remove caps from pull handle by unsnapping.
Remove 4 exposed screws, remove handle.
Remove factory door handle bezel (2) screws.
Remove fold down cup holder (4) screws if equipped.
Grasp edge of door panel at top and pull outward until you feel retainers snap out
from its retainer. Continue this motion all around panel to complete process.
49
Door Panel, Side Cargo Door, Rear
1.
2.
3.
4.
Remove caps from pull handle by unsnapping.
Remove 4 exposed screws, remove handle.
Remove 4 screws from frame around molded insert.
Grasp edge of door panel at top and pull outward until you feel retainers snap out
from its retainer. Continue this motion all around panel to complete process.
Face Plate
1.
2.
3.
4.
5.
6.
7.
8.
Remove TV (see procedure).
Remove VCP (see procedure).
Remove screws from bottom of faceplate.
Expose hidden screw on the front of Soffits by untucking fabric to expose screw,
remove screw.
Remove upper sport top wall wood trim, both sides.
Gently pull at the top of the soffit to remove soffit from J-channel (both sides).
Remove screw-connecting headboard to faceplate (both sides), exposed when soffit
is lowered.
Remove exposed screws in 2-L brackets connecting faceplate to upper wall (both
sides). Lower faceplate.
Head Board
1. Remove Faceplate (see procedure).
2. Remove Map light covers and remove the exposed screws. Lower light and
disconnect harness.
3. Remove buttons and then exposed screws. Pull towards rear to release, and
remove from vehicle.
Headliner
1.
2.
3.
4.
5.
6.
Remove faceplate (see procedure).
Remove rear box (refer to procedure).
Remove Upper Sport Top Walls (see procedure).
Remove center beam by removing 6 screws and disconnecting wire connector.
Remove retaining screws remaining in headliner at center.
Slide headliner forward to clear rear roof, lower rear section, slide out through rear
cargo doors.
Panel Speaker, Rear
1. Remove speakers.
2. Remove door gimps as required and pull fabric loose at each edge of the doors to
expose screws.
3. Remove all exposed screws and remove speaker panel.
Rear Box
1. Expose hidden screw on the front of Soffits by untucking fabric to expose screw,
remove screw.
2. Remove upper sport top wall wood trim, both sides.
3. Gently pull at the top of the soffit to remove soffit from J-channel (both sides) and let
soffit suspend. Remove grab handles.
4. Reach in and remove screws, in L-bracket, which connects rear box to the roof.
5. Remove box out through rear cargo doors.
50
Seat Belts, Mid Seats And Sofa
1. Drop the top of the Soffits by doing the following (left or right side): Remove Upper
sport top wall wood trim (either side). Untuck the fabric at the front and rear of the
driver’s side soffit and remove the exposed screw. Pull the top of the soffit to
release the top from the j-rail. Remove the soffit over the passenger’s side cargo
doors by untucking the fabric at the front of the soffit and remove the exposed
screw. Untuck the fabric on the front and rear of the rear soffit and remove the
exposed screws. Pull at the top of the Soffits and let hang.
2. Remove upper seat belt bolt(s).
* (Critical item ensures when reinstalling seat belt that these 2 nuts are
torqued to 6 to 8 foot lbs.).
3. Pull back seat belt boot located on floor which will expose seat belt anchor bolt,
remove
* (Critical items ensure when reinstalling seat belt anchor bolt that it is
torqued to 22 to 28 foot lbs.).
Shade Removal, Vista Bay Windows
1. Remove 3 screws attaching shade to top of window.
2. Remove shade string grommet located at bottom of window.
Shroud, Rear Cargo Doors
1. Remove shroud screws.
2. Remove screws from factory window latch (ensure that you position your other hand
inside the doorframe under the latch to catch the plate).
3. Grasp shroud and pull outward to remove.
Shroud, Side Cargo Doors
1. Remove window shade; refer to shade removal procedure.
2. Remove exposed screws.
3. Remove 3 screws from factory window latch (ensure that you position your other
hand inside the doorframe under the latch to catch the plate).
4. Remove door lock knob by unscrewing and pulling up.
5. Grasp shroud and pull outward to remove.
Shroud, Vista Bay
1. Remove shades from vista bay window, per procedure.
2. Remove window shroud screws, remove shroud.
Soffit, Passenger, Front
1. Remove shade per procedure.
2. Remove Map light cover and remove the exposed screws. Lower light and
disconnect harness.
3. Expose hidden screw on the front of soffit by untucking fabric to expose screw,
remove screw.
4. Remove upper sport top wall wood trim screws. Lower wood trim.
5. Gently pull at the top of the soffit to remove soffit from J-channel.
6. Remove all exposed screws.
51
Soffit, Passenger, Rear
1. Remove window shades per procedures.
2. Remove front soffit.
3. Remove Map light cover and remove exposed screws. Lower light and disconnect
harness.
4. Expose hidden screw on the front and rear of soffit by untucking fabric to expose
screw, remove screw.
5. Remove upper sport top wall wood trim.
6. Gently pull at the top of the soffit to remove soffit from J-channel.
7. Remove all exposed screws and lower soffit.
Soffit, Driver
1. Remove Map light covers and remove exposed screws. Lower light and disconnect
harness.
2. Expose hidden screw on the front and rear of soffit by untucking fabric to expose
screw, remove screw.
3. Remove upper sport top wall wood trim.
4. Gently pull at the top of the soffit to remove soffit from J-channel.
5. Remove window shades.
6. Remove all exposed screws and lower soffit.
TV
1. Remove 4 exposed screws from TV trim ring, remove ring. (Exposes screws in Lbrackets remove screws).
2. Grasp TV and pull outward until connections are exposed.
3. Disconnect all connections, remove TV.
VCP
1.
2.
3.
4.
5.
Remove TV (per procedures).
Remove VCP box from press fasteners.
Remove VCP box through TV opening.
Remove VCP from VCP box.
Disconnect Electrical connector.
1.
2.
3.
4.
5.
6.
7.
Remove the remote storage from wall, if applicable.
Remove Drivers soffit (per procedures).
Remove shrouds and shades.
Remove mid seat.
Remove sofa.
Untuck fabric at driver’s doorpost and remove screws.
Grab wall at the bottom and tilt out ward. Remove wall.
Wall, Driver Side
Wall, Passenger Side
1.
2.
3.
4.
5.
6.
Remove Passenger rear soffit (per procedures).
Remove shroud.
Push the mid seat forward. Remove sofa.
Untuck fabric at side cargo door post and remove screws.
Expose screws at rear cargo doorpost and remove.
Grab wall at the bottom and tilt out ward. Remove wall.
52
Wall, Sport Top, Upper
1. Remove soffit (refer to soffit removal procedure).
2. Remove rear box.
3. Tilt bottom outward to access L brackets, remove screws from brackets.
4. Support and lower upper sport top wall.
Window, Vista Bay
* Note
This is a 2-person operation.
1. Remove window shroud (per procedures).
2. Remove all screws around the perimeter of the metal window frame.
3. Exit vehicle and go to outside of window and grasp at the top and bottom, pull
outward and set down.
Torque Specifications
1.
2.
3.
4.
5.
6.
7.
8.
9.
Captain’s Chair to Slider -----------------------------------------16-21 FT LB
Pedestal to Floor---------------------------------------------------22-30 FT LB
Removable Seat Plate to Floor ---------------------------------22-30 FT LB
Slider to Pedestal --------------------------------------------------24-29 FT LB
Sofa to Floor --------------------------------------------------------22-30 FT LB
Seatbelt Retractor to Floor---------------------------------------22-30 FT LB
Seatbelt Retractor to Bracket (Dodge SWB) ----------------6-8 FT LB
Seatbelt Retractor to Wall ---------------------------------------22-30 FT LB
Wheel (van and pickup single axle) ---------------------------85 FT LB
53
Table of Contents
Caravan/ Voyager Procedures
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
CD------------------------------------------------------------------------------------ 55
Center Beam ---------------------------------------------------------------------- 55
Cooler ------------------------------------------------------------------------------- 55
Faceplate--------------------------------------------------------------------------- 55
Game Ready ---------------------------------------------------------------------- 55
Head Liner ------------------------------------------------------------------------- 56
Headphone Station -------------------------------------------------------------- 55
Indirect Lighting In Sport Top ------------------------------------------------- 56
Rear Radio and TV Speakers ------------------------------------------------ 56
Rear Radio ----------------------------------------------------------------------- 56
Rear Speaker Box ------------------------------------------------------------- 56
Torque Specifications --------------------------------------------------------- 57
TV ---------------------------------------------------------------------------------- 56
VCP -------------------------------------------------------------------------------- 57
Wall Sport Top ------------------------------------------------------------------ 57
54
1997/1998 Dodge/ Plymouth
Caravan / Voyager
Center Beam
1.
2.
3.
4.
Remove 6 screws from beam.
Lower down.
Disconnect mate-n-lock for reading lights (2 sets).
Disconnect wiring for indirect light 2 wires.
CD
1. Remove faceplate (refer to faceplate removal procedure).
2. Remove screws from top of CD attaching it to backer.
3. Disconnect plug in connector.
Cooler
1.
2.
3.
4.
Remove lid.
Lift cooler out of frame.
Remove screws from exposed brackets.
Lift frame, up and out.
* Note
When reinstalling cooler use care not to run screws into factory wiring harness
located under carpeting and silicone must be placed around drain tube.
Faceplate
1. Remove the face of the radio or remove the radio trim and then the radio, as applicable.
2. Remove the radio by inserting the key (provided with the vehicle upon delivery) and
twisting clockwise. This releases the lock. Pull radio out to remove.
3. Remove 6 screws from faceplate bottom strip.
4. Remove 2 screws from faceplate.
5. Grasp faceplate at bottom edge and pull outward tilting past the CD player, Rear
radio and VCP (use caution not to tear the fabric on the canoes when performing
this procedure).
6. Pull downward at this time releasing faceplate.
Game Ready
1.
2.
3.
4.
Unsnap bezel.
Remove screws.
Pull straight out.
Disconnect wiring.
Headphone Station
1.
2.
3.
4.
Unsnap bezel.
Remove 4 screws.
Pull straight out.
Disconnect mate-n-lock connector.
55
Headliner
1.
2.
3.
4.
Remove faceplate (refer to faceplate removal procedure).
Remove both Sport Top Walls (refer to Wall, Sport Top removal procedure).
Remove rear box (refer to rear box removal procedure).
Remove center light beam (refer to Center Beam removal procedure) exposes hidden screws.
5. Remove screws from headliner.
6. Lower rear of headliner slide to the rear and out.
Indirect Lighting, Sport Top Wall
1.
2.
3.
4.
Remove Game ready, if equipped.
Remove 4 external screws from frame.
Pull straight outward.
Disconnect 2 wires from rear.
Rear Radio
1. Remove radio face.
2. Remove the radio by inserting the key (provided with the vehicle upon delivery) and
twisting clockwise. This releases the lock. Pull radio out to remove.
3. Pull straight out.
4. Disconnect mate-n- lock connector.
TV Speakers
1. Remove 4 screws.
2. Pull straight out.
3. Disconnect 2 speaker wires.
Speaker Box, Rear
1. Remove passenger or drivers Sport Top Wall (refer to Wall, Sport Top removal procedure).
2. Remove trim wood & TV speakers (refer to TV speaker removal procedure).
3. Remove screws from rear cargo door shroud (covers rear of headliner) pull downward to release factory clips.
4. Remove retainer clip exposed after removal of shroud (located approximately center
of the headliner).
5. Reach through speaker hole cutout and remove screw in L bracket going into driver
and passenger side Wall, Sport Top. Repeat for other side.
6. Remove screws from 2-L brackets located above the trim wood cutout.
7. Slide box forward to release and lower down. Remove out through rear door.
TV
1. Remove faceplate (refer to faceplate removal procedure) this will expose 2 L brackets for TV.
2. Remove screws from brackets, pull straight back and out.
3. Disconnect all wiring.
56
VCP
1. Remove faceplate (refer to faceplate removal procedure) this will expose 2 L brackets for VCP.
2. Remove screws from brackets, pull straight back and out.
3. Disconnect all wiring.
Wall, Sport Top
1. Remove faceplate (refer to faceplate removal procedure).
2. Grasp fabric located at top of driver or passenger sliding door rail and factory door
gimp, pull downward until loose this will expose screws, remove screws.
3. Remove factory fan control switch on Sport Top Wall by removing 3 screws and disconnecting wires.
4. Remove clothes hanger.
5. Release top of “D” pillar shroud to loosen.
6. Remove screw from the appropriate side of the rear cargo door shroud (covers rear
of headliner).
7. Remove valance lighting (and game ready if equipped) front and rear 4 screws in
each, pull straight out and disconnect 2 wires.
8. Reach through cutout in Sport Top Wall and unplug connector to headphone station.
9. Remove the appropriate side speaker in rear box 4 screws.
10. Reach through speaker hole and remove 1 screw through L bracket in side of rear
box attaching to upper wall.
11. Reach through valance lighting cutouts in Sport Top Wall and remove screws in L
brackets attaching upper wall to roof wood strips (4 brackets).
12. Pull downward on front of Sport Top Wall until it is below the headboard.
13. Reach in and remove the a/c hoses from the vents.
14. Pull forward and out to remove Sport Top Wall from behind rear box.
Torque Specifications
1.
Wheel------------------------------------------------------- 85 FT LB
57
Table of Contents
Ram and Dakota Pickup Procedures
1.
2.
3.
Dash Trim Wood Removal/Installation (All Pickups) ------------------- 59
Extended Cab Overhead Console------------------------------------------- 62
Torque Specification ------------------------------------------------------------ 62
58
Ram and Dakota Pickup
Dash Trim Wood Removal
(With Or Without Metal Fasteners)
Items Required:
1 inch rigid putty knife
Soft clean cloth
“Tape residue remover” Rubbing Alcohol
Screwdriver, Phillips, medium (screw on kit only)
Removal Procedure
* Note
Removal of a taped on unit is difficult due to the high adhesive strength of products
used by our supplier. In most cases, items will be severely damaged by removal.
1. Remove all screws or fasteners (if applicable) to the dash kit item.
2. Try pulling the part off with your fingers. If part comes off, skip to step # 4.
3. If the part doesn’t pull off, a 1” wide putty knife will help. Start under a corner and
pry upward taking care not to damage vehicle surface. With perseverance and
some putty knife scraping the part should start to pull off. Great care must be exercised when using the putty knife not to damage vehicle area under the part.
4. When the wood bulk of the piece has been removed there will be residue of tape
and, or adhesive. Rubbing your thumb over the area forming a residue ball can
clean off the residue. Additional rubbing will continue to remove residue. Adhesive
remover can be used it will not etch the surface of the dash area. A nondestructive adhesive scraper can also be used. Once again, care must be exercised
not to gouge the surface or mar the surrounding areas.
* Note all adhesives must be removed from the surface if another unit is to be
installed.
5. Clean area with rubbing alcohol or other non-destructive solvent.
Dash Trim Wood
Installation Of Tape Backed
And Screw Fastened Items
Items Required:
*
*
*
*
*
*
Screwdriver, Phillips size #0 Rubbing Alcohol
Hair dryer, 2 speed or Heat gun, 2 speedSuper Glue Gel (optional)
4298 3-M Adhesive Promoter Super Glue Gel Remover (Optional)
Soft clean cloth
#2 Pencil
Gloss Black Paint Pen (Testor’s Or Equivalent)
59
*
*
*
Notes to Installation:
Think through the installation to determine piece position.
The item may show some packing mark(s) when removed from the package. DO
NOT BECOME ALARMED, as they will disappear with the warm air in the vehicle.
All auto manufacturers apply silicon to various interior components to forestall cracking
from cold and heat. The silicon base must be removed for tape backed product adherence.
In vehicle production, manufacturers allow different tolerances for various components.
Though the make and model of any two vehicles may be the same, assembled component tolerance may vary. Vehicle components can often be moved/ adjusted if required
to obtain a perfect fit.
If installation is to be over existing OEM wood dash, we recommended painting the
already installed factory wood dash piece (s) prior to the new installation. Carefully
mask area and paint a thin coat with a semi - gloss or flat lacquer black paint per
manufacturer instruction.
*
WARNING
IF HEAT SOURCE IS USED FOR INSTALLATION, DO NOT OVER HEAT. Over heating may cause cracking and the temperature should not exceed that which would be
uncomfortable to facial skin (100 to 110 degrees f.) Heat should be applied to both the
front and back surface of the item.
Never bend apiece back and fort as this will wrinkle finish.
Never try to bend a dash piece without heating it first - severe damage may occur.
Never attempt to bend hardboard product.
INSTALLATION PROCEDURE:
1. Dry mount part(s) to verify proper fit.
* Note
Perform the following step (Step #2)
Only if item requires bending and is not “hardboard”.
2. Heat and shape the piece into the same contours as mounting area for dry fit. DO
NOT BEND BACK AND FORTH.
3. Using a pencil, outline where the piece will fit. Doing this step will establish reference points for a perfect fit.
4. Place a clean cloth on your finger and work mounting area(s) clean with household
rubbing alcohol. Clean only the mounting area(s). If a clear plastic piece must be
cleaned, use Windex or a similar cleaner. Complete this step twice to ensure
proper clean level.
60
5. NOTE: for additional adhesion a thin coat of 3-M 4298 may be applied to mounting
area. Adhesive promoter seals the surface and increases adhesion. Promoter is
generally used for critical areas such as bends where additional adhesion may be
required or desirable. WARNING, adhesive promoter may cause damage or discoloration to dash. Care must be taken to avoid application of promoter to any
surface, which will not be covered. Furthermore, this additional adhesion negates
any movement of during installation.
6. Position yourself directly in front of part to be installed. To minimize the possibilities
of misalignment remember (Step # 3) to dry fit each piece before installation. Watch
for corner matches, alignment of critical thin sections, bends, etc. Remove the red
plastic from the double backing tape. Heat the piece to be installed once again.
Keeping your reference points in mind, work through each bend and bow, pushing it
into place as you go. Work from one starting point.... DO NOT STICK A TOP PIECE
AND BOTTOM PIECE BEFORE THE MIDDLE PIECE, START AT THE TOP OR
BOTTOM AND WORK ONE WAY.
7. Operate switches , knobs, buttons., as applicable to ensure a proper installation fit.
Should a problem result, lightly file the problem area and remark it. BE CAREFUL
NOT TO SLIP AND SCRATCH THE DASH.
8. To remove fingerprints from installation, moisten a clean soft rag with the alcohol or
Prep Sol and gently wipe wood surface. Erase the pencil lines previously drawn.
We do not recommend using the same cleaning rag for this step.
*
NOTE
The hair dryer (or heat source) may also be used after installation to remove any unnecessary bands or flaws.
*
WARNING
DO NOT GET ANY VINYL DRESSING (e.g. ARMOR ALL) OR OTHER CHEMICALS
ON OR BEHIND THE TAPE. THESE PRODUCTS WILL BREAK DOWN THE
TAPE AND CAUSE FAILURE.
9. If any pieces should lift after installation, heat the part and carefully lift the edge that
has loosened. Heat the piece again. Put a small drop of Super Glue Gel on a round
toothpick and apply to the vehicle dash. Press the piece down firmly for several
minutes.
METAL FASTENERS:
1. Screws are used in a variety of products and applications include items that are
both taped and fastened with screws. Due to the extensive variety of materials, conditions and product conditions and construction methods, torque values are not established for screw on installations.
*
NOTE
If item is combination screw and tape on, mount item as directed for tape on prior to installing screws.
2. Carefully locate and pre-drill all screw holes using 1/16 (.0625) dia, drill bit.
61
*
NOTE
Extreme care must be taken when installing screws to prevent slipping of the driver and
damage to the finished surface to the product. If possible, position a thin hard plastic guard in area of screw hole to absorb a possible slipped driver point impact.
3. Drive screw with minimum required pressure to start. Continue to tighten screw until
bottom of screw head contacts the material being installed. On counterbored screw
holes, the screw head will be bottomed when the screw head is flush or slightly below surface. Once screw head has bottomed, back screw out (counter- clockwise)
1/4 of a turn. The slight back out of the screw is required to avoid damage to the
material from overstress, fatigue and other possible influencing conditions as vibration.
Overhead Console, Dodge Ext. Cab
1. Remove the rear and front map lights by prying off the cover and removing the
exposed screws. Disconnect the wires and remove the light.
2. Untuck the material in the front of the console and remove the exposed screws.
3. Remove the center screws holding the wood trim plate to the console.
4. Remove the exposed screws and lower the console.
5. Disconnect any remaining wires and remove.
Torque Specifications
1.
2.
3.
Steptube Bars (pickup) --------------------------------- 75 FT LB
Wheel (pickup single axle) ---------------------------- 85 FT LB
Wheel, Aluminum (pickup dual axle) ---------------- 140 FT LB
62
Table of Contents
Jeep Procedures
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Air Compressor ------------------------------------------------------------------- 64
CD Player -------------------------------------------------------------------------- 64
CD Remote ------------------------------------------------------------------------ 69
Dash Trim Wood Removal/Installation ------------------------------------- 64
FM Modulator---------------------------------------------------------------------- 69
Fuse Block ------------------------------------------------------------------------- 69
Global Positioning System (GPS) ------------------------------------------- 67
Headliner --------------------------------------------------------------------------- 67
Noise Choke----------------------------------------------------------------------- 69
Rear Storage Box ---------------------------------------------------------------- 68
Rear Tire Carrier ----------------------------------------------------------------- 69
Roof Rack -------------------------------------------------------------------------- 68
Sun Roof (Electric & Manual) ------------------------------------------------- 68
Torque Specification ------------------------------------------------------------ 69
TV Amp ----------------------------------------------------------------------------- 68
TV Antenna ------------------------------------------------------------------------ 68
TV Base ---------------------------------------------------------------------------- 68
TV ------------------------------------------------------------------------------------ 68
VCP ---------------------------------------------------------------------------------- 69
VCP ---------------------------------------------------------------------------------- 69
63
Jeep Procedures
Air Compressor
1. Remove attachment screws.
2. Remove air compressor, disconnect wire harness.
CD Player
1. Remove rear storage box
2. Remove screws from CD mounting bracket and slide CD player from the back of the
rear box.
Dash Trim Wood Removal
(With Or Without Metal Fasteners)
Items Required:
1 inch rigid putty knife
Soft clean cloth
“Tape residue remover” Rubbing Alcohol
Screwdriver, Phillips, medium (screw on kit only)
Removal Procedure
* Note
Removal of a taped on unit is difficult due to the high adhesive strength of products
used by our supplier. In most cases, items will be severely damaged by removal.
1. Remove all screws or fasteners (if applicable) to the dash kit item.
2. Try pulling the part off with your fingers. If part comes off, skip to step # 4.
3. If the part doesn’t pull off, a 1” wide putty knife will help. Start under a corner and
pry upward taking care not to damage vehicle surface. With perseverance and
some putty knife scraping the part should start to pull off. Great care must be exercised when using the putty knife not to damage vehicle area under the part.
4. When the wood bulk of the piece has been removed there will be residue of tape
and, or adhesive. Rubbing your thumb over the area forming a residue ball can
clean off the residue. Additional rubbing will continue to remove residue. Adhesive
remover can be used it will not etch the surface of the dash area. A nondestructive adhesive scraper can also be used. Once again, care must be exercised
not to gouge the surface or mar the surrounding areas.
* Note
All adhesives must be removed from the surface if another unit is to be installed.
5. Clean area with rubbing alcohol or other non-destructive solvent.
64
Dash Trim Wood
Installation Of Tape Backed
And Screw Fastened Items
Items Required:
Screwdriver, Phillips size #0 Rubbing Alcohol
Hair dryer, 2 speed or Heat gun, 2 speedSuper Glue Gel (optional)
4298 3-M Adhesive Promoter Super Glue Gel Remover (Optional)
Soft clean cloth
#2 Pencil
Gloss Black Paint Pen (Testor’s Or Equivalent)
* Notes to Installation:
*
*
Think through the installation to determine piece position.
The item may show some packing mark(s) when removed from the package. DO
NOT BECOME ALARMED, as they will disappear with the warm air in the vehicle.
All auto manufacturers apply silicon to various interior components to forestall cracking
from cold and heat. The silicon base must be removed for tape backed product adherence.
In vehicle production, manufacturers allow different tolerances for various components.
Though the make and model of any two vehicles may be the same, assembled component tolerance may vary. Vehicle components can often be moved/ adjusted if required
to obtain a perfect fit.
If installation is to be over existing OEM wood dash, we recommended painting the
already installed factory wood dash piece (s) prior to the new installation. Carefully
mask area and paint a thin coat with a semi - gloss or flat lacquer black paint per
manufacturer instruction.
*
WARNING
IF HEAT SOURCE IS USED FOR INSTALLATION, DO NOT OVER HEAT. Over heating may cause cracking and the temperature should not exceed that which would be
uncomfortable to facial skin (100 to 110 degrees f.) Heat should be applied to both the
front and back surface of the item.
Never bend apiece back and fort as this will wrinkle finish.
Never try to bend a dash piece without heating it first - severe damage may occur.
Never attempt to bend hardboard product.
65
INSTALLATION PROCEDURE:
1. Dry mount part(s) to verify proper fit.
* Note
Perform the following step (Step #2)
Only if item requires bending and is not “hardboard”.
2. Heat and shape the piece into the same contours as mounting area for dry fit. DO
NOT BEND BACK AND FORTH.
3. Using a pencil, outline where the piece will fit. Doing this step will establish reference points for a perfect fit.
4. Place a clean cloth on your finger and work mounting area(s) clean with household
rubbing alcohol. Clean only the mounting area(s). If a clear plastic piece must be
cleaned, use Windex or a similar cleaner. Complete this step twice to ensure
proper clean level.
* NOTE:
For additional adhesion a thin coat of 3-M 4298 may be applied to mounting area. Adhesive promoter seals the surface and increases adhesion. Promoter is generally used
for critical areas such as bends where additional adhesion may be required or desirable. WARNING, adhesive promoter may cause damage or discoloration to dash.
Care must be taken to avoid application of promoter to any surface, which will not be
covered. Furthermore, this additional adhesion negates any movement of during installation.
5. Position yourself directly in front of part to be installed. To minimize the possibility of
misalignment remember (Step # 3) to dry fit each piece before installation. Watch
for corner matches, alignment of critical thin sections, bends, etc. Remove the red
plastic from the double backing tape. Heat the piece to be installed once again.
Keeping your reference points in mind, work through each bend and bow, pushing it
into place as you go. Work from one starting point.... DO NOT STICK A TOP PIECE
AND BOTTOM PIECE BEFORE THE MIDDLE PIECE, START AT THE TOP OR
BOTTOM AND WORK ONE WAY.
6. Operate switches, knobs, and buttons, as applicable to ensure a proper installation
fit. Should a problem result, lightly file the problem area and remark it. BE CAREFUL NOT TO SLIP AND SCRATCH THE DASH.
7. To remove fingerprints from installation, moisten a clean soft rag with the alcohol or
Prep Sol and gently wipe wood surface. Erase the pencil lines previously drawn.
We do not recommend using the same cleaning rag for this step.
*
NOTE
The hair dryer (or heat source) may also be used after installation to remove any unnecessary bands or flaws.
*
WARNING
DO NOT GET ANY VINYL DRESSING (e.g. ARMOR ALL) OR OTHER CHEMICALS
ON OR BEHIND THE TAPE. THESE PRODUCTS WILL BREAK DOWN THE TAPE
AND CAUSE FAILURE.
8. If any pieces should lift after installation, heat the part and carefully lift the edge that
has loosened. Heat the piece again. Put a small drop of Super Glue Gel on a round
toothpick and apply to the vehicle dash. Press the piece down firmly for several
minutes.
66
METAL FASTENERS:
1. Screws are used in a variety of products and applications include items that are
both taped and fastened with screws. Due to the extensive variety of materials, conditions and product conditions and construction methods, torque values are not established for screw on installations.
* NOTE
If item is combination screw and tape on, mount item as directed for tape on prior to installing screws.
2. Carefully locate and pre-drill all screw holes using 1/16 (.0625) dia, drill bit.
*
NOTE
Extreme care must be taken when installing screws to prevent slipping of the driver and
damage to the finished surface to the product. If possible, position a thin hard plastic
guard in area of screw hole to absorb a possible slipped driver point impact.
3. Drive screw with minimum required pressure to start. Continue to tighten screw until
bottom of screw head contacts the material being installed. On counterbored screw
holes, the screw head will be bottomed when the screw head is flush or slightly below surface. Once screw head has bottomed, back screw out (counter- clockwise)
1/4 of a turn. The slight back out of the screw is required to avoid damage to the
material from overstress, fatigue and other possible influencing conditions as vibration.
GPS (Telepath)
1. Remove Trim bezel.
2. Insert clips for removal at both sides of the GPS and pull out GPS unit.
3. Disconnect electrical connectors, remove unit.
Headliner
1. Remove GPS per GPS procedure.
2. Remove TV power switch, disconnect electrical connector.
3. Remove front overhead console, disconnect electrical connector.
4. Remove sun visors and clips, disconnect electrical connectors.
5. Pull CD remote from Velcro pad.
6. Remove pull handles.
7. Remove Game Ready, disconnect electrical connector.
8. Remove sunroof switch, disconnect electrical connector.
9. Remove rear sunroofs shroud; pull fabric back at all 4 corners and remove screws.
10. Remove headphone jacks, disconnect electrical connectors.
11. Remove rear sport top shroud and port holes.
12. Remove rear overhead console, disconnect electrical connector.
13. Remove rear speaker, disconnect electrical connector.
14. Remove all rear hatch shrouds, disconnect electrical connector.
15. Remove pillar shrouds; remove seat bolt shoulder bolts, pull seat bolt adjustment
knob off, pull pillar shroud off post.
16. Remove TV, per procedures.
17. Disconnect CD remote through the TV mounting hole. Pull remote out from
headliner.
18. Lower headliner and remove through rear hatch.
67
Rear storage box
1.
2.
3.
4.
5.
6.
Remove screws from top tray wood trim.
Remove screws from plastic tray. Lift tray off the rear box.
Remove air compressor, per procedures.
Remove screws from rear storage box to the floor.
Remove screw from box to the wall.
Slide rear box from wall and disconnect CD harness and VCP harness.
Roof rack
1. Remove the bolts from all roof rack arms.
2. Remove roof rack bolts from the sport top.
3. Remove roof rack from the sport top.
Sun roof (electric & manual)
1. Remove roof rack per procedures.
2. Remove headliner per procedures.
3. Remove screws from the sun roof rings. (Electric sunroof – disconnect motor harness from the main harness).
4. From inside the vehicle, push up on the sunroof, and hand to the outside man.
Note: When reinstalling sunroof reapply string sealant around the sunroof before
installation. Sunroof MUST be in channel in roof lip. Replace any striped screws
or the roof will leak.
TV
1. Remove screws from the TV wood base that mount through the headliner.
2. Pull TV away from the headliner and disconnect the wiring.
TV Base
1. Remove screws
2. Remove Base, hold TV in place.
TV Amp
Center Mount TV Amp
1. Remove TV per procedures.
2. Remove screws.
3. Lower and disconnect.
Left Mount TV Amp
1. Remove TV per procedures.
2. Remove screws.
3. Lower and disconnect.
TV Antenna
1. Remove headliner per procedure.
2. Remove tape.
3. Disconnect cables.
68
CD remote
1. Remove front overhead console per procedure.
2. Disconnect FM Modulator.
3. Remove remote from velcro and guide remote through opening.
FM Modulator
1. Remove headliner per procedures.
2. Remove screws.
Noise Choke
1. Remove headliner per procedures.
2. Remove screws.
Fuse Block
1. Lift bottom of left rear seat cushion.
2. Remove screws.
VCP
1. Remove rear storage box per procedures.
2. Remove screw from the VCP mounting brackets and slide VCP out from the back of the rear box.
Rear Tire Carrier
1. Remove wheel insert.
2. Remove spare tire.
3. Release latch, and open.
4. Remove screw in top of support rod.
5. Slide tire carrier up and off support rod.
Torque Specifications
1. Wheel ------------------------------------------------------- 85 FT LB
69
Table of Contents
Electrical Schematics
1.
2.
3.
4.
5.
Ram Van LWB SE--------------------------------------------------------------- 71
Ram Van LWB LE/LX----------------------------------------------------------- 74
Caravan/Voyager Sport Top -------------------------------------------------- 75
Pickup------------------------------------------------------------------------------- 76
Jeep --------------------------------------------------------------------------------- 77
70
CHASIS MANUFACTURER:
VEHICLE TYPE:
FORD, GM, DODGE
FULL SIZE VAN
COMPLETED VEHICLE DESCRIPTION:
MODEL YEAR:
1997
CKT. #
1
2
3
4
5
6
CIRCUIT ITEMS
ELECTRONIC FUSE BLOCK
TV/VCP TAP
INDIRECT LIGHT
UNITEC LIGHT
SWITCH PANEL
STEPWELL LIGHT
UNIVERSAL SE BASE HARNESS
GUAGE
18
18
18
18
18
TEW
TEW
TEW
TEW
TEW
W IRE COLOR
PURPLE
BROWN
ORANGE, WHITE
WHITE, BROWN, ORANGE
WHITE
POWER
ACTUAL
SOURCE
AMPS
BATTERY/IGNITION
IGNITION
IGNITION (SWITCH PANEL)
IGNITION (SWITCH PANEL)/DOOR PIN
IGNITION
DOOR PIN
-0.24 AMP
2.6 AMP
0.0 AMP
0.26 AMP
TOTAL
13.5 AMP
SE BASE HARNESS
HARNESS PART #: 15522010
71
FUSE SIZE
7.5 AMP
10 AMP
10/10 AMP
10/10 AMP
10 AMP
CHASIS MANUFACTURER:
VEHICLE TYPE:
FORD, GM, DODGE
FULL SIZE VAN
COMPLETED VEHICLE DESCRIPTION:
MODEL YEAR:
1997
CKT. #
19
20
21
CIRCUIT ITEMS
GAME READY
TELEVISION
VCP
GUAGE
18 TEW
18 TEW
18 TEW
W IRE COLOR
PURPLE, BLACK
PURPLE, BLACK
PURPLE, BLACK
POWER
ACTUAL
SOURCE
AMPS
IGNITION
IGNITION
IGNITION
.4 AMP
2.95 AMP
1.0 AMP
TOTAL
4.35 AMP
SE TV/VCP OPTION
HARNESS PART #: 15522035
72
FUSE SIZE
7.5 AMP
CHASIS MANUFACTURER:
VEHICLE TYPE:
FORD, GM, DODGE
FULL SIZE VAN
MODEL YEAR:
COMPLETED VEHICLE DESCRIPTION:
1997
CKT. #
1
2
3
CIRCUIT ITEMS
SOFA OPT. H-UP
SOFA MOTOR
SOFA SWITCH
SE LOW/HIGH TOP
GUAGE
12 TEW
12,18 TEW
18 TEW
W IR E C O L O R
RED/WHITE
RED/WHITE,BLUE,BLACK
BLUE, BLACK
POWER
ACTUAL
SOURCE
AMPS
AUTO-NET 110
BATTERY
ELEC SOFA CONTROLLER
-12.5 AMP
0
TOTAL
12.5 AMP
SE POWER SOFA OPTION
HARNESS PART #: 15522015
73
FUSE SIZE
20 AMP
CHASIS MANUFACTURER:
VEHICLE TYPE:
FORD, GM, DODGE
FULL SIZE VAN
MODEL YEAR:
COMPLETED VEHICLE DESCRIPTION:
1997
CKT. #
UNIVERSAL LE/LX BASE HARNESS
CIRCUIT ITEMS
GUAGE
W IRE COLOR
POWER
ACTUAL
SOURCE
AMPS
FUSE SIZE
1
ELECTRONIC FUSE BLOCK
BATTERY/IGNITION
--
2
FLASHLIGHT
18 TEW
ORANGE
IGNITION
0.17 AMP
3
REAR RADIO TAP
18 TEW
ORANGE, RED
IGNITION/BATTERY
--
15/10 AMP
4
TV/VCP TAP
18 TEW
PURPLE
IGNITION
--
7.5 AMP
5
CELLULAR PHONE
18 TEW
RED
BATTERY
0.76 AMP
10 AMP
6
THERMOTRONIX
18 TEW
ORANGE
IGNITION
5.1 AMP
15 AMP
7
CD PLAYER
18 TEW
ORANGE, RED
IGNITION/BATTERY
3 AMP
8
SPEAKER CONTROL
18 TEW
PINK
IGNITION
--
15 AMP
15/10 AMP
9
SILL LIGHT
18 TEW
BROWN
IGNITION (SWITCH PANEL)
0.24 AMP
7.5 AMP
10
SOFA
12 TEW
RED/WHITE, BLUE
BATTERY
12.5 AMP
20 AMP
11
CENTER UNITEC LIGHT
18 TEW
GREEN, WHITE
IGNITION (SWITCH PANEL), DOOR PIN
2.6 AMP
7.5/7.5 AMP
12
UNITEC LIGHT
18 TEW
ORANGE, WHITE
IGNITION (SWITCH PANEL), DOOR PIN
2.6 AMP
15/7.5 AMP
13
SWITCH PANEL
18 TEW
ORN/WHT, WHT/PUR, BLUE, PINK
IGNITION
0.14 AMP
14
SOFA SWITCH
18 TEW
BLUE
SOFA MOTOR SIGNAL
--
15
VISOR LIGHT
18 TEW
ORANGE
IGNITION
0.33 AMP
15 AMP
16
STEPWELL LIGHT
18 TEW
WHITE
DOOR PIN
0.26 AMP
7.5 AMP
17
12 VOLT OUTLET
16 TEW
RED
BATTERY
8.1 AMP
10 AMP
18
12 VOLT OUTLET
16 TEW
RED
BATTERY
7.1 AMP
10 AMP
1 AMP
TOTAL
51.66 AMP
LE/LX BASE HARNESS
HARNESS PART # 15522005
74
CHASIS MANUFACTURER:
VEHICLE TYPE:
DODGE
CARAVAN/VOYAGER
MODEL YEAR:
COMPLETED VEHICLE DESCRIPTION:
1997
CKT. #
CIRCUIT ITEMS
M INI VAN
GUAGE
1
2
IGNITION SICNAL
CONSOLE SWITCH
18 TEW
18 TEW
3
4
5
CD PLAYER
BATTERY HOOK-UP
FUSES
REAR RADIO
18
12
18
18
6
7
TV/VCP
HEADPHONE STATION
8
9
10
11
12
13
14
15
INDIRECT LIGHT
TV XTERNAL SPEAKER
UNITEC LIGHT
COURTESY HOOK-UP
GAME READY
NOISE CHOKE
HARNESS GROUND
RADIO/HEADPHONE GROUND
TEW
TEW
TEW
TEW
18 TEW
18 TEW
18
18
18
18
18
18
14
18
TEW
TEW
TEW
TEW
TEW
TEW
TEW
TEW
W IRE COLOR
YELLOW
BRN,ORN,GRN,ORN/GRN,
PUR,YEL/RED,BLACK
ORANGE, RED
RED
RED, ORANGE
RED, ORANGE, BLK/WHT
GRAY/RED, BLUE/YELLOW
PURPLE
GRY/RED, BLU/YEL,
YEL/RED, YEL/BLK, PINK
BROWN, BLACK
ORN/GRN, YEL/BLACK
GREEN, WHITE, BLACK
WHITE
PURPLE, BLACK
ORANGE, BLACK
BLACK
BLACK/WHITE, PINK
POWER
ACTUAL
SOURCE
AMPS
IGNITION
IGNITION
.104 AMP
IGNITION & BATTERY
BATTERY
IGNITION & BATTERY
IGNITION & BATTERY
2 AMP
1.7 AMP
IGNITION (SWITCHED)
REAR RADIO
3.2 AMP
-
IGNITION (SWITCHED)
TV (SWITCHED) SERIES
IGNITION (SWITCHED), CTSY
DOOR PIN
IGNITION (SWITCHED)
IGNITION (SWITCHED)
CHASIS GROUND
CHASIS GROUND
.75 AMP
1.5 AMP
.4 AMP
SEE CKT.6&12
-
TOTAL
14.9 AMP
BASE HARNESS
HARNESS PART #: 15522125
75
FUSE SIZE
7.5 BAT/15 IGN
CHASIS MANUFACTURER:
VEHICLE TYPE:
FORD, GM, DODGE
PICK-UP
MODEL YEAR:
COMPLETED VEHICLE DESCRIPTION:
1997
CKT. #
CIRCUIT ITEMS
GUAGE
W IRE COLOR
POWER
SOURCE
ACTUAL
AMPS
FUSE SIZE
1
POWER TAP/FUES BLOCK
18, 14 TEW
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
SUN ROOF CONNECTION
LOWER CONSOLE POWR
REAR SLIDER TAP
AIR DAM SWITCH POWER
BRUSH GUARD SWITCH
REAR SLIDER SWITCH
CB HOOK-UP
CONSOLE SWITCH OPT.
CELLULAR PHONE
CB HOOK-UP (OPT.)
CELLULAR PHONE
THERMOTRONIX
FLASHLIGHT
TELEVISION
VCP
GAME READY
REAR WINDOW SLIDER
14 TEW
18, 14 TEW
14 TEW
14 TEW
14 TEW
14 TEW
18 TEW
14 TEW
18 TEW
14 TEW
18 TEW
18 TEW
18 TEW
18 TEW
18 TEW
18 TEW
14 TEW
ORANGE, ORANGE/WHITE,
RED/BLACK, BLACK
ORANGE/WHITE, BLACK
RED/BLACK, ORANGE, BLK
RED, YELLOW
ORANGE, BLACK
ORANGE, BLACK
RED, YELLOW, ORN, BLK
ORANGE, BLACK
ORANGE, BLACK
RED/BLACK, BLACK
ORANGE, BLACK
RED/BLACK, BLACK
ORANGE, BLACK
ORANGE, BLACK
ORANGE, BLACK
ORANGE, BLACK
ORANGE, BLACK
RED, YELLOW
IGNITION & BATTERY
--
7.5, 30, 20 AMP
IGNITION
IGNITION & BATTERY
IGNITION
IGNITION
IGNITION
IGNITION
IGNITION
IGNITION
BATTERY
IGNITION
BATTERY
IGNITION
IGNITION
IGNITION
IGNITION
IGNITION
SWITCHED IGNITION
---8.6 AMP
8.6 AMP
-1.9 AMP
---.4 AMP
5 AMP
.3 AMP
2 AMP
1 AMP
1 AMP
7 AMP
TOTAL
FINAL STAGE MANUFACTUREER:
HARNESS PART #'s: 15521500, 15521520, 15521521, 15521524
76
77
Key #
Item
Color
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Power up
Overhead Switch
CD Remote
Off Road Light Switch
Headphone Station
Power Sunroof Switch
TV
Sunroof, Power
Game Ready Switch
Map Lights
CD Player
Air Compressor
VCP
12 V Outlet
Speaker, TV
Factory Antenna
Fog Lights
Amplifier
Fuse Holder
RED
ORG/WHT, BLK, ORN/GRN, YELL/RED, VIO/WHT
MANF SUPPLIED
WHT/BLK, WHT, BLK
YELL/BLK, YELL/RED
ORN, ORN/BLK, BLK, ORN
YELL/BLK, BLK/WHT, VIO, YELL/RED
ORN, ORN/BLK, BLK, ORN
BLK, VIO
PINK, YELL, GRAY
ORN/BLK, RED/BLK, BLK/WHT
BLK, WHT/RED
BLK/WHT, VIO
RED, BLK
BLU/YELL, BLK/YELL
COXIAL
BLK, WHT/BLK
YELL/BLK, BLU/YELL, BLK, VIO, ORN/GRN
RED/BLK, WHT/RED, RED, ORN/WHT, ORN/BLK, ORN
2
GPS
PNK/WHT, WHT/ORN, BRN, BLK/WHT, RED/BLK, ORN/BLK
Noise Filter
VIO/WHT, BLK/WHT
78
79
CHASIS MANUFACTURER:
VEHICLE TYPE:
FORD, GM, DODGE
FULL SIZE VAN
MODEL YEAR:
COMPLETED VEHICLE DESCRIPTION:
1997
CKT. #
35
36
37
CIRCUIT ITEMS
CONNECT TO 15522035
TV SPEAKER SWITCH
HEADPHONE STATION
GUAGE
18 TEW
18 TEW
18 TEW
W IRE COLOR
YEL/RED, YEL/BLK
YEL/RED, BLU/YEL
YEL/RED, YEL/BLK
POWER
ACTUAL
SOURCE
AMPS
TV
TV
TV
-
FUSE SIZE
TOTAL
FINAL STAGE MANUFACTUREER: MARK III
HARNESS PART #: 15522215
80
-
Table of Contents
Electrical Trouble Shooting Guide
INTELLITEC Smart Fuse Block IPX (LX) --------------------------------------- 82
INTELLITEC Smart Fuse Block Plus (LE) -------------------------------------- 89
INTELLITEC Sofa Control module Model 200 --------------------------------- 96
ESI Auto-Net 440 Load Manager-------------------------------------------------- 99
ESI Auto-Net 230 DUAL SOFA CONTROLLER ------------------------------ 102
81
Trouble Shooting Guide
Electrical
Smart Fuse Block IPX (LX)
Note: The Smart Fuse Block IPX is a centralized power switching, fusing, and distribution center. Power from both the ignition and battery is fed into the block. The power of
the battery is available at this box. Inadvertent shorts at this box could result in damage
and/or injury.
Only a qualified Service Technician should do all servicing of this box.
Tools Required
Low current Test Light
Accurate Voltmeter (digital read-out preferred).
Product Description:
The Smart Fuse Block Plus is intended to be used in conversion vehicles. It provides
fusing for the converter-added loads as well as relay controlled outputs for use with
lighting and TV circuits. These relay outputs include timed and low voltage shut down
features that are used to provide a number of customer pleasing features.
Following are the important customer pleasing features included in this system:
Automatic Interior Light Delay
Keeps the interior lights on for up to 12 seconds after closing the doors. They will go
out immediately when the ignition is switched on. If the doors are left open, the lights
will go out in twenty minutes.
82
Automatic OFF with the Ignition:
The interior lights and TV/VCP turn off when the ignition switch is turned off.
Load Operation Without Keys
Allows the interior lights and TV/VCP to operate without the insecurity of having the key
in the ignition.
Automatic Timed OFF Function
When the loads are operated with the ignition off, they will be automatically shut off 20
minutes after they are turned on with a charged battery. If the battery is low, the loads
will turn off in 2 minutes. After the shut down, the loads can be turned on again for an
additional 20-minute period.
Automatic Low Voltage
Shut Down
When the loads are operated, with ignition off, the battery voltage is monitored. If it
goes below 12 volts, the loads will be shut off in 2 minutes, minimizing the risk of the
loads fully discharging the battery.
Installation
This module is designed to work in all brands of vehicles. The module is mounted at
the “B” pillar and gets its power from the OEM harness. Two wires are connected to the
OEM dome light wires to make the interior light delay operate. The van harness is
plugged into the module. Power for the entire converter - added loads is supplied from
this module.
How it Works
The Smart Fuse Block IPX provides fusing and switching for all the converter-added
loads. There are ten fuses on this block. Two of these fuses provide constant “hot” outputs that are to be utilized for loads such as power sofa, door locks, etc. Two others
provide ignition switched power for loads that should only be operated when the ignition is on, such as rear fan, radar detector etc. Five other fuses feed relay switched
outputs, These are Lights 1, Lights 2, Lights 3, TV, and Courtesy Lights. The last fuse
to used to feed the back lighting on the switch panels.
Switched Outputs
Four of the switched outputs are controlled from a remote switch panel or panels if
more than one is used. The switches are a momentary style operating as push on/ pull
off function. These outputs can be used if the ignition is on or off. If they are on when
the ignition is turned off, they will automatically be turned off. If they are used with the
ignition off, they will go off automatically twenty minutes after they were turned on, to
prevent them from accidentally discharging the battery. If the battery voltage is low
(below 12.1 volts), the lights will be turned off in two minutes instead of the normal
twenty minutes. This signals the user that the battery is going dead and should be
charged before further use.
83
The Switched Outputs are each switched by relays in the Block. Four of these circuits
are operated by the push button switches and turned off when the ignition goes off and
by a twenty-minute timer. An opening of a door or ignition resets this timer.
The ignition holds the timer in reset, so these outputs will stay on all the time the ignition is on. These outputs will all be shut off when the ignition is turned off. If they are
turned on after the ignition is turned off, they remain on for twenty minutes.
The timer has two speeds, which are dependent on the incoming battery voltage. If the
battery is higher than 12.1 volts, the clock runs at its normal speed. If the battery drops
below 12.1 volts, the clock speeds up approximately 10 times so the timer will shut off
in about 2 minutes instead of the normal 20 minutes.
Lights as well as the Courtesy Lights Output, are also controlled by the door pin
switches to provide the courtesy light feature. They will come on when a door is opened
and stay on for twelve seconds after all the doors are closed. If any door is left open,
the lights will automatically turn OFF in twenty minutes. To turn them ON again, ALL
doors must be closed in order to reset the Smart Fuse Block and then resume operation.
All the switch panels operate from a common three-wire cable. These wires are used
for back lighting, ground and switch signal. The Smart Fuse Block IPX switches loads
by utilizing Intellitec’s proprietary multiplexing system. This system is a time division
type which ten, repetitive “time slots” are used to control the various functions of the
system. This allows two way communications between the Block, other modules, and
switch panels. With this capability, each switch panel can have on/off indicators for the
various functions that operate from the three inter-connecting wires. When one of the
switches is pressed, a signal for that particular channel is transmitted on the multiplex
communication line. A control located either in the Block or other module of the system
responds by turning that function on and off and it in turn sends out a signal on the
same line to “tell” the associated indicators on the switch panels to illuminate.
Battery and Ignition Circuits
The Smart Fuse Block IPX does not control the Battery and Ignition circuits. Power to
these outputs is brought into the fuse block from the OEM wiring and is fused on the
block.
The Battery fuses are used for circuits that feed intermittent or uninterruptible loads,
such as power sofa and 12 volt outlet, which may be used to supply a 12-volt cooler.
The ignition fuses are used for circuits that feed loads that should operate only when
the ignition is turned on, such as the rear fan.
The Timer has two speeds, which are dependent on the incoming battery voltage. If the
battery is higher than 12.1 volts, the clock runs at its normal speed. If the battery drops
below 12.1 volts, the clock speeds up approximately 10 times so the timer will shut off
in about 2 minutes instead of the normal 20 minutes.
84
Courtesy Lights
When the doors are opened, Lights 1, Lights 2, and Courtesy Lights circuits are turned
on. This function is operated by a timer that keeps the lights on while the doors are
opened and for up to 12 seconds after they are closed. If the ignition is turned on during this 12 seconds, the Courtesy Lights go out immediately. The timer gets its signal
from the OEM dome light circuit. The dome light circuit is brought into the module via a
two-pin plug, J2. When the door is opened, a voltage appears between these two pins.
(The circuitry will accept either polarity of voltage at this plug.) When the Smart Fuse
Block IPX senses 12 volts, it turns on the Courtesy Light Function.
When the doors are all closed, the Courtesy Light timer begins to run, holding the
lights on for 12 seconds. If the ignition is turned on during this period, the lights will go
out immediately.
Fuses
The fuses are the standard, plastic “ATO”, blade (automotive) type.
There are 10 positions for the fuses in the module.
The 10 fuses and their sizes are as listed:
Circuit
Spare battery
Courtesy Light
Lights 1
Lights 2
Spare Battery
TV/VCP
Lights 3
Rear Fan
Spare Ignition
Panel Back Lt.
Fuse Number
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
Fuse Size
20 a
7.5 a
7.5 a
7.5 a
10 a
7.5 a
7.5 a
20 a
7.5 a
1a
Connector Pin-Out
J5-5
J5-4
J5-3
J5-2
J5-1
J4-4
J4-3
J4-1
J4-2
J7-1
Source
Battery
Battery
Battery
Battery
Battery
Battery
Battery
Ignition
Ignition
Switched Outputs & Ignition
Plugs - Pins and Functions
J1 - .250 Male Fastener - Power Ground (carries less than 2 amps)
J2 - 2 pin in-line Mate-N-Lok Mating Housing - AMP 1-480698-0
Pin
1
2
Function
From OEM Dome Light
From OEM Dome Light
J3 - .250 Male Fastener - Ignition Power Input
85
J4 - 4 pin in-line Mate-N-Lok Mating housing AMP 1-480702-0
Pin
1
2
3
4
Function
Rear Fan Power
Spare Ignition
Lights 3 output
TV/ VCP
Fuse
F8
F9
F7
F6
J5 - Pins in-line Mate-N-Lok Mating housing AMP 1-480763-0
Pin
1
2
3
4
5
Function
Spare Battery
Lights 2 Output
Lights 1 Output
Courtesy Lights Output
Spare Battery
Fuse
F5
F4
F3
F2
F1
J6 - .250 Male Fastener - Battery Input
J7 - 3 pin KK156 - Mating Housing Molex 09-50-8033
Pin
1
2
3
Function
Fuse
Panel Back Lighting
F10
Switch Signal
Switch Panel Ground
Switch Signal Channels:
The system uses ten separate channels to send signals between the modules and
switch panels. Each function of the system is assigned to a particular channel. They
are as follows:
Function
Channel
1
Lights 2
2
Lights 3
3
TV/ VCP
4
Lights 1
Trouble Shooting
Battery and Ignition Circuits:
The OEM battery and Ignition circuits are fused in the block. Power for these circuits
enter the Smart Fuse Block IPX is fused and fed to the connectors, without any control.
If the rear fan, 12-volt outlet, vacuum, or sofa fail to operate, check the fuses, F1 20
amp, F5 10 amp, F8 20 amp and F9 15 amp, using a test light. If any of these have
failed, replace them with the same sized fuse. If these are all good, check the OEM
power feeds coming into J6 and J3. Failure of these outputs would rarely be traced to
problems in the SMART FUSE BLOCK IPX.
86
Switched Outputs
The switched outputs should operate each time a button is pressed, whether the ignition is on or off. To check their operation, press a button while listening to the relays in
the Smart Fuse Block IPX to click. The Relays will operate even if the associated fuses
are opened. Power for these circuits comes from the OEM battery circuit. If the relays
do not operate, check for the presence of battery voltage at the module before going
further. Each of the four-switched circuits is fused individually. If there is a problem with
a particular circuit, check the fuse associated with that circuit.
Courtesy Lights
The courtesy light output should be on when the doors are opened. If the doors are left
opened for more than twenty minutes, they will go off. (If the ignition is on and the
doors are opened, the lights will never go off). To check this output, open the door and
turn the ignition on. Power for this circuit comes from the OEM battery circuit. Check
the Courtesy Light fuse and the presence of ignition and battery voltages before going
further.
Trouble Shooting
Problem
Lights or TV do not
come on.
Lights and TV do not
go off when ignition is
turned off.
Courtesy Lights won’t
come on when doors
are open.
Courtesy Lights won’t
go off when doors are
closed.
Courtesy Lights do not
stay on for 12 seconds
Panel back lighting not
working.
Possible Cause/ Solution
Fuses F3, F4, F6 or F7 7.5 amp open. Check and replace fuse
Listen for relays clicking in module when buttons are pressed. Clicking relays indicate module is working.
Faulty OEM battery feed. Check for power coming from the OEM battery
feed at J6
Check signal line for switch voltage on J7-2. Should be 12 volts and should
drop when button is pressed. If not, check wiring and switch panel. Short
signal line, J7-2, to ground, Lights 1 should switch.
If the above fail to fix the problem, replace module.
Check ignition input at J3. Should be 12 volts with ignition on and 0 volts
with ignition off.
Courtesy Light fuse, F2, open, Replace fuse.
Door pin switches not working. Check for 12 volts between pins of J2 when
doors are open.
Check Courtesy Defeat Switch on dash (GM only).
Door pin switch stuck or shorted. Unplug J2, lights should go off in 12 seconds.
Check courtesy light switch on head light switch.
If the above fail to fix the problem, replace module.
Check ignition feed. Should be 0 volts with ignition off. If not check input
wiring.
Check fuse F10. Replace if open.
If the above fail to fix the problem, replace module.
87
1
2
3
4
FUSES
The fuses used are standard, plastic "ATO", blade (automotive) type.
There are 10 positions for the fuses in the module.
Circuit
Spare Battery
Courtesy Lights
Lights 1
Lights 2
Spare Battery
TV/VCP
Lights 3
Spare Ignition (Rear Fan)
Spare Ignition
Panel Back Lighting
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
Fuse
Size
20 Amp
7.5 Amp
7.5 Amp
7.5 Amp
10 Amp
7.5 Amp
7.5 Amp
20 Amp
15 Amp
1 Amp
Connector
Pin-Out
Power
Source
J5 - 5
J5 - 4
J5 - 3
J5 - 2
J5 - 1
J4 - 4
J4 - 3
J4 - 1
J4 - 2
J7 - 1
Battery
Battery
Battery
Battery
Battery
Battery
Battery
Ignition
Ignition
Switched
Outputs &
Ignition
Pin
1
2
3
4
5
J7 - 3 pin KK156 - Mating housing Molex 09-50-8033
Pin
Function
1 Panel Back Lighting
2 Switch Signal
3 Switch Panels Ground
Wire Color
(YEL)
(BRN)
To turn a light or TV on or off, the voltage on the signal line is changed by
pressing one of the switches on a switch panel. Each function has a corresponding voltage associated with it. They are as follows:
J2 - 2 pin in-line Mate-N-Lok Mating Housing AMP 1-480698-0
Function
From OEM Dome Light
From OEM Dome Light
J3 - .250 Male Faston - Ignition Power input
J4 - 4 pin in-line Mate-N-Lock Mating housing AMP 1-480702-0
Function
Fuse
F10
SWITCH SIGNAL VOLTAGES
J1 - .250 Male Faston - Power Ground (SFB + electronics carry < 2 Amps)
Pin
Fuse
Function
Spare Battery
F5
Lights 2 Output
F4
Lights 1 Output
F3
Courtesy Lights Output
F2
Spare Battery
F1
J6 - .250 Male Faston - Battery Input
PLUGS - PINS & FUNCTIONS
Pin
1
2
F8
F9
F7
F6
J5 - 5 pin in-line Mate-N-Lock Mating housing AMP 1-480763-0
The 10 fuses and their sizes are as listed:
Fuse
Number
Rear Fan Power
Spare Ignition
Lights 3 Output
TV/VCP
Fuse
88
Function
Voltage
Lights 2
Lights 3
Rear Radio/TV/VCP
Lights 1
5.7 volts
3.5 volts
2.1 volts
1.1 volts
Smart Fuse Block Plus (LE)
Note
The Smart Fuse Block Plus is a centralized power switching, fusing, and distribution
center. Power from both the ignition and battery is fed into the block. The power of the
battery is available at this box. Inadvertent shorts at this box could result in damage
and/or injury.
Only a qualified Service Technician should do all servicing of this box.
Tools Required
Low current Test Light
Accurate Voltmeter (digital read-out preferred)
Product Description:
The Smart Fuse Block Plus is intended to be used in conversion vehicles. It provides
fusing for the converter-added loads as well as relay controlled outputs for use with
lighting and TV circuits. These relay outputs include timed and low voltage shut down
features that are used to provide a number of customer pleasing features.
Following are the important customer pleasing features included in this system:
Automatic Interior Light Delay
Keeps the interior lights on for up to 12 seconds after closing the doors. They will go
out immediately when the ignition is switched on. If the doors are left open, the lights
will go out in 20 minutes.
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Automatic OFF with the Ignition
The interior lights and TV/VCP turn off when the ignition switch is turned off.
Load Operation Without Keys
Allows the interior lights and TV/VCP to operate without the insecurity of having the
key in the ignition.
Automatic Timed OFF Function
When the loads are operated with the ignition off, they will be automatically shut off 20
minutes after they are turned on with a charged battery. If the battery is low, the loads
will turn off in 2 minutes. After the shut down, the loads can be turned on again for an
additional 20-minute period.
Automatic Low Voltage
Shut Down
When the loads are operated, with ignition off, the battery voltage is monitored. If it
goes below 12 volts, the loads will be shut off in 2 minutes, minimizing the risk of the
loads fully discharging the battery.
Installation
This module is designed to work in all brands of vehicles. The module is mounted at
the “B” pillar and gets its power from the OEM harness. Two wires are connected to the
OEM dome light wires to make the interior light delay operate. The van harness is
plugged into the module. Power for the entire converter - added loads is supplied from
this module.
Operation
When a door is opened, power is turned on to the Courtesy Lights, and Lights 1 and 2
outputs. When the doors are closed, these outputs remains on for 12 seconds or until
the ignition is turned on.
How it Works
The Smart Fuse Block Plus provides fusing and switching for all the converter-added
loads. There are ten fuses on this block. Two of these fuses provide a constant “hot”
outputs that are to be utilized for loads such as power sofa, door locks, etc. 2 others
provide ignition switched power for loads that should only be operated when the ignition is on, such as rear fan, radar detector etc. 5 other fuses feed relay switched outputs, These are: Lights 1, Lights 2, Lights 3, TV, and Courtesy Lights. The last fuse to
used to feed the back lighting on the switch panels.
The Lights 1, Lights 2, Lights 3, and TV circuits are switched from a remote switch
panel or panels if more than one is used. These outputs can be used if the ignition is
on or off. If they are on when the ignition is turned off, they will automatically be turned
off. If they are used with the ignition off, they will go off automatically 20 minutes after
they were turned on, to prevent them from deeply discharging the battery. If the battery
voltage is low (below 12.1 volts), the lights will be turned off in 2 minutes instead of the
normal 20 minutes. This signals the user that the battery is going dead and should be
charged before further use.
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The door pin switches control the Courtesy Light output. This output will be on, when
the doors are opened and for 12 seconds after they are closed. This output is intended
to be used to feed lights such as step well lights that can only be turned on by the
doors being opened or the headlight switch mounted courtesy light switch. Light circuits
1 and 2 also are controlled by the door pin switches and these lights will also be on
when the courtesy lights are on. If the doors are left open, the lights will automatically
go out in twenty minutes. To turn them on again, all the doors must be closed and reopened.
All the switch panels operate from a common, three-wire cable. These wires are used
for back lighting, ground, and signal. The Smart Fuse Block Plus switches loads by
monitoring the voltage on the signal wire. A resistor in the Block is used to pull the signal line high. The switch panels have various values of resistors associated with each
function. When one of the switches is pressed, the voltage on the signal wire is
dropped to a level that corresponds to that function. Circuitry in the Block senses the
voltage and switches that function on or off.
Battery and Ignition Circuits
The Battery and Ignition circuits are not controlled by the Smart Fuse Block Plus.
Power to these outputs is brought into the fuse block from the OEM wiring and is fused
on the block in a normal fashion.
The Battery fuses are used for circuits that feed intermittent or uninterruptible loads,
such as power sofa and 12 volt outlet, which may be used to supply a 12-volt cooler.
The ignition fuses are used for circuits that feed loads that should operate only when
the ignition is turned on, such as the rear fan.
Switched Outputs
The four Switched Outputs are each switched by a relay in the block. Each of these circuits is operated by the push button switches and turned off when the ignition goes off
and by a 20-minute timer. An opening of a door or ignition resets this timer. The ignition
holds the timer in reset, so these outputs will stay on all the time the ignition is on.
These outputs will all be shut off when the ignition is turned off. If they are turned on
after the ignition is turned off, they remain on for 20 minutes.
The timer has 2 speeds, which are dependent on the incoming battery voltage. If the
battery is higher than 12.1 volts, the clock runs at its normal speed. If the battery drops
below 12.1 volts, the clock speeds up approximately 10 times so the timer will shut off
in about 2 minutes instead of the normal 20 minutes.
Courtesy Lights
When the doors are opened, Courtesy Lights, Lights 1, and Lights 2 circuits are turned
on. This function is operated by a timer that keeps the lights on while the doors are
opened and for up to 12 seconds after they are closed. If the ignition is turned on during this 12 seconds, the Courtesy Lights go out immediately.
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The timer receives it’s impute from the OEM dome light circuit. The dome light circuit is
brought into the module via a two-pin plug, J2. When the door is opened, 12 volts appear between these two pins. (The circuitry will accept either polarity of voltage at this
plug.) When the Smart Fuse Block senses 12 volts Plus, it turns on the Courtesy Light
Function. When the doors are all closed, the Courtesy Light timer begins to run, holding the lights on for 12 seconds. If the ignition is turned on, the lights will go out immediately.
If the doors are left open, the courtesy lights will go off in 20 minutes. To get the courtesy Lights output to come on again, after this happens, the timer will have to be reset.
Closing all the doors can do this and re-opening one or the ignition can be turned on.
Fuses
The fuses are the standard, plastic “ATO”, blade (automotive) type.
There are 10 positions for the fuses in the module. These are fed directly from the battery, through the ignition, Switched Outputs, the Courtesy Light relay, and for panel
back lighting.
The 10 fuses and their sizes are as listed:
Circuit
Power Sofa
Courtesy Light
Lights 1
Lights 2
Spare Battery
TV/VCP
Lights 3
Rear Fan
Spare Ignition
Panel Back Lt.
Fuse Number
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
Fuse Size
20 a
7.5 a
7.5 a
7.5 a
10 a
7.5 a
7.5 a
20 a
7.5 a
1a
Connector Pin-Out
J5-4
J5-4
J5-2
J5-1
J5-1
J4-4
J4-3
J4-1
J4-2
J7-1
Source
Battery
Ignition
Battery
Battery
Battery
Battery
Battery
Ignition
Ignition
Switched Outputs & Ignition
Plugs - Pins and Functions
J1 - .250 Male Fastener - Power Ground (carries less than 2 amps)
J2 - 2 pin in-line Mate-N-Lok Mating Housing - AMP 1-480698-0
Pin
1
2
Function
From OEM Dome Light
From OEM Dome Light
J3 - .250 Male Fastener - Ignition Power Input
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J4 - 4 pin in-line Mate-N-Lok Mating housing AMP 1-480702-0
Pin
1
2
3
4
Function
Rear Fan Power
Spare Ignition
Lights 3 output
TV/ VCP
Fuse
F8
F9
F7
F6
J5 - Pins in-line Mate-N-Lok Mating housing AMP 1-480763-0
Pin
1
2
3
4
5
Function
Fuse
F5
F4
F3
F2
F1
Spare Battery
Lights 2 Output
Lights 1 Output
Courtesy Lights Output
Spare Battery
J6 - .250 Male Fastener - Battery Input
J7 - 3 pin KK156 - Mating Housing Molex 09-50-8033
Pin
1
2
3
Function
Panel Back Lighting
Switch Signal
Switch Panel Ground
Fuse
F10
Switch Signal Voltages
To turn a light or TV on and off, the voltage on the signal line is changed by pressing
one of the switches on a switch panel. Each function has a corresponding voltage associated with it. They are as follows:
Function
Lights 2
Lights 3
TV/ VCP
Lights 1
Voltage
5.7 Volts
3.5 Volts
2.1 Volts
1.1 Volts
Trouble Shooting
Battery and Ignition Circuits
The OEM battery and Ignition circuits are fused in the block. Power for these circuits
comes into the BLOCK and is fused and fed to the connectors, without any control. If
the rear fan, 12-volt outlet, vacuum, or sofa fail to operate, check the fuses, F1 20 amp,
F5 7.5 amp, F8 20 amp and F9 15 amp, using a test light. If any of these have failed,
replace them with the same size fuse. If these are all good, check the OEM power
feeds coming into J6 and J3. Failure of these outputs would rarely be traced to problems in the BLOCK.
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Switched Outputs
The switched outputs should operate each time a button is pressed, whether the ignition is on or off. To check their operation, press a button while listening to the relays in
the Smart Fuse Block Plus. The Relays will operate even if the associated fuses are
opened. Power for these circuits comes from the OEM battery circuit. If the relays do
not operate, check for the presence of battery voltage at the module before going further. Each of the four-switched circuits is fused individually. If there is a problem with a
particular circuit, check the fuse associated with that circuit.
Courtesy Lights
The courtesy lights output should be on when the doors are opened. If the doors are
left opened for more than 20 minutes, they will go off. (If the ignition is on and the doors
are opened, the lights will never go off). To check this output, open the door and turn
the ignition on. Power for this circuit comes from the OEM battery and Ignition circuits.
Check the Courtesy Light fuse and the presence of these voltages before going further.
Trouble Shooting
Problem
Lights or TV do not
come on.
Lights and TV do not
go off when ignition is
turned off.
Courtesy Lights won’t
come on when doors
are open.
Courtesy Lights won’t
go off when doors are
closed.
Courtesy Lights do not
stay on for 12 seconds
Panel back lighting not
working.
Possible
Cause/ Solution
Fuses F3, F4, F6 or F7 7.5 amp open. Check and replace fuse
Listen for relays clicking in module when buttons are pressed. Clicking relays indicate module is working.
Faulty OEM battery feed. Check for power coming from the OEM battery
feed at J6
Check signal line for switch voltage on J7-2. Should be 12 volts and should
drop when button is pressed. If not, check wiring and switch panel.
Short signal line, J7-2, to ground, Lights 1 should switch.
Replace Module.
Check ignition input at J3. Should be 12 volts with ignition on and 0 volts
with ignition off.
Courtesy Light fuse, F2, open, Replace fuse.
Door pin switches not working. Check for 12 volts between pins of J2 when
doors are open.
Check Courtesy Defeat Switch on dash (GM only).
Door pin switch stuck or shorted. Unplug J2, lights should go off in 12 seconds.
Check courtesy light switch on head light switch.
Replace module.
Check ignition feed. Should be 0 volts with ignition off. If not check wiring.
Check fuse F10. Replace if open.
Replace Module.
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FUSES
J4 - 4 pin in-line Mate-N-Lock Mating housing AMP 1-480702-0
The fuses used are standard, plastic "ATO", blade (automotive) type.
Pin
1
2
3
4
There are 10 positions for the fuses in the module.
The 10 fuses and their sizes are as listed:
Circuit
Fuse
Number
Spare Battery
Courtesy Lights
Lights 1
Lights 2
Spare Battery
TV/VCP
Lights 3
Spare Ignition (Rear Fan)
Spare Ignition
Panel Back Lighting
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
Fuse
Size
20 Amp
7.5 Amp
7.5 Amp
7.5 Amp
10 Amp
7.5 Amp
7.5 Amp
20 Amp
15 Amp
1 Amp
Connector
Pin-Out
Power
Source
J5 - 5
J5 - 4
J5 - 3
J5 - 2
J5 - 1
J4 - 4
J4 - 3
J4 - 1
J4 - 2
J7 - 1
Battery
Battery
Battery
Battery
Battery
Battery
Battery
Ignition
Ignition
Switched
Outputs &
Ignition
Fuse
F8
F9
F7
F6
J5 - 5 pin in-line Mate-N-Lock Mating housing AMP 1-480763-0
Pin
1
2
3
4
5
Fuse
Function
Spare Battery
F5
Lights 2 Output
F4
Lights 1 Output
F3
Courtesy Lights Output
F2
Spare Battery
F1
J6 - .250 Male Faston - Battery Input
J7 - 3 pin KK156 - Mating housing Molex 09-50-8033
Pin
Function
1 Panel Back Lighting
2 Switch Signal
3 Switch Panels Ground
PLUGS - PINS & FUNCTIONS
Fuse
F10
Wire Color
(YEL)
(BRN)
SWITCH SIGNAL VOLTAGES
J1 - .250 Male Faston - Power Ground (SFB + electronics carry < 2 Amps)
To turn a light or TV on or off, the voltage on the signal line is changed by
pressing one of the switches on a switch panel. Each function has a corresponding voltage associated with it. They are as follows:
J2 - 2 pin in-line Mate-N-Lok Mating Housing AMP 1-480698-0
Pin
1
2
Function
Rear Fan Power
Spare Ignition
Lights 3 Output
TV/VCP
Function
From OEM Dome Light
From OEM Dome Light
J3 - .250 Male Faston - Ignition Power input
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Function
Voltage
Lights 2
Lights 3
Rear Radio/TV/VCP
Lights 1
5.7 volts
3.5 volts
2.1 volts
1.1 volts
Sofa Control Module Model 200
Note: The MONOPLEX sofa control is a centralized power switching controller used to
operate a four way, slide-recline power sofa. Power from the battery of the vehicle is
fed to this control. Inadvertent shorts at this box could result in damage and/or injury.
Only a qualified Service Technician should do all servicing of this box.
Tools Required
Low current test light
DC Voltmeter
Product Description
The MONOPLEX Sofa Controller is intended to be used in conversion vehicles to control the operation of a two-way or four-way, slide recline power sofa. It allows easy wiring of multiple switches and provides electronic shutdown at the end of travel to prevent
annoying circuit breaker or fuse openings.
By utilizing the MONOPLEX System, only one light-gauge wire and ground are needed
to connect the multiple switches. The control is located near the sofa so the four motor
wires can easily be connected to it. A single 12-gauge wire feeds power to the control
from the fuse block.
To operate the sofa, the three position, momentary rocker is pressed and held in the direction of the function desired (slide or recline). If the direction is wrong, the switch is
released and pressed again. After the sofa has reached its desired position, the switch
is released. If it is held until the sofa reaches it’s mechanical stops, the control will
automatically shut off the power. This feature helps prevent damage to the sofa if it is
operated under a load such as someone sitting on it.
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How it Works
The MONOPLEX Sofa Control utilizes relay switching to control the power to the two
sofa motors. To limit the amount of current of current drawn, only one motor is allowed
to operate at any given time. When the unit is at rest, all the motor leads are connected
to ground. To operate a sofa motor, 12 volts are applied to the desired motor by the
controller.
To prevent damaging the motors or opening of the fuse or circuit breaker, the controller
senses the current drawn by the motors. If it exceeds a preset level, the controller shuts
off. To restart the motor, release the switch and press it again. This will reverse the direction.
The controller operates by sensing the voltage on the MONOPLEX bus wire. When the
MONOPLEX bus is at 12 volts, the motors are at rest. When the bus is at 6 volts, the
controller drives the recline motor. When the bus is at 0 volts, the controller drives the
slide motor. (Note: This voltage must be read with a voltmeter. A test light will offer too
much load for this circuit). If more than one switch at a time is pressed, the sofa will operate in the Slide mode.
Setting the Stop Adjustment
The STOP ADJUST is used to set the level of current, above which the motor will be
shut off. The proper adjustment of this control is at a level that is sufficient for proper
operation of the sofa, but so high as to overload the fuse or circuit breaker.
Start the setting procedure with the control set in the approximate center of rotation.
Operate the sofa, both slide and recline (lifting the back from it’s open position usually
requires the maximum current.), through the full range. If the sofa stops prematurely,
slightly increase (turn the control clockwise) the setting and test again. If it is hitting the
stops too hard, decrease (turn the control counter clockwise) the setting.
Trouble Shooting
The controller contains three relays to drive the two motors in both directions. A simple
test to see if the controller is operating can be done by disconnecting the sofa motors,
pressing a switch, and listening to the relays. At each press of the switch, at least one
relay should click.
Problem
Sofa doesn’t
move in one or either direction
Sofa doesn’t
move to mechanical stop.
Possible Cause/Solution
Sofa jammed. Check for mechanical obstructions. Clear path.
Power not coming from fuse block. Check for 12 volts on pin J1. Replace fuse
Ground connection missing.
Faulty switch wiring. Momentarily ground J7, relays should close, sofa should
slide. If not, check for power at J2, J3, J4, and J5. One terminal has 12 volts.
If not, replace control
Motor wires disconnected or broken. Check and repair wiring.
Stop current miss-adjusted. re-adjust Stop control to higher level. (Warning:
raising this setting too high may cause opening of the circuit protection).
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Pins and Function
Pin
J1
J2
J3
J4
J5
J6
J7
Function
+12 volt power impute
Slide motor common
Recline Motor Common
Recline Motor +
Slide Motor +
Ground
MPX bus
98
ESI AUTO-NET 440 LOAD MANAGER
Operation
Your Mark III Conversion Vehicle may be equipped with an Auto-Net 440 Load
manager. The Auto-Net 440 distributes the battery voltage to the power front seats and
rear sofa. The purpose of the Auto-Net 440 is to limit the use of the power seats and
rear sofa to one operation at a time. By limiting the usage, there will be a reduction in
current drawn from the battery.
Driver Seat - The driver can always adjust his/her seat, even if the passenger seat or
sofa is being operated. If the passenger seat or rear sofa is in operation, these seats
will stop functioning if the driver begins to operate his/her seat.
Passenger seat - The passenger can adjust his/her seat if neither the driver seat not
the rear sofa is being operated. The passenger seat will stop functioning when the
driver begins to operate
Rear Sofa - The rear sofa can be adjusted if neither the driver seat nor the passenger
seat is being operated. The rear sofa will stop functioning when the driver begins to
operate his/her seat while the rear sofa is in operation.
Installation
The Auto-Net 440 is equipped with 0.250” male spade terminals for easy connection to
the wire harness. No adjustments need to be made to the Auto-Net 440 once it is
properly installed. The Auto-Net 440 is protected against reverse wiring. The following
describes the connections to the Auto-Net 440:
Battery - The fused input to power the seats, usually from the fuse block. It is not
recommended to connect this to any power source that is not fuse protected.
Load A - The power output to be connected to the driver seat.
Load B - The power output to be connected to the passenger seat.
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Load C - The power output to be connected to the rear sofa controller.
Ground - The ground for the Auto-Net 440 ONLY. This terminal is not designed as
ground for the motors of the power seats. A wire with a ring terminal is included and
can be used as the ground for the Auto-Net 440. If the spade terminal is used instead
of the wire/ring terminal, the wire/ring should be cut and discarded.
SERVICE
Tools Required: VoltMeter, Two (2) #1156 lamps connected in parallel.
Problem: None of the seats are functional.
Troubleshooting: Measure for voltage between Auto-Net 440 “Ground” and “Battery”.
If no voltage is present check fuse at fuse block or bad wiring. Verify Auto-Net 440 is
properly grounded.
If 11.0 - 14.5 volts is present, disconnect wires from LOAD A, LOAD B, and LOAD C on
the Auto-Net 440. Measure for voltage between ground and each LOAD pin. If 11.0 14.5 volts is present, reconnect one wire at a time and measure voltage. If all three
LOAD pins still have 11.0 - 14.5 volts after all wires are connected, troubleshoot wiring
and motors of seats. If the voltage is not present after the wires are reconnected, check
for a short or current draw on one of the LOAD pins.
If the LOAD wires are disconnected, there is 11.0 - 14.5 volts measured between
GROUND and BATTERY of the Auto-Net 440, and no output voltage on the LOAD
pins, replace the Auto-Net 440.
Note
Even though the Auto-Net 440 shuts off power to the passenger seat and sofa, there
should always be an output voltage from LOAD A.
Problem: Passenger Seat or Sofa stop working when the driver seat is on.
Troubleshooting: This is the normal operation of the Auto-Net 440.
Problem: Not all seats are functional.
Troubleshooting: Without any seat operating, measure for presence of 11.0 - 14.5
volts on each LOAD pin. If voltage is present, activate power seat or sofa. Verify
voltage is still present for that particular LOAD pin. Check motor, switch, or wiring for
seat.
If no voltage is present on one LOAD pin, disconnect LOAD wires. Measure for voltage
between ground and each LOAD pin. If 11.0 - 14.5 volts is present, reconnect one wire
at a time and measure voltage. If all three LOAD pins still have 11.0 - 14.5 volts after all
wires are connected, troubleshoot wiring and motors of seats. If the voltage is not
present after the wires are reconnected, check for a short or current draw on one of the
LOAD pins.
If the LOAD wires are disconnected, there is 11.0 - 14.5 volts measured between
GROUND and BATTERY of the Auto-Net 440, and no output voltage on the LOAD
pins, replace the Auto-Net 440.
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ADVANCED TROUBLESHOOTING
The AUTO-NET 440 requires a minimum current draw of 2 Amps on the LOAD pins in
order for it to switch off the other circuits. To verify the Auto-Net 440 is functioning
correctly, two #1156 lamps can be parallel to simulate the required current draw.
The following conditions will occur when the lamp is connected between vehicle ground
and each LOAD pin:
LOAD connected to LOAD A - lamp will not light no voltage present on LOAD B or LOAD
C.
LOAD connected to LOAD B - lamp will not light, no voltage present on LOAD C, voltage
will still be present on LOAD A.
LOAD connected to LOAD C - lamp will not light, no voltage present on LOAD B, voltage
will still be present on LOAD A.
Note
IF ANY OF THESE OPERATIONS DO NOT FUNCTION, REPLACE THE MODULE.
101
ESI Auto-Net 230 Dual Sofa Controller
Your Mark III Conversion vehicle may be equipped with a power slide and recline sofa.
An Auto-Net 230 interprets the overhead and rear switches and moves the sofa in the
proper direction. The Auto-Net 230 performs the recline up and down along with the
slide forward and back. Only one motion can occur at a given time. The Auto-Net 230
provides four directions of travel from a two-direction switch.
Overhead Switch
When the sofa needs to recline up or down, depress the left sofa button and hold it. If
the sofa is traveling in the wrong direction, release the switch. Once again depress the
switch and hold it. The sofa should be traveling the opposite direction. Release the
switch once the sofa is in the desired position. An automatic shut-off will stop the motor
at the end of travel.
When the sofa needs to slide forward or back, depress the right sofa button and hold it.
If the sofa is traveling in the wrong direction, release the switch. Once again depress
the switch and hold it. The sofa should be traveling the opposite direction. Release the
switch once the sofa is in the desired position. An automatic shut-off will stop the motor
at the end of travel.
Rear switch panel
When the sofa needs to recline up or down, depress the top of the switch marked “U/D”
and hold it. If the sofa is traveling in the wrong direction, release the switch. Once
again depress the switch and hold it. The sofa should be traveling the opposite
direction. Release the switch once the sofa is in the desired position. An automatic
shut-off will stop the motor at the end of travel.
When the sofa needs to slide forward or back, depress the bottom of the switch marked
“F/B” and hold it. If the sofa is traveling in the wrong direction, release the switch. Once
again depress the switch and hold it. The sofa should be traveling the opposite
direction. Release the switch once the sofa is in the desired position. An automatic
shut-off will stop the motor at the end of travel.
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Installation
The Auto-Net 230 utilizes two (2) AMP Mate-n-Lok connectors for connection to the
sofa power, and switches.
The three- (3) pin connector has the following usage:
Pin 1 - Vehicle ground (supplies groundside for motor)
Pin 2 - Switch output
Pin 3 - Fused battery input
The four- (4) pin connector has the following usage:
Pin 1 - Motor BPin 2 - Motor APin 3 - Motor A+
Pin 4 - Motor B+
A fused battery input capable of sourceing 30 Amps is connected to the battery Input of
the Auto-Net 230. A vehicle ground capable of carrying 30 Amps must also be
connected to the Auto-Net 230.
A modified rocker switch or push-button switch is required to operate the Auto-Net 230.
The rocker switch must have a 470ohm resistor connected to the outer terminals. The
switch input of the Auto-Net 230 is connected to the center terminal of the switch.
Ground is connected to the lower terminal of the switch. The upper terminal of the
switch is not connected to any wires.
The motors are connected directly to the four-pin connector of the Auto-Net 230. The
Auto-Net 230 supplies the proper voltages to the motors for the required direction of
travel. The motors should not be grounded or directly connected to any other source for
power other than the Auto-Net 230.
The Auto-Net 230 has a current adjust to cut-off the power to the motors during a stall.
The Auto-Net 230 comes factory shipped with the setting at midpoint which, is
equivalent to 20-22 Amps. Some adjustment may be necessary based upon any drag
the sofa possess from installation and other unknown conditions. To test the proper
level, send the sofa in one direction until it stalls. The power should disconnect after 2 3 seconds. If it does not, the level needs to be lowered. If the motor stalls before
reaching the end of travel, the level needs to be increased.
103
Service
Tools required: Voltmeter
Problem: All directions of sofa are non-functional.
Troubleshooting: Measure for 11.0 - 14.5 volts between pin 1 and 3 of the three-pin
connector. If no voltage is measured, check fuses at fuse block or check for bad wiring.
If voltage is present, measure voltage at pin 2 of three-pin connector. The voltage
should be approximately 12 volts with no switch closure. When the switch is closed, the
voltage should drop to 3 - 6 volts in one direction of the switch and 0.5 to 3 volts in the
other direction. If voltage doesn’t drop when the switch is closed, check switch and
switch wiring.
If the relays are heard clicking on when the switch is closed, check motors or bad
wiring to motors. If necessary replace, Auto-Net 230.
Problem: Motor stops before end of travel.
Troubleshooting: Adjust the setting of the current level to accommodate surges or
frame binding. It is not recommended to exceed the 75% limit of the adjustment. If this
is necessary, it is advisable to check motors and frame for drag.
104
Graphics Trouble Shooting Guide
1.
2.
3.
4.
5.
6.
7.
8.
9.
General Requirements --------------------------------------------------------- 106
Tools--------------------------------------------------------------------------------- 106
Solvents ---------------------------------------------------------------------------- 106
Application Temperature ------------------------------------------------------- 106
Surface Preparation ------------------------------------------------------------- 106
Application Procedure Key Points ------------------------------------------- 107
Maintenance Cleaning Materials--------------------------------------------- 107
Cleaning Procedure ------------------------------------------------------------- 108
Graphics Removal --------------------------------------------------------------- 108
105
Trouble Shooting Guide
Graphics
General Information
General Requirements
* IMPORTANT:
The following information should be carefully reviewed before proceeding:
•
•
•
•
•
Tools
•
•
•
•
Plastic Applicator, PA-1 (Blue or Gold)*
Masking Tape
Felt Block Applicator**
Low Friction Sleeve, SA-1*
(For certain applications, such as unpremashed screen-printed Graphics, use a low
friction sleeve on the plastic applicator to minimize the possibility of surface
scratching).
Pin or air release tool*
Razor blades
Industrial heat gun
Detergent and water solution (1% or 1/2 teaspoon per quart of water)
•
•
•
DuPont’s Prep-Sol Brand Solvent Cleaner
Isopropyl Alcohol
VMP Naphtha
Solvents
* Available from 3M
** Available from local craft store
Application Temperature
The graphics tape can be applied when air and application surface temperatures are
between 65 degrees and 90 degrees. Surfaces may be heated in order to raise the
surface temperature. Portable heater, heat lamps, or hot water may accomplish this.
Surface Preparation
All surfaces must be considered contaminated and must be cleaned prior to application
of film or fabricated parts. On repainted vehicles, paint must be thoroughly dry before
any attempt to apply decals to the vehicle is made. 48 hours after painting is recommended.
The recommended procedure is as follows:
1. Wash the surface with detergent and water before solvent wiping.
2. Dampen a clean cloth with Isopropyl alcohol or DuPont Prep-Sol Brand Solvent
Cleaner #3919S and wipe the substrate surface.
3. Dry the surface with lint-free cloth before the solvent evaporates.
106
Application Procedure
Key Points
1. Make sure the surface temperatures are between the minimum and maximum
specified.
2. Air surface temperatures should be between the minimum and maximum specified.
3. Position the stripe to the vehicle. Use one of the following methods:
• For large pieces or stripes position and hold the graphics on the vehicle. Apply
masking tape to position and hold the graphics on the vehicle. Apply a masking tape
hinge to the piece to further stabilize it to the vehicle.
• If the graphics tape is small, freely position and apply the part after liner removal.
4. Remove the liner. The liner is best removed by flicking a corner of the film away
from the liner. Remove the liner at 180 degrees from the marking.
5. For large graphics or long stripes, a wet application method is usually suggested.
After the liner has been removed, liberally spray the adhesive side of the part with
the suggested detergent and water solution. Apply the part to the vehicle as usual,
but be sure to squeegee out all liquid from beneath the graphics.
6. Using a 4-inch plastic squeegee, pressurize the graphics to the vehicle. Use vertical, firm, overlapping strokes. Hold the end of the graphics off the vehicle with light
tension to prevent it from pre-adhering and foaming air bubbles.
7. Remove the application tape from the graphics at a 180-degree angle to the graphic
design. Use a slow constant speed, taking care to avoid pulling against the graphic
areas containing points or sharp corners.
8. Repressurize the entire surface of the tape stripe with the squeegee to obtain
maximum adhesion to the painted area and to remove all air bubbles and wrinkles.
9. Inspect application for bubbles and/or areas not completely pressurized. Remove
bubbles as follows:
10. Use a straight pin or air release tool, puncture the bubble at its edge.
11. Use finger or squeegee to force air out through the hole made in the film.
* Note
All SCOTCHAL High Performance Protective 8598/8599 Film
12. This film is applied exactly like the SCOTCHAL decorative films except the film
should always be applied wet using a 50/50 mixture of isopropyl alcohol and water.
Maintenance
Cleaning Materials
A wet, non-abrasive cleaner of the type suitable for high quality painted surfaces is
recommended for use on graphics fabricated with SCOTCHAL. The cleaner chosen
must be:
1. Non - abrasive
2. Neither highly acidic or highly alkaline.
3. Free of strong aromatic solvents or alcohol.
107
Cleaning Procedure
1. Wash the marking with a soft brush, rag, or sponge using a detergent, which satisfies the above requirements such as Dreft, Vel or Surf. Wash thoroughly from the
top down. Avoid abrading the surface by unnecessary scrubbing. Once suds have
been applied, keep a steady stream of water flowing on the surface to wash away
any dirt particles.
2. Rinse the entire surface with clean water. Allow to drain dry.
3. If tar, oil diesel smut, or bituminous material remains after completing step 1 and 2
above, wipe with a rag dampened with kerosene, mineral sprits, heptane, or VM&P
Naphta*. Do not use other solvents. Wash with detergents and water, then rinse
with clean water.
4. To remove pollen and fungus, wash the surface with a 3 - 5% sodium hypchlorite
(Hilex, Clorex, etc.)* Solution or detergent and water. Rinse with clean water.
5. To remove crayon, lipstick, etc. select an appropriate solvent (such as kerosene,
mineral spirits, heptane, or VM&P Naphtha.)* Which testing shows to be efficient in
removing the contaminant.
Graphics Removal
The following are recommended removal methods for SCOTCHAL graphic films.
Method A
In order to remove SCOTCHAL graphic markings with a minimum of damage to the
substrate, the following methods are recommended:
1. Use Wood grain and Stripe Remover, * Part Number 08909, available from 3M.
2. Use a Brand Natural Cleanser* for any remaining adhesive residue. Follow the directions on the can.
Method B
The following method makes use of heat as a method of removal.
1. Heat one corner of the graphics film with a heat gun, heat lamp, or hot water. Insert
a razor or knife-edge under the corner to loosen the graphics film from the surface.
Pull film back slowly at less than 90 degree angle while continuing to apply heat to
the film just ahead of the area which is being removed. Slow pulling action is required where paint to metal bond may be weak.
2. If adhesive residues remains after removal of film, such adhesive may be removed
by using 3M Brand Natural Cleaner* and then scraping with the PA-1 Plastic Applicator.
* * See the appropriate MSDS sheets for proper handling and disposal methods.
Method C
Scotch-Brite Molding Adhesive and Stripe Removal Discs are fast and easy to use. The
unique construction of the discs assures long life and allows easy conformability to
contours. Because the discs are flexible and have no sharp edges, they will not damage underlying paint. Not recommended for use on acrylic lacquer paints.
The discs are faster and cleaner than solvent or chemical adhesive removers and are
non-combustible as well.
108
Table of Contents
Custom Wheels and Tires Trouble Shooting Guide
1.
2.
3.
Load Ratings of Wheels-------------------------------------------------------- 110
Balancing Wheels --------------------------------------------------------------- 110
Wheel Installation ---------------------------------------------------------------- 110
109
Troubling Shooting Guide Custom Wheels and Tires
* Warning
Vehicles equipped with aluminum wheels need to be maintained to proper lug torque.
Upon initial installation, lug nuts must be torqued. After the first 50 miles, lug nuts must
be retorqued per the torque specification chart. This procedure must be repeated
whenever the wheel is removed from the vehicle.
Load Ratings of Wheels
Wheel load ratings are based on the vehicle weight that each wheel is capable of
safely carrying.
Because of the cargo carrying design of pickups and utility vehicles, they are subject to
greater loads on the rear wheels than passenger cars. Caution must be taken to insure
that the total rear axle load (cargo + vehicle) does not exceed the load rating of the
wheels. Caution must also be taken to insure that the maximum tire diameter is not exceeded.
* Warning
Do not exceed the maximum tire diameter as stated on the load-rating label.
* Warning
Do not exceed 40 PSI when seating the tire to the bead of the rim.
Balancing Wheels
It is highly recommended that all four wheel and tire assemblies be balanced dynamically from the bolt holes to reduce tire wear, road noise and vibration. If a static (bubble) balance is used this should also be from the boltholes.
Wheels with steel rims accept conventional clip-on weights.
Aluminum rims accept clip-on weights for aluminum wheels, the use of adhesive
weights is not recommended.
All wheels are checked for LATERAL and RADIAL run out before leaving the factory to
minimize balancing problems. If difficulty in balancing is encountered, check for improper installation, balancing or tire truness. A suggested remedy to some balancing problems is to deflate the tire, rotate approximately 180 degrees on the rim, reinflate and re-balance.
Wheel Installation
* Warning
Check the lug nut thread engagement. The engagement must be at least equal to the
diameter of the thread; less thread engagement is unsafe and can cause loss of torque.
110
* Warning
Do not allow the lug nut to bottom out on the stud shoulder or on the mounting surface,
this is an extremely dangerous and unsafe condition, as the torque of the lug nut is not
actually being applied to the wheel.
1. Lug nuts should be tightened in a criss-cross (star) pattern to insure uniform pressure and alignment.
2. The use of impact wrenches is not recommended due to the possibility of irregular
tightening, thread stripping or inaccurate torque. Additionally, their use can mar the
finish of some wheels. A thin wall socket and torque wrench must be used for proper
installation.
3. Tighten all lug nuts to the vehicles owners manual recommendation or use the following torque specifications:
Custom Wheels
Custom wheels with the lug nuts covered by a cap use the same lug nut as OEM wheels.
Custom wheels with the lug nuts exposed use a special lug nut.
* Warning!
Lug nut torque for custom wheels must be checked at the 50 miles and after lug nuts are
removed for any reason.
The proper lug nut torque is as follows:
•
•
•
Torque Specifications
Standard single wheel axle is 85 ft. Lb.
Optional dual wheel axle with stainless steel wheel covers is 105 ft. Lb.
Optional dual wheel axle with Alcoa aluminum wheels is 140 ft. Lb. These wheels utilize
a decorative plastic lug nut covers. To remove the 1 1/16” lug nut, remove the plastic
decorative covers first.
*
Warning!
Failure to properly torque lug nuts at the prescribed intervals could result in the lug nuts
loosening and coming off, wheel loss, damage to the vehicle and serious personal injury or
death.
111
Table of Contents
Rear Air Auxiliary Unit Trouble Shooting Guide
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Dodge “B” Van Information ---------------------------------------------------- 113
Dodge “B” Van Factory Connection Points-------------------------------- 114
Dodge “B” Van Heat Concerns----------------------------------------------- 117
Dodge “B” Van Cooling Concerns ------------------------------------------- 120
Dodge “B” Van Electrical Concerns ----------------------------------------- 124
Dodge “B” Van Air Flow Concerns ------------------------------------------ 125
Dodge “B” Van Test Procedures--------------------------------------------- 126
Dodge “B” Wiring Diagram ---------------------------------------------------- 127
Dodge “B” Parts Descriptions------------------------------------------------- 128
Dodge “B” Replacement Procedures ------------------------------------- 130
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
Table of Contents
Pickup Rear Sliding Window Trouble Shooting Guide
1.
2.
3.
4.
5.
6.
7.
8.
9.
Micro Drive Trouble Shooting and Replacement -------------------------------------137
Micro Drive Retrofit Procedure for Power Drive --------------------------------------138
Old Drive System Removal and Replacement with Micro Drive ------------------138
Power Slider Upper Glass Track ---------------------------------------------------------139
Leak Detection and Repair ----------------------------------------------------------------139
Sealant Leaks Encapsulated Windows -------------------------------------------------140
Window and Seal Leaks, Mullion Replacement --------------------------------------140
Slider Window Motor and Cable Removal ---------------------------------------------140
Window Removal ----------------------------------------------------------------------------140
136
Trouble Shooting Guide
Rear Slider Window
With this troubleshooting guide a technician’s responsibility is to:
1. Determine if there is power to the motor so it operates both directions (check fuse
and switch if there is no power)
2. Check the upper and lower channels the glass slides in for obstructions, or pinching
the upper track (trim interference). The track is easily removed to check operation.
3. Replace a drive system and/or upper track to repair a malfunctioning window.
4. On Ford and Dakota pickup trucks, be able to identify whether the Powerslider is a
gasket or glue-in installation.
5. Utilize the leak repair procedure if needed.
We do not require your technicians to disassemble drives and replace individual components, as the complete drive is easily changes. 1992 - 1994 models require reattaching the cable to the glass with rear-view mirror adhesive (included with drive kit)
and 1995 - 1996 models feature a quick disconnect system allowing very easy replacement.
Micro Drive
Trouble Shooting / Replacement
*
Note
These procedures are for windows manufactured with the micro drive system,
Not for retrofitting an earlier drive system.
* Note
Before exchanging a drive unit make sure you have checked power supply connections
at the motor, switch, ground, and check 20-amp fuse.
* Note
If the window only operates in one direction, check the switch with a test light.
* Note
If the motor runs, but the glass does not move, check to see of the attachment clip is
bonded to the glass.
1. Open Window - Cable connector must be past split in drive tube. Remove from attachment clip. If there is binding assist by hand or remove motor to push open.
2. Remove screw from drive tube.
3. Slide drive tube section to expose attachment clip.
4. Release cable connector from attachment clip.
5. Pull cable-retaining clip from the drive tube. Insert a paper clip etc. In hole to prevent losing clip.
6. Slide cable out of drive tube.
7. Slide cable by hand to verify glass slides freely.
8. If glass slides freely, remove drive unit from truck and install new drive unit.
9. If glass is binding or difficult to move by hand, inspect upper and lower tracks for
interference. Replace upper track if necessary, and correct trim interference if
pushing on upper track.
10. Drive unit is installed in reverse order.
137
Micro Drive Retrofit Procedure
For Power Drive
*
Note
These procedures are for installing a micro drive replacement drive on a window
manufactured with the older drive. Before 9/94
* Note
To replace a drive unit, you need rear view mirror adhesive (Loctite No. 11067) and
alcohol to clean the bonding surfaces properly.
* Note
Before replacing - have you checked for power? Check connections at the motor,
switch, ground and check 20amp fuse.
* Note
Inspect upper track for interference from interior trim. If present, this must be corrected.
Old Drive System Removal/
Replacement with Micro Drive
*
Note
Before beginning inspect your replacement drive to make sure it has the threaded drive
tube fitting!
* Note
If the glass clip is already detached from the glass, that may be the problem. Reattach
and Test
The cable assembly must be detached from the window by removing the bonded glass
clip from the sliding glass panel.
1. Mark the position of the glass clip with a piece of tape. The position is important.
Mark on the outside of the glass.
2. Tap a razor between the glass and glass clip to release the clip. Be careful not to
scratch the glass.
3. Unscrew threaded drive tube fitting from the drive tube (where the cable meets window) and slide cable out.
4. Remove mounting screws and cable clamps. Then take the drive unit out of the vehicle.
5. Insert the glass clip into the slotted cable end of the new drive unit. Slide the cable
and clip into the drive tube. Clean the clip thoroughly with alcohol before installing.
6. Thread the fitting into the drive tube.
7. Slide the glass to the proper location to line up the clip correctly with the tape mark.
8. Clean the glass and clip with alcohol. Apply a thin coat of loctite primer and let dry.
(5 minutes or more in cold temperatures).
9. Apply a thin even coat of adhesive, and bond the clip to the glass. Hold for 30 seconds.
* Note
In cold weather it may help to warm the glass and clip with a heat gun.
10. After 30 minutes, check operation of window.
138
Powerslider Upper Glass Track
* Note
To determine if the upper track is defective, remove the track and run the window. If it
does not operate normally there is another problem.
* Note
This procedure does not require window removal
* Note
If you replace the upper track on an EPS880 Chevy/GMC, or EPS950 Ford glue in
Powerslider, make sure the interior trim does not push against the upper track. This will
collapse the track and can damage the drive unit. Install spacer blocks, loosen, or
modify the trim so it does not interfere.
1. With the glass in the open position, use pliers to pull the upper glass track out of the
window frame, slide the track out from over the top of the sliding glass.
2. Place the replacement track angled end into the window frame just in front of the
sliding glass. You will notice that the weather striping of the track is looped around
the square end cut of the track. Place your finger over the loop of the weather strip
while you slide the replacement track into the frame and over the top of the sliding
track.
3. Once the replacement track is in position, snap the track into the frame channel. Be
sure the track is flush to the vertical frame post and is snapped into the full depth of
the window channel. The glass track must be open for free movement of the sliding
glass, with no interference from the vehicle trim.
Leak Detection and Repair
General information
•
•
•
•
•
•
•
Leaks should be fixed without removing the window (except gasket installation
leaks).
Water and air leaks are handled the same.
You must determine the cause of the leak to make the proper repair.
Leak types:
1. Installation - sealant leaks/ poorly installed gasket
2. Window seals/ Baffles - miscut or missing seals, missing or poorly aligned baffles (water usually over flows inside the channel)
3. Truck body seams/cargo lights - poorly sealed roof seams, poorly installed cargo
lights (usually leaks from top corners or light)
Run water over the top of the window frame to test for sealant leaks (1 - 2 minutes).
If you cannot see a leak, apply soapy water around the window area and turn on the
A/C or fan on high and look for bubbles to form outside (normal around weep holes).
It is normal for some water to enter the bottom channel of a sliding window. They
are designed to drain water - out.
If water enters faster than it can drain there is likely a defective or missing seal on
the window.
139
Sealant Leaks Encapsulated Windows
You can seal the entire window by masking off the window frame and body, and applying a thin bead of sealant there. Smooth with a wet finger and remove tape for a clean
finish. (Recommend black silicone).
Leaking urethane sealant may have been applied incorrectly, or “blown out” by slamming doors when still wet.
Interior trim. May have to be pulled back or loosened to locate and repair leak.
Locate leak and fill hole from inside with urethane or silicone. Use a small tip and a
small screw driver or awl etc. To spread sealant around and push into hole.
Window and Seal Leaks
Mullion Replacement
1. Remove Exterior Weather-strip (top and bottom)
2. Use a block of wood - tap mullion off glass.
3. Line up glazing channel and press mullion on.
* Note
Frame/mullion joint - small gaps can be filled with black silicone or butyl.
Mullions are replaceable complete with seals (press fit).
• Inspect all corners to make sure weather stripping runs full length.
• Make sure weather strip is in contact with glass.
Exterior weather strip - top and bottom of window opening. If missing too much water
can enter channel.
Pickup
Power Slider Window
Slider window
Motor and cable removal:
1. Slide window to full open position
2. Unplug slider motor, (Located behind rear seat) remove motor mounting screws
(Philip head)
3. Remove cable mounting clips (2) attaching cable to wall
4. Remove “c” clip from passenger cable rail
5. Remove Philip head screw from driver side end of window rail, lift up on rail end and
remove (exposes window clip)
6. Remove cable from window clip
7. Remove cable from track by pulling.
Window removal:
1.
2.
3.
4.
Leave cable in track
Remove factory window shroud located inside vehicle
Remove up to 8 window retaining clips
Remove gasket by inserting a flat tool from the inside and push outward all along
the edges to remove
5. Grasp window from outside and remove
140
Table of Contents
Custom Security Systems Trouble Shooting Guide
1.
Trouble Shooting -----------------------------------------------------------------142
141
Trouble Shooting Guide For
Mark III Custom Security Systems
By Rostra
Voltmeter
Positive
Pin #1
Gray Wire
Pin #15
Negative
*
NOTE: Connect negative
lead to chassis ground
PIN #
FUNCTION
CORRECT VOLT/ OHM READING
1
Valet Switch
Position 1 - Very low (near zero) ohm reading - indicates continuity to ground
Position 2 - Infinite ohm reading - indicates open to
ground
2
Door Pin Switch
3
Automatic Door Lock
4
Accessory Power
7
8
Ground
Door Lock
9
Door Unlock
10
11
Constant 12 Volts
Horn
14
Parking Lights
* The valet switch should be in position 2 for normal
security operation.
Door closed - 12 volts
Door open - 0 volts
Brake pedal NOT depressed - 0 volts
Brake pedal depressed - 12 volts
Key off - 0 volts
Key on - 12 volts
At ALL times - near zero ohm reading
Use test jumper - connect to ground, touch pin, door
should lock
Use test jumper - connect to ground, touch pin, door
should unlock
At ALL times - 12 volts
Horn NOT depressed - infinite ohms reading
Horn depressed - very low (near zero) ohm reading
Parking lights off - 0 volts
Parking Lights on - 12 volts
142
Table of Contents
Running Boards
1.
Running Board Removal/Installation --------------------------------------------------- 144
143
Running Board
Removal/installation
Removal
Remove self-tapping screws that secure fender flare to body. Remove fender flare.
Remove self-tapping screws that secure running board to body.
Remove step treads PAL nuts.
Remove step tread and running board.
Remove excess tape from body and clean running board and fender flare surfaces with
alcohol.
Note: Do not remove the metal support brackets from the frame. This is a critical
alignment area. Only remove the running boards from the support brackets. This
will ensure replacement running boards are properly aligned to the body panels.
Installation
Remove excess tape from rocker panel and clean rocker panel mounting surface with
alcohol.
Peel off approximately 2-3” of tape red plastic backing at each end of the running board
and allow to hang over the side as shown.
144
Position running board on support bracket ensuring a tight fit to van body.
Install step tread ensuring the pegs fit correctly through holes in both running board
and supports bracket. Secure step thread with 3/16” PAL nuts.
Drill through holes in front running board section using self-tapping screws.
Ensure running board is mounted flush to rocker panel.
145
Drill through holes in rear running board section using self-tapping screws.
Ensure running board is mounted flush to rocker panel.
Check alignment of running board then peel away red plastic backing and attach running board to side of vehicle.
Position front and/or rear wheel flare on wheel well and attach by drilling through flare
with self-tapping screws.
Ensure fender flare is mounted flush to body panel.
146
1997/1998
Parts
Manual
Version 97/98.1.0.Chrysler 7/1/98
1
1997/1998 Chrysler
Parts Manual
Table of Contents
A/C Blower Assembly ------------------------------------------------------------------------ 127
A/C Blower Seal ------------------------------------------------------------------------------- 130
A/C Evaporator/ Heater Core -------------------------------------------------------------- 127
A/C Expansion Valve------------------------------------------------------------------------- 127
A/C Lines and Heater Hose ---------------------------------------------------------------- 131
A/C Lines --------------------------------------------------------------------------------------- 131
A/C O-ring Kit for A/C Line Fittings ------------------------------------------------------- 130
A/C Power Pack Assembly ----------------------------------------------------------------- 128
A/C Relay --------------------------------------------------------------------------------------- 129
A/C Resistor------------------------------------------------------------------------------------ 129
A/C Return Vent ------------------------------------------------------------------------------- 127
A/C Vent----------------------------------------------------------------------------------------- 7
A/C Water Valve------------------------------------------------------------------------------- 129
Air Compressor -------------------------------------------------------------------------------- 8
Auto Net 230, Dual Seat Controller ------------------------------------------------------- 10
Auto Net 440, Load Manager -------------------------------------------------------------- 11
Bed Rail, Pickup------------------------------------------------------------------------------- 123
Bumper Cover, Front------------------------------------------------------------------------- 123
CD Player Cartridge -------------------------------------------------------------------------- 16
CD Player FM Modulator -------------------------------------------------------------------- 18
CD Player Main Unit-------------------------------------------------------------------------- 15
CD Player Wired Remote ------------------------------------------------------------------- 17
CD Player Wireless Remote---------------------------------------------------------------- 16
Center Beam, Molded, LE, Full Size Van Without Rear Air ------------------------- 13
Center Beam, Molded, LX, Full Size Van ----------------------------------------------- 12
Center Beam, Molded, SE, Full Size Van Without Rear Air------------------------- 13
Center Beam, Wood, SWB Without Rear Air ------------------------------------------- 14
Clothes Hanger, Fold-Down ---------------------------------------------------------------- 40
Console Overhead, Pickup ----------------------------------------------------------------- 47
Console Overhead, Pickup ----------------------------------------------------------------- 48
Console, Floor, 4 X 2 Pickup --------------------------------------------------------------- 36
Console, Floor, TV/VCP, Full Size Vans ------------------------------------------------ 103
Console, Overhead, Molded, Full Size Van--------------------------------------------- 124
Cupholder, Fold Out-------------------------------------------------------------------------- 6
Cupholder, Folding --------------------------------------------------------------------------- 20
Cupholder, Thermotronics, B-Van -------------------------------------------------------- 19
DC Outlet --------------------------------------------------------------------------------------- 21
Door Panel, Front Door, B-Van ------------------------------------------------------------ 22
Door Panel, Front, B-Van ------------------------------------------------------------------- 23
Door Panel, Front, B-Van ------------------------------------------------------------------- 28
Door Panel, Front, B-Van ------------------------------------------------------------------- 29
Door Panel, Front, B-Van ------------------------------------------------------------------- 34
2
Door Panel, Rear Cargo, B-Van ----------------------------------------------------------- 25
Door Panel, Rear Cargo, B-Van ----------------------------------------------------------- 33
Door Panel, Side Cargo, B-Van ----------------------------------------------------------- 24
Door Panel, Side Cargo, B-Van ----------------------------------------------------------- 25
Door Panel, Side Cargo, B-Van ----------------------------------------------------------- 26
Door Panel, Side Cargo, B-Van ----------------------------------------------------------- 30
Door Panel, Side Cargo, B-Van ----------------------------------------------------------- 31
Door Panel, Side Cargo, B-Van ----------------------------------------------------------- 32
Face Plate, LE/LX Model, B-Van ---------------------------------------------------------- 38
Face Plate, SE Model, B-Van -------------------------------------------------------------- 38
Fire Extinguisher ------------------------------------------------------------------------------ 37
Fuse Block, Smart, IPX ---------------------------------------------------------------------- 57
Fuse Block, Smart, Plus --------------------------------------------------------------------- 58
Grab Handle------------------------------------------------------------------------------------ 40
Graphics, B-Van------------------------------------------------------------------------------- 118
Graphics, B-Van------------------------------------------------------------------------------- 119
Graphics, B-Van------------------------------------------------------------------------------- 120
Graphics, Voyager/ Caravan --------------------------------------------------------------- 121
Graphics, Voyager/ Caravan --------------------------------------------------------------- 122
Light, Map/reading, Double Lens---------------------------------------------------------- 41
Light, Map/Reading, Single Lens---------------------------------------------------------- 42
Portable Phone Antenna Kit ---------------------------------------------------------------- 45
Portable Phone Floor Adapter ------------------------------------------------------------- 46
Radio, Rear, Power Acoustic #PA 860--------------------------------------------------- 50
Rear Storage Compartment Door, B-Van ----------------------------------------------- 51
Running Board, Aluminum, B-Van -------------------------------------------------------- 49
Running Boards, B-Van --------------------------------------------------------------------- 118
Running Boards, Pickup--------------------------------------------------------------------- 123
Seat Belt Receiver/ Receptacle------------------------------------------------------------ 56
Seat Belt Retractor, B-Van------------------------------------------------------------------ 52
Seat Belt, Sofa Mid Position---------------------------------------------------------------- 53
Seat Pedestal Shroud, B-Van -------------------------------------------------------------- 44
Seat Pedestal Sliders – B-Van------------------------------------------------------------- 55
Seat Pedestal, Mid Position, B-Van ------------------------------------------------------ 43
Seat Pedestal, Power, B-Van -------------------------------------------------------------- 39
Seat Pedestal, Power, Lower Shroud, B-Van ------------------------------------------ 39
Seat Pedestal, Power, Upper Shroud, B-Van ------------------------------------------ 39
Seat, Front and Mid -------------------------------------------------------------------------- 54
Shade, Cargo Door --------------------------------------------------------------------------- 59
Shade, Vista Bay Window ------------------------------------------------------------------ 60
Shroud, Cargo door -------------------------------------------------------------------------- 61
Sofa Control Module, Model 200 ---------------------------------------------------------- 64
Sofa Motor, Single ---------------------------------------------------------------------------- 62
Sofa Motor, Triple ----------------------------------------------------------------------------- 63
Sofa, Front View, Full Size Van------------------------------------------------------------ 66
Sofa, Rear View, Full Size Van ------------------------------------------------------------ 65
Speaker Grill, 4” X 6”------------------------------------------------------------------------- 71
Speaker Grill, 5.25”, Blaupunkt ------------------------------------------------------------ 75
Speaker Grill, 6” X 9”------------------------------------------------------------------------- 72
Speaker Grill, 6”, SOFFARE---------------------------------------------------------------- 73
Speaker Grill, TV, 4”-------------------------------------------------------------------------- 74
3
Speaker Switch Module, IPX, With Mute ------------------------------------------------ 67
Speaker Switch Module, MPX ------------------------------------------------------------- 68
Speaker, 4” X 6”, OEM----------------------------------------------------------------------- 69
Speaker, 5.25”, Blaupunkt ------------------------------------------------------------------ 76
Speaker, Dual Cone, SOFFARE ---------------------------------------------------------- 77
Speaker, TV, 4”-------------------------------------------------------------------------------- 70
Speaker, Woofer, SOFFARE--------------------------------------------------------------- 78
Step Plate, Front Bumper ------------------------------------------------------------------- 118
Steptubes, Pickup----------------------------------------------------------------------------- 79
Switch Plate, (Mood/ Reading)------------------------------------------------------------ 95
Switch Plate, (Mood/ Reading/ Sofa) ---------------------------------------------------- 96
Switch Plate, (Mood/ Reading/ Sofa/ Speaker) --------------------------------------- 82
Switch Plate, (Mood/ Reading/ Speaker) ----------------------------------------------- 81
Switch Plate, (Mood/ TV/ Reading) ------------------------------------------------------ 83
Switch Plate, (Mood/ TV/ Reading/ Sofa/ Speaker) ---------------------------------- 86
Switch Plate, (Mood/ TV/ Reading/ Sofa/ Speaker) ---------------------------------- 87
Switch Plate, (Mood/ TV/ Reading/ Speaker)------------------------------------------ 85
Switch Plate, (Mood/ TV/ Reading/Sofa) ----------------------------------------------- 84
Switch Plate, (Mood/Reading/ TV Power/ TV Speaker) ---------------------------- 88
Switch Plate, Game Ready ---------------------------------------------------------------- 91
Switch Plate, Head Phone Jack (TV/Rear Radio) ------------------------------------ 80
Switch Plate, Head Phone Jack, Radio ------------------------------------------------- 89
Switch Plate, Head Phone Jack, TV ----------------------------------------------------- 90
Switch Plate, Mood Light and Sofa ------------------------------------------------------ 93
Switch Plate, Mood Light ------------------------------------------------------------------- 92
Switch Plate, Sofa 4 Way ------------------------------------------------------------------ 94
Switch, Mute, Speaker ----------------------------------------------------------------------- 35
Tire Carrier Disc ------------------------------------------------------------------------------- 118
Tire Carrier Trim Ring ------------------------------------------------------------------------ 118
Tire, Long Trail T/A --------------------------------------------------------------------------- 98
Tire, Radial T/A -------------------------------------------------------------------------------- 97
Tire, Trail T/A ---------------------------------------------------------------------------------- 99
Transmitter, Alarm ---------------------------------------------------------------------------- 9
TV Remote, Audiovox------------------------------------------------------------------------ 105
TV, Audiovox, 13” ----------------------------------------------------------------------------- 100
TV, Audiovox, 5”------------------------------------------------------------------------------- 101
TV, Audiovox, 9”------------------------------------------------------------------------------- 102
TV, Flexvision, Audiovox, #CTV-5060 --------------------------------------------------- 104
Valance, Low Top, Gloss, LX -------------------------------------------------------------- 110
Valance, Low Top, Satin Finish, SE ------------------------------------------------------ 114
Valance, Sport Top, Gloss, LE------------------------------------------------------------- 112
Valance, Sport Top, Gloss, LX------------------------------------------------------------- 113
Valance, Sport Top, Satin Finish, SE----------------------------------------------------- 111
VCP, Audiovox--------------------------------------------------------------------------------- 108
Visor---------------------------------------------------------------------------------------------- 109
Wall, Deluxe, Full Size Van----------------------------------------------------------------- 125
Wall, Deluxe, Top Plate, Full Size Van--------------------------------------------------- 125
Wall, Deluxe. Trim Ring --------------------------------------------------------------------- 35
Wheel, Alumitec, Pickup--------------------------------------------------------------------- 116
Wheel, Alumitec, Van ------------------------------------------------------------------------ 115
Wheel, Prime, Caravan/ Voyager --------------------------------------------------------- 117
4
Window Louver, Pickup---------------------------------------------------------------------- 123
Window Sill ------------------------------------------------------------------------------------- 126
Window, Rear Slider, Motor, Pickup ------------------------------------------------------ 123
Window, Rear Slider, Pickup --------------------------------------------------------------- 123
Window, Vista Bay---------------------------------------------------------------------------- 106
Window, Vista Bay, Handle----------------------------------------------------------------- 106
Window, Vista Bay, Screen----------------------------------------------------------------- 106
Window, Vista Bay, Vent Hole cover ----------------------------------------------------- 107
5
Model
-
Item No.
-
Part Description
Cupholder, flip out
FAWN
6
Part No.
14800160
Quantity
1
Model
All
Item No.
-
Part Description
A/C Vent
7
Part No.
1444210 CS
Quantity
4
Model
All
Item No.
-
Part Description
Air Compressor – 12V
8
Part No.
13400200
Quantity
1
Model
All
Item No.
-
Part Description
Alarm Transmitter
9
Part No.
13220385
Quantity
2
Model
Astro
Item No.
-
Part Description
Auto-Net 230 Dual Sofa Controller
10
Part No.
13260159
Quantity
1
Model
Astro
Item No.
-
Part Description
Auto-Net 440 Load Manager
11
Part No.
13260157
Quantity
1
Model
LX
Item No.
-
Part Description
Center Beam Molded, LX Model, Full
Size Van
12
Part No.
CS
Quantity
1
Model
SE
Item No.
-
LE
-
Part Description
Center beam molded, SE model
without rear air – satin finish
Center beam molded, LE model
without rear air – gloss finish
13
Part No.
CS
Quantity
1
CS
1
Model
Dodge
SWB
Item No.
-
Part Description
Center Beam Dodge SWB Sport Top
and Low Top Without Rear Air
14
Part No.
13761700
Quantity
1
Model
All
Item No.
-
Part Description
CD player Blaupunkt main unit #CDRF6ir
15
Part No.
13200450
Quantity
1
1
2
Model
All
All
Item No.
1
2
Part Description
CD Player Cartridge
CD Player Wireless Remote
16
Part No.
13200450-3
13200450-2
Quantity
1
1
Model
All
Item No.
-
Part Description
CD Player Wired Remote
17
Part No.
13200450
Quantity
1
Model
All
Item No.
-
Part Description
CD Player FM Modulator
18
Part No.
13200450-1
Quantity
1
Model
B-Van
Item No.
-
Part Description
Thermotronics Cupholder
19
Part No.
CS
Quantity
1
Model
All
Item No.
-
Part Description
Cupholder, folding
20
Part No.
14800120
Quantity
1
Model
-
Item No.
-
Part Description
DC Outlet
21
Part No.
14100131
Quantity
1
Model
B-Van
Item No.
-
Part Description
Dodge Door Panel
22
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Dodge Door Panel
23
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Dodge Door Panel
24
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Dodge Door Panel
25
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Dodge Door Panel
26
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Dodge Door Panel
27
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Dodge Door Panel
28
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Dodge Door Panel
29
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Dodge door panel
30
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Dodge Door Panel
31
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Dodge Door Panel
32
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Dodge Door Panel
33
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Dodge Door Panel
34
Part No.
CS
Quantity
1
2
1
Model
G-Van
Item No.
1
G-Van
1
Part Description
Trim Ring, Deluxe Wall
(Radio/CD Player)
Switch, Mute, Speaker
35
Part No.
13771433
Quantity
1
13260170
1
Model
Pickup
Item No.
-
Part Description
Floor Console
36
Part No.
13770166
Quantity
1
Model
All
Item No.
-
Part Description
Fire Extinguisher
37
Part No.
13400210
Quantity
1
1
2
6
7
5
3
4
Model
SE
SE
SE
SE
SE
SE
SE
Item No.
1
2
3
4
5
6
7
Part Description
Faceplate Right Side Satin Finish
Faceplate Left Side, Satin Finish
TV Piece Lower, Satin Finish
TV Piece, Right, Satin Finish
TV Piece, Left, Satin Finish
VCP Trim Ring, Satin Finish
Storage Compartment Door, Satin
Finish
Part No.
13761857
13761855
13761874
13761872
13761872
13761876
13761452
Quantity
1
1
1
1
1
1
1
Model
LE/LX
LE/LX
LE/LX
LE/LX
LE/LX
LE/LX
LE/LX
Item No.
1
2
3
4
5
6
7
Part Description
Faceplate Right Side Gloss Finish
Faceplate Left Side, Gloss Finish
TV Piece Lower, Gloss Finish
TV Piece, Right, Gloss Finish
TV Piece, Left, Gloss Finish
VCP Trim Ring, Gloss Finish
Storage Compartment Door, Gloss
Finish
Part No.
13761857
13761855
13761874
13761872
13761872
13771463
13771462
Quantity
1
1
1
1
1
1
1
38
1
2
Model
B-Van
B-Van
B-Van
Item No.
1
2
Part Description
Front Pedestal, Electric
Upper Shroud
Lower Shroud
39
Part No.
13300911-2
CS
CS
Quantity
2
2
2
1
2
Model
All
All
Item No.
1
2
Part Description
Grab Handle CS
Clothes hanger, fold down CS
40
Part No.
14450400-04
14301830-34
Quantity
1
2
Model
All
Item No.
-
Part Description
Map/reading Light, Double Lens CS
41
Part No.
14472205
Quantity
1
Model
All
Item No.
-
Part Description
Map/reading Light, Single Lens CS
42
Part No.
14472200
Quantity
1
Model
B-Van
Item No.
-
Part Description
Pedestal, Mid Position
43
Part No.
13300635
Quantity
1
Model
B-Van
Item No.
-
Part Description
Pedestal Shroud
44
Part No.
CS
Quantity
1
Model
All
Item No.
-
Part Description
Portable Phone Antenna kit
45
Part No.
13210510
Quantity
1
Model
All
Item No.
-
Part Description
Portable Phone Floor adapter
46
Part No.
13210510
Quantity
1
Model
Pickup
Item No.
-
Part Description
Pickup Overhead Console
47
Part No.
13770815
Quantity
1
Model
T-300
Pickup
Item No.
-
Part Description
T-300 Pickup Overhead Console
48
Part No.
CS
Quantity
1
Model
B-Van
B-Van
Item No.
-
Part Description
Running Board Aluminum - LWB
Running Board Aluminum - SWB
49
Part No.
14310470
14310500
Quantity
1
1
Model
All
Item No.
1
Part Description
Rear Radio – Power Acoustic
#PA860
50
Part No.
13200528
Quantity
1
Model
B-Van
Item No.
-
Part Description
Rear Storage Compartment Door
51
Part No.
13771460
Quantity
1
Model
B-Van
Item No.
-
Part Description
Seat Belt Retractor
52
Part No.
CS
Quantity
1
Model
All
Item No.
-
Part Description
Seat Belt Sofa Mid Position
53
Part No.
CS
Quantity
1
Model
All
Item No.
-
Part Description
Front and Mid Seat
54
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Seat Pedestal Sliders
55
Part No.
14580300
Quantity
1
Model
-
Item No.
-
Part Description
Seat Belt, Receiver/ Receptacle
56
Part No.
CS
Quantity
1
Model
All
Item No.
-
Part Description
Smart Fuse Block IPX
57
Part No.
13260500
Quantity
1
Model
All
Item No.
-
Part Description
Smart Fuse Block PLUS
58
Part No.
13260610
Quantity
1
Model
All
Item No.
-
Part Description
Cargo Door Shade
59
Part No.
CS
Quantity
1
Model
All
Item No.
-
Part Description
Shade, Vista Bay Window
60
Part No.
CS
Quantity
1
Model
All
Item No.
-
Part Description
Shroud, Cargo door
61
Part No.
CS
Quantity
1
Model
All
Item No.
-
Part Description
Sofa Motor, Single (Up/Down)
62
Part No.
64350002
Quantity
1
Model
All
Item No.
-
Part Description
Sofa Motor, Three
(Up/Down, Forward, Rearward)
63
Part No.
64350002
Quantity
1
Model
All
Item No.
-
Part Description
Sofa Control Module, Model 200
64
Part No.
13260145
Quantity
1
Model
All
Item No.
-
Part Description
Sofa, Full Size Van, Rear View
65
Part No.
CS
Quantity
1
Model
All
Item No.
-
Part Description
Sofa, Full Size Van, Front View
66
Part No.
CS
Quantity
1
Model
All
Item No.
-
Part Description
IPX Speaker Switch w/Mute
67
Part No.
13260504
Quantity
1
Model
All
Item No.
-
Part Description
MPX Speaker switch Module
68
Part No.
13260605
Quantity
1
Model
All
Item No.
-
Part Description
4” x 6” OEM Speaker
69
Part No.
13210070
Quantity
1
Model
All
Item No.
-
Part Description
4” TV Speaker
70
Part No.
13212385
Quantity
1
Model
All
Item No.
-
Part Description
Speaker grill, 4” X 6”
71
Part No.
13210007
Quantity
1
Model
All
Item No.
-
Part Description
6” X 9” Speaker Grill
72
Part No.
13212100
Quantity
1
Model
All
Item No.
-
Part Description
6” SOFARE Speaker Grill
73
Part No.
13210001
Quantity
1
Model
All
Item No.
-
Part Description
4” TV Speaker grill
74
Part No.
13212380
Quantity
1
Model
All
Item No.
-
Part Description
5.25” Speaker Grill (Blaupunkt)
75
Part No.
Not
Available
Quantity
1
Model
All
Item No.
-
Part Description
5.25” Speaker (Blaupunkt)
76
Part No.
13212710
Quantity
1
Model
All
Item No.
-
Part Description
SOFARE Dual Cone Speaker
77
Part No.
13210002
Quantity
1
Model
All
Item No.
-
Part Description
SOFFARE Woofer Speaker
78
Part No.
13210003
Quantity
1
Model
T-300
Pickup
T-300
Pickup
T-300
Pickup
Item No.
-
Part Description
Step Tube, Ext Cab 4X4,
Set
Step Tube, Std Cab 4X4,
Driver Side
Step Tube, Std Cab 4X4,
Passenger Side
79
Part No.
15130175
Quantity
1
15130150
1
15130151
1
Model
All
Item No.
-
Part Description
Switch Plate, Head Phone Jack,
TV and Rear Radio
80
Part No.
13210365
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Mood/ Reading/
Speaker – Mute/radio
81
Part No.
13260188
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Mood/ Reading/ Sofa/
Speaker – Mute/Radio
82
Part No.
13260191
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Mood/ TV/ Reading
83
Part No.
13260182
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Mood/ TV/ Reading/
Sofa
84
Part No.
13260196
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Mood/ TV/ Reading/
Speaker – TV/Radio
85
Part No.
13260192
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Mood/ TV/ Reading/
Sofa/ Speaker – Radio/ Mute/ TV
86
Part No.
13260180
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Mood/TV/ Reading/
Sofa/ Speaker – TV/Radio
87
Part No.
13260194
Quantity
-
Model
All
Item No.
-
Part Description
Switch Plate, Mood/ Reading/
TV Power/ TV Speaker
88
Part No.
13260240
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Head Phone Jack,
Radio
89
Part No.
13260201
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Head Phone Jack,
TV
90
Part No.
13260305
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Game Ready
91
Part No.
13210520
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Mood Light, Small
92
Part No.
13260165
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Mood Light and Sofa
93
Part No.
13260160
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Sofa, 4 Way
94
Part No.
13260158
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Mood/ Reading
95
Part No.
13260186
Quantity
1
Model
All
Item No.
-
Part Description
Switch Plate, Mood/ Reading/ Sofa
96
Part No.
13260184
Quantity
1
Model
All
Item No.
-
All
-
All
-
Part Description
BF Goodrich, Radial T/A
225/70R-15
BF Goodrich, Radial T/A
235/70R-15
BF Goodrich, Radial T/A
255/70R-15
97
Part No.
14500535
Quantity
1
14500500
1
14500505
1
Model
All
Item No.
-
Part Description
BF Goodrich, Long Trail TA
LT235/75R-15
98
Part No.
14500110
Quantity
1
Model
All
Item No.
-
Part Description
BF Goodrich, Trail TA
LT245/75R-16
99
Part No.
15220040
Quantity
1
Model
All
Item No.
-
Part Description
TV 13” Audiovox
100
Part No.
14390614
Quantity
1
Model
All
Item No.
-
Part Description
5” TV Audiovox
Part No.
14390620
Quantity
1
Model
All
Item No.
-
Part Description
9” TV Audiovox
Part No.
14390610
Quantity
1
Model
All
Item No.
-
Part Description
TV/VCP Floor Console,
Full Size Van
Part No.
13771910
Quantity
1
Model
All
Item No.
-
Part Description
Audiovox Flexvision #CTV-5060
Part No.
14390650
Quantity
1
Model
All
Item No.
-
Part Description
TV Remote Audiovox
Part No.
14395010
Quantity
1
Model
All
All
All
Item No.
-
Part Description
Vista Bay Window
Handle for Sliding Window
Window Screen
Part No.
CS
14359351
14359366
Quantity
1
1
1
Model
All
Item No.
-
Part Description
Vista Bay Window Vent Hole Cover
Part No.
14350830
Quantity
1
Model
All
Item No.
-
Part Description
VCP Audiovox
Part No.
14720010
Quantity
1
Model
B-Van
Item No.
-
Part Description
Visor, Full Size Van
Part No.
CS
Quantity
1
Model
B-Van
LX
B-Van
LX
B-Van
LX
Item No.
-
Part Description
Valance, Gloss Finish
Driver Front , Low Top
Valance, Gloss Finish
Driver Rear, Low Top
Valance, Gloss Finish
Passenger Rear, Low Top
Part No.
13772210
Quantity
1
13772211
1
13772212
1
Model
B-Van
SE
B-Van
SE
B-Van
SE
B-Van
SE
Item No.
-
Part Description
Valance, Satin Finish
Driver Front, High Top
Valance, Satin Finish
Driver Rear, High Top
Valance, Satin Finish
Passenger Rear, High Top
Storage Compartment Door Side
Satin Finish SE Model
111
Part No.
13762120
Quantity
1
13762122
1
13762124
1
13761450
1
Model
B-Van
LE
B-Van
LE
B-Van
LE
B-Van
LE
Item No.
-
Part Description
Valance, Gloss Finish
Driver Front, High Top
Valance, Gloss Finish
Driver Rear, High Top
Valance, Gloss Finish
Passenger Rear, High Top
Storage Compartment Door Side
Gloss Finish LE Model
112
Part No.
13772120
Quantity
1
13772122
1
13772124
1
13771461
1
Model
B-Van
LX
B-Van
LX
B-Van
LX
B-Van
LX
Item No.
-
Part Description
Valance, Gloss Finish
Driver Front, High Top
Valance, Gloss Finish
Driver Rear, High Top
Valance, Gloss Finish
Passenger rear, High Top
Storage Compartment door Side
Gloss Finish LX Model
113
Part No.
13772120
Quantity
1
13772122
1
13772124
1
13771461
1
Model
B-Van
SE
B-Van
SE
B-Van
SE
Item No.
-
Part Description
Valance, Satin Finish
Driver Front , Low Top
Valance, Satin Finish
Driver Rear, Low Top
Valance, Satin Finish
Passenger Rear, Low Top
114
Part No.
13762130
Quantity
1
13762132
1
13762134
1
Model
B-Van
Item No.
-
Part Description
Alumitec Wheel
115
Part No.
15210265
Quantity
1
Model
T-300
Pickup
T-300
Pickup
Item No.
-
Part Description
Alumitec Wheel Painted
Part No.
15210510
Quantity
1
-
Alumitec Wheel Polished
15210515
1
116
Model
Caravan/
Voyager
Item No.
-
Part Description
Prime Wheel
117
Part No.
15210605
Quantity
1
4
3
4
5
1
6
2
8
7
9
Model
B-Van
B-Van
B-Van
B-Van
B-Van
B-Van
B-Van
B-Van
B-Van
B-Van
Item No.
1
2
3
4
5
6
7
8
9
Part Description
Graphics
Running Board Passenger Side
Running Board Driver Side
Front Flair Driver side
Front Flair Passenger Side
Rear Flair Driver Side
Rear Flair Passenger Side
Tire Carrier, Trim Ring
Tire Carrier, Center Disc
Step Plate, Front Bumper
118
Part No.
CS
14711085
14711080
14711060
14711070
14711065
14711075
14430180
14430168
14490225
Quantity
1
1
1
1
1
1
1
1
1
1
Model
B-Van
Item No.
-
Part Description
Graphics, Van
119
Part No.
CS
Quantity
1
Model
B-Van
Item No.
-
Part Description
Graphics, Van
120
Part No.
CS
Quantity
1
Model
Voyager/
Caravan
Voyager/
Caravan
Voyager/
Caravan
Item No.
-
Part Description
Graphics, Van
Part No.
CS
Quantity
1
-
Running Board, Driver Side
14710515
1
-
Running Board, Passenger Side
14710516
1
121
Model
Voyager/
Caravan
Item No.
-
Part Description
Graphics, Van
122
Part No.
CS
Quantity
1
1
11
5,6,7,8
9,10
3
2
4
Model
Pickup
Pickup
Pickup
Pickup
Pickup
Pickup
Pickup
Pickup
Pickup
Pickup
Pickup
Item No.
1
2
3
4
5
6
7
8
9
10
11
Part Description
Bed Rail
Window, Rear Slider
Window, Rear Slider, Motor
Bumper Cover, Front
Running Board, Std Cab, DS
Running Board, Std Cab, PS
Running Board, Ext Cab, DS
Running Board, Ext Cab, PS
Running Board, DS Bed
Running Board, PS Bed
Window Louver - Set
DS – Driver Side
PS – Passenger Side
123
Part No.
15130205
15140270
15141020
14710907
15120242
15120241
15120253
15120254
15120243
15120244
15150255
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
Model
B-Van
Item No.
-
Part Description
Console, Overhead, Molded
124
Part No.
CS
Quantity
1
1
2
Model
B-Van
B-Van
B-Van
Item No.
1
2
Part Description
Wall, Deluxe
Vent, A/C Return
Wall, Deluxe, Top Plate
125
Part No.
CS
CS
CS
Quantity
1
1
1
Model
B-Van
B-Van
B-Van
B-Van
B-Van
B-Van
B-Van
B-Van
B-Van
Item No.
-
Part Description
Window Sill, SE, DS, Front, LWB
Window Sill, SE, DS, Rear, LWB
Window Sill, SE, PS, Rear, LWB
Window Sill, LE, DS, Front, LWB
Window Sill, LE, DS, Rear, LWB
Window Sill, LE, PS, Rear, LWB
Window Sill, LX, DS, Front, LWB
Window Sill, LX, DS, Rear, LWB
Window Sill, LX, PS, Rear, LWB
DS – Driver Side
PS – Passenger Side
126
Part No.
13761509
13761486
13761487
13771509
13771486
13771487
13771509
13771486
13771487
Quantity
1
1
1
1
1
1
1
1
1
1
2
3
Model
All
All
All
Item No.
1
2
3
Part Description
A/C Evaporator/ Heater Core
A/C Blower Assembly
A/C Expansion Valve
127
Part No.
14446041
14446040
14446042
Quantity
1
1
1
Model
G-Van
Ford
Dodge
Astro
Item No.
-
Part Description
Power Pack Assembly
Power Pack Assembly
Power Pack Assembly
Power Pack Assembly
128
Part No.
14446002
14446012
14446024
14446032
Quantity
1
1
1
1
1
2
3
Model
All
All
All
Item No.
1
2
3
Part Description
Relay
Resistor
Water Valve
129
Part No.
14446043
14446044
14446045
Quantity
1
1
1
1
2
Model
All
All
Item No.
1
2
Part Description
A/C Line Fitting O-ring Kit
A/C Blower Seal
130
Part No.
N/A
N/A
Quantity
1
1
1
2
5
Model
B-Van
LWB
B-Van
LWB
B-Van
SWB
B-Van
SWB
All
Item No.
1
Part Description
A/C Line, Liquid
Part No.
14446020
Quantity
1
2
A/C Line, Suction
14446021
1
1
A/C Line, Liquid
14446022
1
2
A/C Line, Suction
14446023
1
5
Heater Hose, 5/8”
14446015
1
131
ILLUSTRATED GUIDE
for 9000 SYSTEM
ILLUSTRATED GUIDE
for 9000 SYSTEM
EMI DIGITAL ELECTRONIC CONTROL CENTER
FEATURES
The DECC system uses state of the art surface mount components and has the following
diverse features and functions:
1 - DECC Main Fuse Panel - Software driven digitally controlled switching system
with internal timer, voltage sensors for low battery and sofa-current protection
and systems sampling 22 times each second.
State of the Art surface mount electronics combined with robust relay and fuse
system assuring the highest level of durability and reliability.
Digitally controlled software driven technology providing the greatest system
flexibility and operational consistency.
Full sofa motor controller system with 30 amp rated relays to assure optimum
performance.
Sofa motor reversing delay to prevent excessive shock to mechanical and
electrical systems.
Driver position sofa override (Lock-Out) feature to prevent any unauthorized
operation of the power sofa.
Timer for "door open" courtesy lights (20 seconds-software adjustable).
Timer for DECC panel light to assure that the light will not remain on
unintentionally.
Timer/warning alert for low battery (1 minute) then system will shut down.
Timer to keep power up after "ignition off" for 20 minutes, then system powers
down.
System becomes active when the door is opened and the 20 minute timer
restarts. The Courtesy light circuit will power down if a door is left open to
prevent Low Battery (20 minute). To reactivate the system you must close all
doors and reopen to restart the timer.
Switch activation priority system - "first switch"
Driver priority control over all interior lights.
Sofa lock defaults to "normal operation" when ignition is turned off.
Fully fused circuit protection for B+ and ignition (15 fuses and 1 PCB mounted
automatic reset fuse).
Driver controlled full stereo speaker switching select/mute system.
Electronic circuitry has been designed with out-put and in-put noise protection
devices to prevent audio interference and systems operational interference.
All wiring harness connectors are mounted on the underside of DECC main
fuse panel (no visible wires).
All vehicle conversion functions are on one PCB.
10 discrete relay circuits available.
Full stereo audio source switching system.
Robust sofa motor control system (30 amp relays)
Main switch panel (6 Button) is fully software active for reassigning
function positions.
DECC Main Fuse Panel has back lighting, spare fuses, fuse puller and separate
sofa fuse location.
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 1
2 - Main Switch Panel (6 button) is the key control center for the driver. From this
position all critical functions can be controlled.
Mood lights are controlled from this position.
Read lights are controlled from this position.
Driver controls TV power.
Driver can select speaker audio sources between TV and Factory radio and can
mute the speakers at anytime.
Driver can quickly "lock-out" the sofa motor control from the rear sofa switches.
The position of each switch function at the Main Switch Panel can be
reassigned by initiating the reprogramming function at the DECC panel and
following a simple intuitive step by step procedure for button reassignment.
Aux position is for future expansion.
3 -Sofa Control Switch (4 button switch) is designed to provide access to sofa function
controls from the seat area.
One switch location can operate each directional feature of the sofa.
UP
DOWN
FORWARD
BACK
Switch is available in a 2 button configuration (UP and DOWN)
All sofa switch functions can be "Locked Out" by Driver Main Switch Panel.
"Lock Out" feature will default to operational when the ignition is turned off.
Main Switch Panel Function Position Reassignment Program
This will allow the reassignment of each button function. The factory assigned switch
functions remain a permanent base for each switch position.
These preset positions are:
Top, left to right
1 - Mood lights
Bottom, left to right 4 - Sofa Lock
2 - Read Lights
5 - Auxlliary
3 - TV Power
6 - TV/Radio Mute
Step 1 The reassignment program is activated when the DECC panel light is
depressed and held for 20 seconds. The MSP will give an audible alert advising
that the system is ready for reassignment.
Step 2 The #1 switch position LED color will change advising that this is the start point.
Push the specific button to assign position #1 (i.e. to move TV Power function to
position #1 push switch #3, TV power will operate at position #1)
Step 3 The next button LED will change color advising that the last selection was
accepted and the next position is ready for reassignment. (i.e. to assign sofa
lock to position #2 push sofa lock button #4, position #2 will now operate sofa
lock feature).
Step 4 Follow each step as before to reassign each new function and position.
Step 5 After reassigning button #6 the MSP will give an other audible alert advising that
the switch reassignments have been accepted.
NOTE - If you desire to return the factory preset positions start the reassignment
program as stated in step #1. The LED will change color, push button #1 to
recover the factory preset.
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
AMP DRAW for 1998 EMI LE/LX Harness in Full Size vans and Astros
1.
Accessory One (ignition)
5 Thermotronics
1 Audio Amp
1 Rear Radio
2.
15 Amp Fuse
9.
Read Light
1 Overhead light
10. Mood Light
Draws 8.25 Amps
Accessory Two (Ignition)
5 Amp Fuse
Draws .69 Amps
7.5 Amp Fuse
1 Center Light Beam
Mood Light Above and
Below each Window Draws 4.79 Amps
15 Amp Fuse
Open for future expansion
3.
Accessory Three (Battery)
11. Accessory (TV/VCP)
15 Amp fuse
1 TV
1 VCP (playing)
5 Power Outputs (Cell Phone)
1 Rear Radio
1 Air Pump
Draws 3.80 Amps
4.
Accessory Four (Battery)
12. Accessory
15 Amp Fuse
Courtesy
8 Overhead Lights
and Step Well Light
13. Accessory
Read Light
7.
Read Light
1 Overhead Light
8.
Read Light
1 Overhead Light
15 Amp Fuse
14. Accessory
15 Amp Fuse
Draws 4.01 Amps
Draws .69 Amps
5 Amp Fuse
15. Power Seat
1 Overhead light
15 Amp Fuse
Open for future expansion
15 Amp Fuse
1 Overhead light
6.
Draws 3.40 Amps
Open for future expansion
Open for future expansion
5.
7.5 Amp fuse
25 Amp Fuse (factory)
Draws .69 Amps
1 Driver side
1 Passenger side
5 Amp Fuse
16. Power Sofa
Draws .69 Amps
5 Amp Fuse
1 Sofa
Draws 4.23 Amps
Draws 4.23 Amps
30 Amp Fuse
Draws 22.5 to 35.0 Amps
Draws .69 Amps
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 2
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
PASSENGER-SIDE
"D" PILLAR
DRIVER-SIDE
"B" PILLAR
DRIVER-SIDE
"D" PILLAR
DRIVER-SIDE
"C" PILLAR
PASSENGER-SIDE
"C" PILLAR
PASSENGER SIDE VIEW
DRIVER SIDE VIEW
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 3
REVISION A - 4-29-98
DRIVER-SIDE
OVERHEAD
LIGHTS CONNECTION
(4-PIN VIOLET CONNECTOR)
ILLUSTRATED GUIDE
for 9000 SYSTEM
OVERHEAD
LIGHTS CONNECTION
(9 - PIN GREY CONNECTOR)
AVAILABLE CIRCUITS
ORG w/WHT
Right Rear Reading
Lamp power
YLW w/BLK
Right Front Reading
Lamp power
PNK w/BLK
Left Rear Reading
Lamp power
GRN w/WHT
Left Front Reading
Lamp power
WHT w/RED
Mood & Valance
Lamp power
ORG w/BLK
Courtesy Lamp power
YLW w/WHT
Ignition
RED w/WHT
Constant 12v
BLACK
Chassis Ground
AVAILABLE CIRCUITS
RED w/WHT
Constant 12v
YLW w/WHT
Ignition
ORG w/BLK
Courtesy
BLACK
Chassis Ground
TV/VCP CONNECTION
(6-PIN NATURAL CONNECTOR)
AVAILABLE CIRCUITS
BLK
Chassis Ground
WHT w/BLK
TV/VCP Power
PINK
Audio Input Right (+)
WHT
Audio Input Right (-)
GREY
Audio Input Left (+)
GREY w/BLK
Audio Input Left (-)
4-PIN COM LINE
AVAILABLE CIRCUITS
PIN 1 SWITCHED +12 VDC
PIN 2 GROUND
PIN 3 CLOCK
PIN 4 DATA
DRIVER-SIDE
FLOOR LIGHTS CONNECTION
(4-PIN VIOLET CONNECTOR)
DRIVER-SIDE "C"
PILLAR CONNECTION
(6 - PIN BROWN CONNECTOR)
AVAILABLE CIRCUITS
RED w/WHT
Constant 12v
YLW w/WHT
Ignition
ORG w/BLK
Courtesy
BLACK
Chassis Ground
AVAILABLE CIRCUITS
RED w/YLW
Left Spkr Output (-)
YLW w/RED
Left Spkr Output (+)
WHT w/RED
Mood & Valance
Lamp power
YLW w/WHT
Ignition
RED w/WHT
Constant 12v
BLACK
Chassis Ground
AUDIO AMP
CONNECTION
(8-PIN WHITE CONNECTOR)
DECC
ACCESSORY CONNECTION
(3-PIN BLUE CONNECTOR)
DIGITAL ELECTRONIC
CONTROL CENTER
AVAILABLE CIRCUITS
RED w/YLW
Left Spkr Output (-)
YLW w/RED
Left Spkr Output (+)
WHT w/GRN
Right Spkr Output (+)
WHT w/ORG
Right Spkr Output (-)
AVAILABLE CIRCUITS
RED w/WHT
Constant 12v
YLW w/WHT
Ignition
BLACK
Chassis Ground
REAR (AUX.) RADIO
ACCESSORY CONNECTION
(5-PIN BLACK CONNECTOR)
AVAILABLE CIRCUITS
RED
Radio Right Channel (+)
GREEN
Radio Left Channel (+)
YLW w/WHT
Ignition
RED w/WHT
Constant 12v
BLK w/WHT
Dedicated Audio System
Chassis Ground
SOFA MOTOR CONNECTION
(4-PIN RED CONNECTOR)
AVAILABLE CIRCUITS
GRN w/BLK
Sofa Slide Mtr Pwr
VIOLET
Sofa Tilt Mtr Pwr
BLU w/WHT
Sofa Slide Mtr Pwr
ORANGE
Sofa Tilt Mtr Pwr
DRIVER SIDE VIEW
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
6-PIN AUDIO CONNECTION
PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
AVAILABLE CIRCUITS
- LEFT RADIO
- COMMON
- RIGHT RADIO
- RIGHT AUDIO (TV)
- COMMON
- LEFT AUDIO (TV)
PAGE 4
4-PIN COM LINE
AVAILABLE CIRCUITS
PIN 1 SWITCHED +12 VDC
PIN 2 GROUND
PIN 3 CLOCK
PIN 4 DATA
ACCESSORY CONNECTION
(3-PIN BLUE CONNECTOR)
AVAILABLE CIRCUITS
RED w/WHT
Constant 12v
YLW w/WHT
Ignition
BLACK
Chassis Ground
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
4-PIN COM LINE
PASSENGER-SIDE "C"
PILLAR CONNECTION
(6 - PIN YELLOW CONNECTOR)
AVAILABLE CIRCUITS
PIN 1 SWITCHED +12 VDC
PIN 2 GROUND
PIN 3 CLOCK
PIN 4 DATA
AVAILABLE CIRCUITS
WHT w/GRN
Right Spkr Output (-)
WHT w/ORG
Right Spkr Output (+)
WHT w/RED
Mood & Valance
Lamp power
YLW w/WHT
Ignition
RED w/WHT
Constant 12v
BLACK
Chassis Ground
ACCESSORY CONNECTION
(3-PIN BLUE CONNECTOR)
AVAILABLE CIRCUITS
RED w/WHT
Constant 12v
YLW w/WHT
Ignition
BLACK
Chassis Ground
PASSENGER SIDE VIEW
6-PIN AUDIO CONNECTION
PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
AVAILABLE CIRCUITS
- LEFT RADIO
- COMMON
- RIGHT RADIO
- RIGHT AUDIO (TV)
- COMMON
- LEFT AUDIO (TV)
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 5
REVISION A - 4-29-98
TO REAR RADIO
(12-PIN WHITE CONNECTOR)
AVAILABLE CIRCUITS
RED w/WHT
Constant 12V
YLW w/WHT
Ignition
RED
Aux. Radio Right Channel (+)
GRN
Aux. Radio Left Channel (+)
BLK
Chassis Ground
TO CD MODULE
(3-PIN BLUE CONNECTOR)
AVAILABLE CIRCUITS
YLW w/WHT
Ignition
RED w/WHT
Constant 12V
BLK
Chassis Ground
ILLUSTRATED GUIDE
for 9000 SYSTEM
FRONT ACCESSORY
HARNESS
P.N. 02-76013
CD POWER FEED
HARNESS
P.N. 02-00102
TO AUXILLARY
(2-PIN GREEN CONNECTOR)
GRN
BLK
TO CD PLAYER
AVAILABLE CIRCUITS
RED w/WHT
Constant 12V
YLW w/WHT
Ignition
AVAILABLE CIRCUITS
Switched Auxillary Power
Chassis Ground
FRONT ACCESSORY
HARNESS
P.N. 02-76013
TO CELL PHONE
(2-PIN WHITE CONNECTOR)
AVAILABLE CIRCUITS
RED w/WHT
Constant 12V
BLK
Chassis Ground
TO GAME CENTER
(2-PIN WHITE CONNECTOR)
AVAILABLE CIRCUITS
YLW w/WHT
Ignition
BLK
Chassis Ground
TO REAR SPEAKER CONNECTION
(8-PIN WHITE CONNECTOR)
PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
PIN 7
PIN 8
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
AVAILABLE CIRCUITS
Left Output (+)
Left Output (-)
Right Output (+)
Right Output (-)
Left Input (+)
Left Input (-)
Right Input (+)
Right Input (-)
PAGE 6
TO THERMOTRONICS
(2-PIN WHITE CONNECTOR)
DRIVER SIDE FLOOR
HARNESS
P.N. 02-76005
AVAILABLE CIRCUITS
YLW w/WHT
Ignition
BLK
Chassis Ground
REVISION A - 4-29-98
TO CARGO LIGHTS
(3-PIN CONNECTOR)
ILLUSTRATED GUIDE
for 9000 SYSTEM
DRIVER OVERHEAD
HARNESS
P.N. 02-76004
AVAILABLE CIRCUITS
RED w/WHT
Constant 12v
ORG w/BLK
Courtesy
BLK
Chassis Ground
CEILING LIGHTS
HARNESS
P.N. 02-76016
AVAILABLE CIRCUITS
WHT w/RED
Mood & Valance
Lamp Power
BLK
Chassis Ground
MAIN
HARNESS
AVAILABLE CIRCUITS
RED w/WHT
Constant 12v
ORG w/BLK
Courtesy
BLK
Chassis Ground
TO MAIN HARNESS
CONNECTION
(4-PIN VIOLET CONNECTOR)
TO READING LIGHTS
(3-PIN CONNECTOR)
4-PIN CONNECTOR
TO MAIN SWITCH
PANEL
(4-PIN COM LINE)
AVAILABLE CIRCUITS
PIN 1 - SWITCHED +12 VDC
PIN 2 - GROUND
PIN 3 - CLOCK
PIN 4 - DATA
AVAILABLE CIRCUITS
GRN w/WHT
Left Front Reading
Lamp Power
ORG w/BLK
Courtesy
BLK
Chassis Ground
TV/VCP
MODULE
P.N. 02-76002
AVAILABLE CIRCUITS
RED w/WHT
Constant 12v
YLW w/WHT
Ignition
ORG w/BLK
Courtesy
BLK
Chassis Ground
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
AVAILABLE CIRCUITS
PNK w/BLK
Left Rear Reading
Lamp Power
ORG w/BLK
Courtesy
BLK
Chassis Ground
TO MOOD LIGHTS
(1-PIN CONNECTOR)
AVAILABLE CIRCUITS
RED w/WHT
Constant 12v
ORG w/BLK
Courtesy
BLK
Chassis Ground
TO COURTESY LIGHTS
(3-PIN CONNECTOR)
AVAILABLE CIRCUITS
ORG w/WHT
Right Rear Reading
Lamp Power
ORG w/BLK
Courtesy
BLK
Chassis Ground
TO READING LIGHTS
(3-PIN CONNECTOR)
TO PASSENGER
SIDE VISOR LIGHTS
(3-PIN CONNECTOR)
MAIN
HARNESS
TO READING LIGHTS
(3-PIN CONNECTOR)
PAGE 7
TO READING LIGHTS
(3-PIN CONNECTOR)
AVAILABLE CIRCUITS
YLW w/BLK
Right Front Reading
Lamp Power
ORG w/BLK
Courtesy
BLK
Chassis Ground
TO TV / VCP
CONNECTION
AVAILABLE CIRCUITS
VCP POWER
TV POWER
TV AUDIO
NOISE FILTER - INPUT & OUTPUT
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
DRIVER SIDE
"C" PILLAR
HARNESS
P.N. 02-76010
TO SPEAKERS
(1-PIN TABS)
AVAILABLE CIRCUITS
YLW w/RED
Left Speaker Output (+)
RED w/YLW
Left Speaker Output (-)
TO MOOD LIGHTS
(1-PIN TABS)
AVAILABLE CIRCUITS
WHT w/RED
Constant 12V
BLK
Chassis Ground
ACCESSORY CONNECTION
(3-PIN BLUE CONNECTOR)
AVAILABLE CIRCUITS
RED w/WHT
Constant 12v
YLW w/WHT
Ignition
BLACK
Chassis Ground
TO SPEAKERS
(1-PIN TABS)
AVAILABLE CIRCUITS
YLW w/RED
Left Speaker Output (+)
RED w/YLW
Left Speaker Output (-)
SOFA MOTOR CONNECTION
(4-PIN RED CONNECTOR)
POWER SOFA MOTOR MODULE
(4-PIN NATURAL CONNECTOR)
AVAILABLE CIRCUITS
GRN w/BLK
Sofa Slide Mtr Pwr
VIOLET
Sofa Tilt Mtr Pwr
BLU w/WHT
Sofa Slide Mtr Pwr
ORANGE
Sofa Tilt Mtr Pwr
AVAILABLE CIRCUITS
GRN w/BLK
Sofa Slide Mtr Pwr
VIOLET
Sofa Tilt Mtr Pwr
BLU w/WHT
Sofa Slide Mtr Pwr
ORANGE
Sofa Tilt Mtr Pwr
TO POWER SOFA
(1-PIN TABS)
POWER SOFA MOTOR
HARNESS
P.N. 02-76009
PASSENGER
DRIVER-SIDE
SIDE
VIEW
VIEW
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 8
AVAILABLE CIRCUITS
GRN w/BLK
Sofa Slide Mtr Pwr
BLU w/WHT
Sofa Slide Mtr Pwr
VIOLET
Sofa Tilt Mtr Pwr
ORANGE
Sofa Tilt Mtr Pwr
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
TO SPEAKERS
(1-PIN TABS)
AVAILABLE CIRCUITS
YLW w/RED
Left Speaker Output (+)
RED w/YLW
Left Speaker Output (-)
TO SPEAKERS
(1-PIN TABS)
AVAILABLE CIRCUITS
YLW w/RED
Left Speaker Output (+)
RED w/YLW
Left Speaker Output (-)
TO 12V OUTPUTS
(1-PIN TABS)
PASSENGER SIDE
"C" PILLAR
HARNESS
P.N. 02-76011
AVAILABLE CIRCUITS
RED w/WHT
Constant 12V
BLACK
Chassis Ground
REAR ACCESSORY
HARNESS
P.N. 02-76007
TO MOOD LIGHTS
(1-PIN TABS)
AVAILABLE CIRCUITS
WHT w/RED
Constant 12V
BLK
Chassis Ground
ACCESSORY CONNECTION
(3-PIN BLUE CONNECTOR)
AVAILABLE CIRCUITS
RED w/WHT
Constant 12v
YLW w/WHT
Ignition
BLACK
Chassis Ground
PASSENGER SIDE VIEW
PAGE 3 OF 4
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 9
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
6 BUTTON MAIN SWITCH ASSEMBLY
MOUNTING
HOLE
4-PIN COM LINE
FROM 9000 MAIN
HARNESS
PIN 1
PIN 2
PIN 3
PIN 4
-
SWITCHED +12 VDC
GROUND
CLOCK
DATA
MOUNTING
HOLE
CAUTION: DISCONNECT THE NEGATIVE (-)
BATTERY TERMINAL BEFORE
DISCONNECTING ANY SWITCHES
SNAP-IN PEG ON BEZEL
TO SNAP ON BASE
OPTION 1
OPTION 2
MOOD
READ
TV PWR
MOOD
READ
SOFALOCK
AUX
MUTE
MUTE
AUX
P.N. 03-00005 - 6 BUTTON MAIN SWITCH ASSEMBLY
MOOD
READ
TV PWR
EMI P.N. 22-00001 DECAL,UPPER 6 BUTTON MAIN (MRT)
SOFALOCK
AUX
6 BUTTON
BEZEL
MUTE
EMI P.N. 22-00002 DECAL, LOWER 6 BUTTON MAIN (SAM)
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
OPTION 3
TV PWR
P.N. 03-00031 - 6 BUTTON MAIN SWITCH ASSEMBLY
MOOD
READ
TV PWR
EMI P.N. 22-00001 DECAL,UPPER 6 BUTTON MAIN (MRT)
MUTE
AUX
EMI P.N. 22-00041 DECAL, LOWER 6 BUTTON MAIN (MAB)
PAGE 10
MOOD
READ
SOFALOCK
AUX
MUTE
P.N. 03-00033 - 6 BUTTON MAIN SWITCH ASSEMBLY
MOOD
READ
MUTE
EMI P.N. 22-00030 DECAL,UPPER 6 BUTTON MAIN (MRM)
SOFALOCK
AUX
EMI P.N. 22-00033 DECAL, LOWER 6 BUTTON MAIN (SAB)
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
3 BUTTON MAIN SWITCH ASSEMBLY
MOUNTING
HOLE
4-PIN COM LINE
FROM 9000 MAIN
HARNESS
PIN 1
PIN 2
PIN 3
PIN 4
-
SWITCHED +12 VDC
GROUND
CLOCK
DATA
MOUNTING
HOLE
SNAP-IN PEG ON BEZEL
TO SNAP ON BASE
MOOD
3 BUTTON
BEZEL
CAUTION: DISCONNECT THE NEGATIVE (-)
BATTERY TERMINAL BEFORE
DISCONNECTING ANY SWITCHES
READ
MUTE
P.N. 03-00032 - 3 BUTTON MAIN SWITCH ASSEMBLY
MOOD
READ
MUTE
EMI P.N. 22-00030 DECAL,UPPER 6 BUTTON MAIN (MRM)
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 11
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
2 BUTTON SOFA SWITCH ASSEMBLY
CAUTION: DISCONNECT THE NEGATIVE (-)
BATTERY TERMINAL BEFORE
DISCONNECTING ANY SWITCHES
4-PIN COM LINE
(LOCATED ON PASSENGER-SIDE
NEAR REAR WHEEL-WELL)
PIN 1
PIN 2
PIN 3
PIN 4
-
SWITCHED +12 VDC
GROUND
CLOCK
DATA
2 BUTTON BEZEL
WITH SOFA GRAPHICS
P.N. 03-00026 - 2 BUTTON SOFA SWITCH ASSEMBLY
UP
SNAP-IN PEG ON BEZEL
TO SNAP ON BASE
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
DOWN
EMI P.N. 22-00003 DECAL,UPPER 4 BUTTON SOFA (UP/DOWN)
PAGE 12
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
4 BUTTON SOFA SWITCH ASSEMBLY
CAUTION: DISCONNECT THE NEGATIVE (-)
BATTERY TERMINAL BEFORE
DISCONNECTING ANY SWITCHES
4-PIN COM LINE
(LOCATED ON PASSENGER-SIDE
NEAR REAR WHEEL-WELL)
PIN 1
PIN 2
PIN 3
PIN 4
-
SWITCHED +12 VDC
GROUND
CLOCK
DATA
4 BUTTON BEZEL
WITH SOFA GRAPHICS
UP
DOWN
FORWARD
BACK
P.N. 03-00027 - 4 BUTTON SOFA SWITCH ASSEMBLY
UP
DOWN
EMI P.N. 22-00003 DECAL,UPPER 4 BUTTON SOFA (UP/DOWN)
SNAP-IN PEG ON BEZEL
TO SNAP ON BASE
FORWARD
BACK
EMI P.N. 22-00004 DECAL,LOWER 4 BUTTON SOFA (FOWARD/BACK)
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 13
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
TV/RADIO - TV/RADIO ASSEMBLY
CAUTION: DISCONNECT THE NEGATIVE (-)
BATTERY TERMINAL BEFORE
DISCONNECTING ANY SWITCHES
6-PIN AUDIO CONNECTOR
(LOCATED ON DRIVER & PASSENGER-SIDE
NEAR REAR WHEEL-WELL)
PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
-
LEFT RADIO
COMMON
RIGHT RADIO
RIGHT AUDIO (TV)
COMMON
LEFT AUDIO (TV)
2 BUTTON BEZEL
TV/RADIO
TV/RADIO
P.N. 03-00021 - TV/RADIO - TV/RADIO STATION
SNAP-IN PEG ON BEZEL
TO SNAP ON BASE
TV/RADIO
TV/RADIO
EMI P.N. 22-00027 DECAL,UPPER AUDIO (TV/RADIO - TV/RADIO)
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 14
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
TV - TV STATION ASSEMBLY
6-PIN AUDIO CONNECTOR
(LOCATED ON DRIVER & PASSENGER-SIDE
NEAR REAR WHEEL-WELL)
PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
-
LEFT RADIO
COMMON
RIGHT RADIO
RIGHT AUDIO (TV)
COMMON
LEFT AUDIO (TV)
2 BUTTON BEZEL
TV
TV
P.N. 03-00025 - TV - TV STATION
SNAP-IN PEG ON BEZEL
TO SNAP ON BASE
TV
TV
EMI P.N. 22-00019 DECAL,UPPER AUDIO (TV - TV)
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 15
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
RADIO - RADIO STATION ASSEMBLY
CAUTION: DISCONNECT THE NEGATIVE (-)
BATTERY TERMINAL BEFORE
DISCONNECTING ANY SWITCHES
6-PIN AUDIO CONNECTOR
(LOCATED ON DRIVER & PASSENGER-SIDE
NEAR REAR WHEEL-WELL)
PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
-
LEFT RADIO
COMMON
RIGHT RADIO
RIGHT AUDIO (TV)
COMMON
LEFT AUDIO (TV)
2 BUTTON BEZEL
RADIO
RADIO
P.N. 03-00030 - RADIO - RADIO STATION
SNAP-IN PEG ON BEZEL
TO SNAP ON BASE
RADIO
RADIO
EMI P.N. 22-00032 DECAL,UPPER AUDIO (RADIO - RADIO)
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 16
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
DECC
Troubleshooting Flowchart
CALL
for
Assistance
START
NO
Turn on the
ignition
Does it
work?
YES
Push button
on DECC
Replace
DECC
FINISHED
YES
Does it
work?
NO
Check OEM
Fuses
Check Battery
voltage
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
NO
Charge or
Replace
Battery
Does it
work?
YES
FINISHED
NO
Is voltage
above
10.5?
YES
PAGE 17
Reset
DECC
Push button
on DECC
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
START
HEADPHONE STATION
Troubleshooting Flowchart
Turn on the
ignition
Fix
NO
FINISHED
Turn power
on Rear Radio
Fix
NO
Do you
have TV
pwr?
NO
Refer to TV/VCP
Troubleshooting
Flowchart
CALL
for
Assistance
YES
Is it
good?
NO
Are
Fuses
good?
Check
Fuses
YES
Check
connection at
Rear Radio
Harness
NO
Is it
good?
Replace
Headphone
Station
FINISHED
YES
CALL
for
Assistance
YES
Does it
work?
YES
Do you
have Radio
pwr?
FINISHED
NO
Test
audio lines
Check
connection
at "C" Pillar
Fix
NO
Is it
good?
YES
Check
connection
at "C" Pillar
FINISHED
NO
Replace
YES
FINISHED
FINISHED
YES
Plug into
Radio Heaphone
Outlet
Does it
work?
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
Remove
Heaphone
Station
Replace
Headphone
Station
YES
Does it
work?
NO
NO
Plug into
TV Heaphone
Outlet
PAGE 18
Does it
work?
YES
Remove
Heaphone
Station
Test
audio lines
REVISION A - 4-29-98
B - 5-11-98
Plug into
Radio Heaphone
Outlet
FINISHED
ILLUSTRATED GUIDE
for 9000 SYSTEM
START
Replace
lights
MOOD LIGHTS
Turn on the
ignition
Troubleshooting Flowchart
YES
Open any
door
Passenger
side?
YES
Are all
indirect
ligths
on?
NO
Are one
or more on
but not
all?
YES
YES
With
button amber
are all
lights
off?
Are
Fuses
good?
YES
NO
Reprogram
DECC
Does it
work?
NO
NO
NO
Check
connection
at "C" Pillar
Replace
YES
Check
connection
at light
Is it
good?
Are lights
off?
YES
Fix
NO
FINISHED
NO
Check
Comm. line
Fix
Are
line(s)
good?
NO
Replace
line(s)
YES
YES
NO
Is it
good?
NO
Check
connection at
light that is not on
Disconnect ORG
courtesy from
OEM
YES
Check
for power
YES
Check
Fuses
Is it
good?
NO
Same as
Driver side
Is one
of them
on?
NO
NO
Close all
doors
With
button green
are all
lights
off?
Driver
side?
YES
NO
CALL
for
Assistance
YES
FINISHED
Replace
DECC
Check
OEM
FINISHED
YES
FINISHED
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
CALL
for
Assistance
YES
Is it
good?
PAGE 19
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
SOFA
START
Troubleshooting Flowchart
Turn on the
ignition start the vehicle
FINISHED
Make sure the sofa
lock is turned off
Replace
sofa switch
FINISHED
Replace
the DECC
YES
Push the sofa
button (up/down)
Replace
fuse
Is it
good?
NO
Replace
comm line
Replace
sofa harness
NO
FINISHED
YES
Does it
work?
NO
Is it
good?
YES
Check the
comm line
Is it
good?
YES
NO
FINISHED
Do the
relays "click"
in the
DECC?
YES
NO
Check the
fuse
Replace
sofa motor
Fix
NO
Check the
connection at
sofa motor
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
Is the
connection
good?
PAGE 20
YES
YES
Check for
power at
sofa connection
Is it
good?
Check Red sofa
harness for
power
NO
REVISION A - 4-29-98
B - 5-11-98
Harness
Rev. #
0
ILLUSTRATED GUIDE
for 9000 SYSTEM
START
SPEAKER
Harness
Rev. #
2
Troubleshooting Flowchart
Turn on the
ignition
FINISHED
Push button
on DECC
Refer to
TV/Radio
schematic
Do you
have any
rear speaker
sound?
Harness
Rev. #
3
FINISHED
NO
Replace
DECC
NO
Are
there
pinched
wires?
NO
YES
Is it a
Full size
Chevy?
NO
Disconnect
audio pass
through
Do rear YES
speakers
work?
Consult
OEM
FINISHED
YES
YES
Is it
good?
YES
Refer to
TV/Radio
Schematic
NO
Fix
FINISHED
FINISHED
Fix
FINISHED
NO
Do you
have one
side out
(Dr, Pass)?
YES
Check
connection
at "C" Pillar
Is it
good?
YES
Check
harness
revision #
Check
speaker
connection
Check
speaker
Replace
sofa
switch
Replace
DECC
YES
NO
Does mute
function
as
mute?
YES
NO
Do any
buttons
function as
mute?
FINISHED
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
NO
Remove
sofa switch
Reset
DECC
Does it
work?
NO
YES
PAGE 21
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
START
TV/VCP
Troubleshooting Flowchart
Turn on the
ignition
YES
FINISHED
NO
Turn on TV
power button
(Amber)
Fix
Replace
FINISHED
Does
it have
power?
Fix
NO
Does it
work?
NO
Are
Fuses
good?
Check
Fuses
YES
Do you
YES
have Audio?
Check
TV/VCP
harness
Is
connection
good?
FINISHED
YES
Check Audio
connection
Reset
DECC
Replace
DECC
Is
there
power?
Does TV
NO
speaker have
audio?
Unplug
audio jack
Fix
Cycle Mute
button
NO
YES
FINISHED
NO
YES
Does
it have
power?
Check plug
for power
Check plug
for ground
YES
Is
audio jack
plugged
in?
NO
YES
NO
Replace
YES
NO
FINISHED
Does it
work?
Fix
FINISHED
YES
NO
YES
YES
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
Do you
have good
volume?
NO
Check Audio
connection
PAGE 22
Make sure tip
is NOT to
ground
Is
Tip to
ground?
NO
CALL
for
Assistance
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
Instructions for Resetting the DECC
ASTRO
1.
Disconnect the NEGATIVE (-) battery terminal from the battery.
2.
Wait 10 seconds.
3.
Reconnect the NEGATIVE (-) battery terminal to the battery.
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 23
REVISION A - 4-29-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
Instructions for Resetting the DECC
CHEVY
1.
Disconnect the NEGATIVE (-) battery terminal from the battery.
2.
Wait 10 seconds.
3.
Reconnect the NEGATIVE (-) battery terminal to the battery.
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 24
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
Instructions for Resetting the DECC
DODGE
1.
Disconnect the NEGATIVE (-) battery terminal from the battery
OR Remove both OEM fuses labled "Van Conv Batt" and
"Van Conv Ign" located in the front of the fuse panel under the hood.
2.
Wait 10 seconds.
3.
Reconnect the NEGATIVE (-) battery terminal to the battery.
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 25
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
Instructions for Resetting the DECC
FORD
1.
Disconnect the NEGATIVE (-) battery terminal from the battery
OR Remove OEM fuse #21 located in the fuse panel under the hood.
2.
Wait 10 seconds.
3.
Reconnect the NEGATIVE (-) battery terminal to the battery.
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 26
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
Instructions for Resetting the DECC
GMC
1.
Disconnect the NEGATIVE (-) battery terminal from the battery.
2.
Wait 10 seconds.
3.
Reconnect the NEGATIVE (-) battery terminal to the battery.
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 27
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
ASTRO POWER-UP
PC1.1
NATURAL
BLK
BLK
C1.C
BLK
RED/WHT
C1.A
BLK
RED
C1.B
BLK
PC1.3
NATURAL
RED/WHT
PC1.2
NATURAL
RED
1234
ASTRO
POWER-UP
HARNESS
02-76022
RED
CONNECTOR
BLK
1
2
NATURAL
CONNECTOR
ETAC
23-00007
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
BEHIND
"D" WALL
BEHIND
"D" WALL
PAGE 28
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
CHEVY POWER-UP
PC1.1
NATURAL
BLK
BLK
C1.D
BLK
RED/WHT
C1.A
BLK
RED
C1.B
BLK
PC1.3
NATURAL
RED/WHT
PC1.2
NATURAL
RED
1234
CHEVY
POWER-UP
HARNESS
02-76003
RED
CONNECTOR
BLK
1
2
NATURAL
CONNECTOR
ETAC
23-00007
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
BEHIND
"D" WALL
BEHIND
"D" WALL
PAGE 29
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
DODGE POWER-UP
PC1.1
NATURAL
BLK
BLK
B1
BLK
RED/WHT
C1.2
BLK
RED
C1.1
BLK
PC1.3
NATURAL
RED/WHT
PC1.2
NATURAL
RED
1234
DODGE
POWER-UP
HARNESS
02-76017
RED
CONNECTOR
BLK
1
2
NATURAL
CONNECTOR
ETAC
23-00007
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
BEHIND
"D" WALL
BEHIND
"D" WALL
PAGE 30
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
FORD POWER-UP
PC1.1
NATURAL
BLK
BLK
C1.C
BLK
RED/WHT
C1.A
BLK
RED
C1.B
BLK
PC1.3
NATURAL
RED/WHT
PC1.2
NATURAL
RED
1234
FORD
POWER-UP
HARNESS
02-76021
RED
CONNECTOR
BLK
1
2
NATURAL
CONNECTOR
ETAC
23-00007
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
BEHIND
"D" WALL
BEHIND
"D" WALL
PAGE 31
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
GMC POWER-UP
PC1.1
NATURAL
BLK
BLK
C1.D
BLK
RED/WHT
C1.A
BLK
RED
C1.B
BLK
PC1.3
NATURAL
RED/WHT
PC1.2
NATURAL
RED
1234
GMC
POWER-UP
HARNESS
02-76003
RED
CONNECTOR
BLK
1
2
NATURAL
CONNECTOR
ETAC
23-00007
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
BEHIND
"D" WALL
BEHIND
"D" WALL
PAGE 32
REVISION A - 4-29-98
B - 5-11-98
BEHIND
DECC
ILLUSTRATED GUIDE
for 9000 SYSTEM
BLK
C3.1
GRAY
MOOD LIGHT
MOOD LIGHT
BUTTON #1
4 PAIR COMM LINE
(DIGITAL DATA)
MOOD
CEILING
LIGHTS
02-76016
ETAC
23-00007
GREEN
CONNECTOR
(FUSE #10)
1
2
3
4
5
6
C3.9
GRAY
BLK
WHT/RED
BLK
CENTER
OVERHEAD
LIGHT
BEAM
WHT/RED
CEILING
LIGHTS
02-76016
B7
C10.4
BROWN
B7
BLK
WHT/RED
DRIVER
SIDE
"C" PILLAR
02-760010
PASSENGER SIDE
"C" PILLAR
02-760011
C22.4
YELLOW
WHT/RED
WHT/RED
"C" PILLAR DRIVER
SIDE BELOW
WINDOWS
BLK
B7
B7
WHT/RED
B10
B11
WHT/RED
WHT/RED
BLK
B11
BLK
WHT/RED
BLK
B12
B13
WHT/RED
WHT/RED
WHT/RED
WHT/RED
B12
BLK
"C" PILLAR
PASSENGER SIDE
ABOVE WINDOWS
"C" PILLAR DRIVER
SIDE ABOVE
WINDOWS
BLK
B11
BLK
B12
B13
BLK
"C" PILLAR
PASSENGER SIDE
BELOW WINDOWS
B11
B12
BLK
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
BLK
B10
BLK
WHT/RED
WHT/RED
BLK
BLK
PAGE 33
REVISION A - 4-29-98 , B - 5-11-98
BEHIND
DECC
BLK
READ LIGHT
BUTTON #2
READ/COURTESY
LIGHT
READ
"B" PILLAR TOP
CEILING
LIGHTS
02-76016
C3.1
GRAY
ILLUSTRATED GUIDE
for 9000 SYSTEM
ETAC
23-00007
RED/WHT
ORG/BLK
ORG/BLK
GREEN
CONNECTOR
(FUSE # )
4 PAIR COMM LINE
(DIGITAL DATA)
BLK
BLK
NATURAL
CONNECTOR
(FUSE # )
1
2
3
4
5
6
7
8
1
2
3
4
5
6
C3.5
GRAY
YLW/BLK
LEFT FRONT
READING LIGHT
C3.7
GRAY
ORG/BLK
YLW/BLK
BLK
YLW/BLK
YLW/BLK
PNK/BLK
PNK/BLK
"B"
PILLAR
TOP
CEILING
LIGHTS
02-76016
BLK
C3.6
GRAY
BLK
PNK/BLK
PNK/BLK
BLK
C3.8
GRAY
C2.1
VIOLET
BLK
ORG/WHT
LEFT REAR
READING LIGHT
ORG/WHT
"B" PILLAR TOP
CEILING
LIGHTS
02-76016
C3.5
GRAY
ORG/BLK
BLK
NEAR DRIVER
MAP LIGHT
GRN/WHT
BLK
RIGHT REAR
READING LIGHT
ORG/WHT
GRN/WHT
ORG/BLK
RED/WHT
DRIVER
OVERHEAD
HARNESS
02-76004
RED/WHT
ORG/BLK
ORG/BLK
ORG/BLK
ORG/BLK
ORG/BLK
RIGHT FRONT
READING LIGHT
C3.3
GRAY
GRN/WHT
ORG/BLK
BLK
BLK
ORG/BLK
BLK
BLK
ORG/BLK
REAR CARGO
LIGHT
RED/WHT
RED/WHT
BLK
DRIVER &
PASSENGER
MAP LIGHTS
ORG/BLK
ORG/BLK
RED/WHT
ORG/BLK
RED/WHT
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
DRIVER
OVERHEAD
HARNESS
02-76004
C2.3
VIOLET
RED/WHT
PAGE 34
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
TV/VCP POWER
TV PWR
BUTTON #3
TV PWR
BEHIND
DECC
4 PAIR COMM LINE
(DIGITAL DATA)
GREEN
CONNECTOR
(FUSE #11)
ETAC
23-00007
1
2
3
4
5
6
WHT/BLK
TV/VCP
HARNESS
02-76002
BLK/WHT
C4.1
NATURAL
MIDDLE OF
"B" PILLAR
B7
WHT/BLK
TV/VCP
HARNESS
02-76002
02-76501
MIDDLE OF
"B" PILLAR
RED
TV/VCP
FILTER
BLU
WHT/BLK
BEHIND TV
C4.1
NATURAL
B4
WHT/BLK
BLK/WHT
BLK/WHT
VCP
B4
B3
WHT/BLK
TV
BLK/WHT
BLK/WHT
B3
BLK/WHT
BLK/WHT
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 35
REVISION A - 4-29-98
B - 5-11-98
ILLUSTRATED GUIDE
for 9000 SYSTEM
UP
DOWN
UP
DOWN
FORWARD
BACK
SOFALOCK
SOFALOCK
4 PAIR COMM LINE
(DIGITAL DATA)
SOFALOCK
BUTTON #4
NATURAL
CONNECTOR
(30 AMP FUSE
BOTTOM RIGHT)
PC1.2
NATURAL
CONNECT
TO OEM
POWER-UP
ETAC
23-00007
6 5 4 3 2 1
BEHIND
DECC
RED
RED
BLK/RED
ORG
BLK/RED
GRN/BLK
VIO
C13.3
RED
C13a.1
NATURAL
GRN/BLK
C13a.3
NATURAL
C13.1
RED
BLU/WHT
VIO
C13a.2
NATURAL
GRN/BLK
C13.2
RED
ORG
C13a.4
NATURAL
BLU/WHT
VIO
ORG
C13.4
RED
SOFA HARNESS
02-76009
BLK
M
M
FORWARD & BACK
SOFA MOTOR
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
UP & DOWN
SOFA MOTOR
PAGE 36
ILLUSTRATED GUIDE
for 9000 SYSTEM
AUXILIARY
AUX
4 PAIR COMM LINE
(DIGITAL DATA)
AUXILIARY
BUTTON #5
ETAC
23-00007
4 3 2 1
C32.2
GRN
BLK
LOCATED
BEHIND "D"
WALL
GRN
C32.1
GRN
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 37
ILLUSTRATED GUIDE
for 9000 SYSTEM
MUTE
MUTE
4 PAIR COMM LINE
(DIGITAL DATA)
MUTE
BUTTON #6
ETAC
23-00007
FROM
FRONT RADIO
C12.5
NATURAL
C12.1
NATURAL
C12.6
NATURAL
C12.2
NATURAL
C12.5
NATURAL
C12.1
NATURAL
C12.6
NATURAL
C12.2
NATURAL
PINK
BLU/WHT
LOCATED
BEHIND "D"
WALL
WHT
C4.4
NATURAL
C4.3
NATURAL
B2
C4.1
NATURAL
TV
B2
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 38
LOCATED
BEHIND "D"
WALL
ILLUSTRATED GUIDE
for 9000 SYSTEM
PROGRAM SEQUENCES
STANDARD - 6 BUTTON SWITCH
MOOD
READ
5 BUTTON SWITCH (NO SOFA)
TV PWR
MOOD
READ
TV PWR
3
1
2
3
1
2
SOFA
AUX
MUTE
MUTE
AUX
4
5
6
4
5
6
BUTTON SEQUENCE
BUTTON SEQUENCE
PRESS: 1, 2, 3, 4, 5, 6
PRESS: 1, 2, 3, 6, 5, 4
3 BUTTON SWITCH (NO SOFA & NO TV/VCP)
MOOD
READ
MUTE
1
2
3
4
5
6
BUTTON SEQUENCE
PRESS: 1, 2, 6, 3, 4, 5
THIS INSTRUCTIONS IS PROPRIETARY PROPERTY OF ELECTRO-MOTION INC. ANY INFORMATION CONTAINED HEREIN
IS NOT TO BE USED, COPIED OR RELEASED TO THIRD PARTIES WITHOUT EXPRESS WRITTEN CONSENT OF ELECTRO-MOTION INC.
PAGE 39
LABOR TIMES PICKUP TRUCK
FORD AND DODGE
Ford Dodge
Dr. Bottom Cover .................. 1.0
1.5
Dr. Back Cover...................... 1.0
1.5
Pass Bottom Cover .............. 1.0
1.5
Pass Back Cover .................. 1.0
1.5
Console Back Cover ............ .5
.5
Console Bottom Cover ...........5
.5
Jumpseat Back Cover.......... 1.5
1.5
Jumseat Bottom Cover ........ 1.5
1.5
98 Jumpseat Back Cover.... .5
.5
98 Jumseat Bottom Cover ... .5
.5
LABOR TIMES
NEW CHEVY DYNASTY OR ULTIMA
Dynasty Ultima
Complete Drivers Seat ......... .5
Complete Passenger Seat ... .5
Console ................................. .5
(LSSI CHEVY)
PAY GM FLAT RATE TIMES
.5
.5
.5
LX WITH OPTIONALGRAPHICS
LABOR TIMES
.2
.5
.2
1.0
.3
.3
HOOD LOGO - .2
HOOD TAPE - .3
SPORT TOP REAR LOGO - .2
CARGO DOOR REAR DRIVER GRAPHICS - .3
CARGO DOOR REAR PASSENGER GRAPHICS - .3
.3
.2
.3
.2
.2
LX WITH STANDARD GRAPHICS
LABOR TIMES
.2
.3
.5
.6
.3
.4
.3 .4
HOOD LOGO - .2
HOOD TAPE - .3
SPORT TOP REAR LOGO - .2
CARGO DOOR REAR DRIVER GRAPHICS - .3
CARGO DOOR REAR PASSENGER GRAPHICS - .3
.3 .5 .2
.3 .3
LE WITH OPTIONALGRAPHICS
LABOR TIMES
.2
.4
.4
.3
.4
1.0
.2
.4
HOOD LOGO - .2
HOOD TAPE - .3
SPORT TOP REAR LOGO - .2
CARGO DOOR REAR DRIVER GRAPHICS - .3
CARGO DOOR REAR PASSENGER GRAPHICS - .3
.4
.4
.2
.3
LE WITH STANDARD GRAPHICS
LABOR TIMES
.2
.3
.5
.3
.4 .4 .3
.4
HOOD LOGO - .2
HOOD TAPE - .3
SPORT TOP REAR LOGO - .2
CARGO DOOR REAR DRIVER GRAPHICS - .3
CARGO DOOR REAR PASSENGER GRAPHICS - .3
.4
.3 .4 .5 .2
.2
SE WITH OPTIONALGRAPHICS
LABOR TIMES
.2 .2
.4
.1
.3 .3
.1 .3
.4
HOOD LOGO - .2
HOOD TAPE - .3
SPORT TOP REAR LOGO - .2
CARGO DOOR REAR DRIVER GRAPHICS - .3
CARGO DOOR REAR PASSENGER GRAPHICS - .3
.3
.3
.2
.4 .3 .3
.2
SE WITH STANDARD GRAPHICS
LABOR TIMES
.2
.3
.5
.2
.2
.3
.3
HOOD LOGO - .2
HOOD TAPE - .3
SPORT TOP REAR LOGO - .2
CARGO DOOR REAR DRIVER GRAPHICS - .3
CARGO DOOR REAR PASSENGER GRAPHICS - .3
.2
.3
.3 .3
.4 .2