8e electrical CHRYSLER VOYAGER 2004 Service Manual

and test again to be certain that the adjuster is not
at its travel limit. If the power seat track adjuster
still fails to operate in only one direction, refer to
Diagnosis and Testing Power Seat Switchin this
section. If the power seat track adjuster fails to oper-
ate in more than one direction, perform the following
tests. For complete circuit diagrams, refer to Wiring
Diagrams .
TESTING POWER SEAT TRACK MOTORS
(1) Check the power seat circuit breaker under the
seat. If OK, go to Step 2. If not OK, replace the
faulty power seat circuit breaker. (2) Check for battery voltage at the power seat cir-
cuit breaker under the seat. If OK, go to Step 3. If
not OK, repair the open fused B(+) circuit to the fuse
in the Intelligent Power Module as required. (3) Remove the outboard seat cushion side shield
from the seat. Disconnect the seat wire harness con-
nector from the power seat switch connector recepta-
cle. Check for battery voltage at the fused B(+)
circuit cavity of the power seat wire harness connec-
tor for the power seat switch. If OK, go to Step 4. If
not OK, repair the open fused B(+) circuit to the
power seat circuit breaker under the seat as
required. (4) Check for continuity between the ground cir-
cuit cavity of the power seat wire harness connector
for the power seat switch and a good ground. There
should be continuity. If OK, go to Step 5. If not OK,
repair the open ground circuit to ground as required. (5) Test the power seat switch. Refer to Diagnosis
and Testing Power Seat Switch in this section. If
the switch tests OK, test the circuits of the power
seat wire harness between the inoperative power seat
track adjuster motor and the power seat switch for
shorts or opens. If the circuits check OK, replace the
faulty power seat track unit. If the circuits are not
OK, repair the power seat wire harness as required.
REMOVAL
WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
UTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY. (1) Remove the appropriate seat from the vehicle
and place it on a clean work surface(Refer to 23 -
BODY/SEATS/SEAT - REMOVAL). (2) If the vehicle is so equipped, remove the Mem-
ory Seat/Mirror Module (MSMM) retaining screws. (3) If the vehicle is so equipped, disconnect the
MSMM electrical connectors and remove the MSMM
from the power seat track. (4) Remove the rear fabric blocker trim panel from
the rear of the front seat. (5) Remove the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION SIDE COVERS - REMOVAL). (6) Disconnect all electrical connectors connecting
the power seat track to the seat assembly. (7) Pull the seat back trim cover up slightly to
access and remove the two seat back frame mounting
bolts and also remove two seat back recliner bolts. (8) Remove four seat track mounting bolts from
the seat cushion pan. (9) Remove the power seat track from the seat.
INSTALLATION
(1) Position the seat cushion on the seat track.
(2) Install the four seat track retaining bolts in the
seat cushion pan. Torque the bolts to 28.5 N´m. (3) Position the seat back and install the two seat
back frame mounting bolts and the two seat back
recliner bolts. Torque the bolts to 55 N´m. (4) Route and connect the electrical connectors
between the power seat track and the seat assembly. (5) Install the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION SIDE COVERS - INSTALLATION). (6) Install the rear fabric blocker trim panel on the
rear of the front seat. (7) If the vehicle is so equipped, position the Mem-
ory Seat/Mirror Module (MSMM) and connect the
MSMM electrical connectors. (8) Install the MSMM retaining screws.
(9) Install the seat assembly in the vehicle (Refer
to 23 - BODY/SEATS/SEAT - INSTALLATION).
PASSENGER POWER SEAT
TRACK
DESCRIPTION
The four-way passenger side power seat option
includes a electrically operated power seat track unit
located under the passenger side front seat. The
power seat circuit breaker is mounted on the rear of
the power seat track, just behind the seat rear trim
panel. The lower half of the power seat track is
secured to the floor panel via four studs and nuts
that must be accessed from the underside of the vehi-
8Ns - 16 POWER SEAT SYSTEMRS
DRIVER POWER SEAT TRACK (Continued)

REMOVAL
WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
UTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.(1) Remove the appropriate seat from the vehicle
(Refer to 23 - BODY/SEATS/SEAT - REMOVAL). (2) Remove the rear fabric blocker trim panel from
the rear of the front seat. (3) Remove the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION SIDE COVERS - REMOVAL). (4) Disconnect all electrical connectors connecting
the power seat track to the seat assembly. (5) Pull the seat back trim cover up slightly to
access and remove the two seat back frame mounting
bolts and seat back recliner bolts. (6) Remove four seat track mounting bolts from
the seat cushion pan. (7) Remove the power seat track from the seat.
INSTALLATION
(1) Position the seat cushion on the seat track.
(2) Install the four seat track retaining bolts in the
seat cushion pan. Torque the bolts to 28.5 N´m. (3) Position the seat back and install the two seat
back frame mounting bolts and the two seat back
recliner bolts. Torque the bolts to 55 N´m. (4) Route and connect the electrical connectors
between the power seat track and the seat assembly. (5) Install the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION - INSTALLATION). (6) Install the rear fabric blocker trim panel on the
rear of the front seat. (7) Install the seat assembly in the vehicle (Refer
to 23 - BODY/SEATS/SEAT - INSTALLATION).
8Ns - 18 POWER SEAT SYSTEMRS
PASSENGER POWER SEAT TRACK (Continued)

(2) Turn the ignition key to the ON position. Exit
vehicle with the scan tool.
(3) After checking that no one is inside the vehicle,
connect the battery negative remote terminal.
(4) Read and record theACTIVEDiagnostic Trou-
ble Code (DTC) data.
(5) Read and record anySTOREDDTC's.
(6) Refer to the proper Body Diagnostic Procedures
manual if any DTC's are found in Step 4 and Step 5.
(7) If the airbag warning lamp either fails to light,
or goes ON and stays ON, there is a system malfunc-
tion. To test the airbag warning lamp (bulb) opera-
tion in the cluster, refer to Electrical, Instrument
Cluster, Diagnosis and Testing - Instrument Cluster.
Refer to the proper Body Diagnostic Procedures man-
ual for any other system problems.
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
AIRBAGS
DEPLOYED AIRBAG
The vehicle interior may contain a very small
amount of sodium hydroxide powder, a by-product of
airbag deployment. Sodium hydroxide powder can
irritate the skin, eyes, nose and throat. Wear safety
glasses, rubber gloves, and long sleeved clothing
when cleaning any of the powder residue from the
vehicle.
If you find that the cleanup is irritating your skin,
run cool water over the affected area. Also, if you
experience nasal or throat irritation, exit the vehicle
for fresh air until the irritation ceases. If irritation
continues, see a physician.
UNDEPLOYED AIRBAG
The airbags must be stored in its original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag module. When carrying or han-
dling an undeployed airbag module, the trim side of
the airbag should be pointing away from the body to
minimize possibility of injury if accidental deploy-
ment occurs. Do not place undeployed airbag face
down on a solid surface, the airbag will propel into
the air if accidental deployment occurs.
STANDARD PROCEDURE - SERVICE AFTER AN
AIRBAG DEPLOYMENT
DRIVER AIRBAG
After a Driver Airbag has been deployed due to a
collision, the followingMUSTbe replaced:
²Driver Airbag²Clock Spring Assembly
²Steering Wheel
²Complete Steering Column Assembly w/Lower
Steering Column Coupler
All other airbag and vehicle components should be
closely inspected following any airbag deployment,
and should be replaced when visible damage is
incurred.
PASSENGER AIRBAG
After a Passenger Airbag has been deployed due to
a collision. the followingMUSTbe replaced:
²Passenger Airbag
²Instrument Panel and Pad Assembly
All other airbag and vehicle components should be
closely inspected following any airbag deployment,
and should be replaced when visible damage is
incurred.
SEAT AIRBAG
After a Seat Airbag has been deployed due to a col-
lision. the followingMUSTbe replaced:
²Complete Seat Back Assembly
All other airbag and vehicle components should be
closely inspected following any airbag deployment,
and should be replaced when visible damage is
incurred.
SEAT BELTS AND TENSIONERS
After a frontal impact where an airbag has been
deployed due to a collision. the followingMUSTbe
replaced:
²Front Seat Belt Buckle (driver and passenger)
with integral Tensioners.
All other seat belts should be closely inspected for
cuts, tears, fraying, or damage in any way following
any frontal impact or airbag deployment. The other
seat belts are to be replaced when visible damage is
incurred. Inspect the Lower Anchors and Tether for
CHildren (LATCH) child restraint anchors for dam-
age after an impact event and replace as needed.
CLEAN UP PROCEDURE
Roll or fold the airbag towards its mounting point
(i.e. instrument panel, steering wheel, or seat back).
Then tape the ripped cover over the deployed airbag
if applicable.
Use a vacuum cleaner to remove any residual pow-
der from the vehicle interior. Work from the outside
in to avoid kneeling or sitting in a contaminated
area. Vacuum the heater and A/C outlets as well (Fig.
1). If the heater or air conditioner was in RECIRC
mode at time of airbag deployment, operate blower
motor on low speed and vacuum powder residue
expelled from the heater and A/C outlets. Multiple
RSRESTRAINTS8O-3
RESTRAINTS (Continued)

vacuum cleaning may be necessary to decontaminate
the interior of the vehicle.
CHILD RESTRAINT ANCHOR
DESCRIPTION
Vehicles manufactured for sale in the North Amer-
ican market are equipped with a Lower Anchors and
Tether for CHildren, or LATCH child restraint
anchorage system. The LATCH system provides for
the installation of suitable child restraints in certain
seating positions without using the standard equip-
ment seat belt provided for that seating position. The
second seat in these models are equipped with a
fixed-position child restraint upper tether anchor
(Fig. 3) and child restraint lower anchors (Fig. 2).
The third seat is equipped with only a fixed-position
child restraint upper tether anchor in the middle
seating position. Vehicles manufactured for sale out-
side of North America are equipped with fixed-posi-
tion child restraint upper tether anchors.
Vehicles manufactured for sale in North America
also have two lower anchors for each rear outboard
seating position (Fig. 2) in the second row seating
position. These anchors are welded to the seat cush-
ion frame. They are each accessed from the front of
their respective seats, at each side where the seat
back meets the seat cushion. These lower anchors
cannot be adjusted or repaired and, if faulty or dam-
aged, the seat must be replaced as a unit.
WARNING: DURING, AND FOLLOWING, ANY CHILD
RESTRAINT ANCHOR SERVICE, DUE TO IMPACT
EVENT OR VEHICLE REPAIR, CAREFULLY INSPECT
ALL MOUNTING HARDWARE, TETHER STRAPS
AND ANCHORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. IF A CHILD RESTRAINT
ANCHOR IS FOUND DAMAGED IN ANY WAY, THE
ANCHOR MUST BE REPLACED WITH THE SEAT
ASSEMBLY. FAILURE TO DO SO COULD RESULT IN
PERSONAL INJURY OR DEATH.
OPERATION
See the owner's manual in the vehicle glove box for
more information on the proper use of all of the fac-
tory-installed child restraint anchors.
CLOCK SPRING
DESCRIPTION
The clock spring is screwed to a plastic mounting
platform on the steering column behind the steering
wheel. The clock spring is used to maintain a contin-
uous electrical circuit between the wiring harness
and the drivers airbag.
OPERATION
This assembly consists of a flat ribbon like electri-
cally conductive tape which winds and unwinds with
the steering wheel rotation. The clock spring cannot
be repaired. If the clock spring is faulty, damaged, or
if the airbag has been deployed, the clock spring
must be replaced.
Fig. 1 VACUUM HEATER AND A/C OUTLETS -
TYPICAL
Fig. 2 CHILD RESTRAINT LOWER ANCHORS
SECOND ROW - LOCATION - TYPICAL
Fig. 3 CHILD RESTRAINT UPPER TETHER/ANCHOR
- 2ND ROW
8O - 4 RESTRAINTSRS
RESTRAINTS (Continued)

STANDARD PROCEDURE - CLOCK SPRING
CENTERING
If the rotating tape (wire coil) in the clock spring is
not positioned properly with the steering wheel and
the front wheels, the clock spring may fail. The fol-
lowing procedure MUST BE USED to center the
clock spring if it is not known to be properly posi-
tioned, or if the front wheels were moved from the
straight ahead position.
(1) Position steering wheel and front wheels
straight ahead.
(2) Release hood latch and open hood.
(3) Disconnect and isolate the battery negative
cable.
(4) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(5) Remove driver airbag from steering wheel
(Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER
AIRBAG - REMOVAL).
(6) Disconnect wire connectors from back of driver
airbag.
(7) Disconnect the 2±way connector from remote
radio control harness.
(8) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
(9) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(10) Rotate the clock spring rotor clockwise until
the rotor stops. Do not apply excessive force.
(11) From the end of travel, rotate the rotor two
turns counterclockwise until the wires end up at the
top.
(12) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(13) Connect the 4±way harness connector to the
speed control/horn harness to the clock spring.
(14) Connect the 2±way connector to the remote
radio control harness.
(15) Install the driver airbag (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION). Torque the two screws to 10 N´m (90 in.
lbs.).
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
REMOVAL
(1) Position steering wheel and front wheels
straight ahead.(2) Release hood latch and open hood.
(3) Disconnect and isolate the battery negative
cable.
(4) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(5) Remove driver airbag from steering wheel
(Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER
AIRBAG - REMOVAL).
(6) Disconnect wire connectors from back of driver
airbag.
(7) Disconnect the 2±way connector from remote
radio control harness.
(8) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
(9) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(10) Remove steering column shrouds and discon-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - REMOVAL).
(11) Disconnect 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(12) Remove clock spring from column assembly by
removing the two retaining screws that attach the
clock spring to the column.
INSTALLATION
(1) Install the clock spring on the column.
(2) Connect the 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(3) Install the steering column shrouds and con-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - INSTALLATION).
(4) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(5) Connect the 4±way harness connector to the
speed control/horn harness to the clock spring.
(6) Connect the 2±way connector to the remote
radio control harness.
(7) Install the driver airbag (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION). Torque the two screws to 10 N´m (90 in.
lbs.).
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
RSRESTRAINTS8O-5
CLOCK SPRING (Continued)

(7) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
INSTALLATION
DEPLOYED AIRBAG
(1) Perform clean up procedure (Refer to 8 - ELEC-
TRICAL/RESTRAINTS - STANDARD PROCEDURE
- SERVICE AFTER AN AIRBAG DEPLOYMENT).
(2) Install a new steering column assembly and
lower steering column coupler (Refer to 19 - STEER-
ING/COLUMN - INSTALLATION).
(3) Install the new clock spring.
(4) Connect the 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(5) Install the steering column shrouds and con-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - INSTALLATION).
(6) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(7) Connect the 4±way harness connector to the
speed control/horn harness to the clock spring.
(8) Connect the 2±way connector to the remote
radio control harness.
(9) Install the driver airbag and the two screws
retaining the airbag. Tighten screws to 10 N´m (90
in. lbs.)
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
UNDEPLOYED AIRBAG
(1) Connect the harness connector on the DAB
cover (horn, speed controls) to the clock spring.
(2) Connect the squib connectors to the DAB.
(3) Position a new airbag into the airbag cavity.
(4) Install the two screws retaining the airbag.
Tighten screws to 10 N´m (90 in. lbs.)
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
DRIVER AIRBAG TRIM COVER
REMOVAL
The horn switch is integral to the driver airbag
trim cover. If either component is faulty or damaged,
the entire driver airbag trim cover and horn switch
unit must be replaced.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge.
(2) Remove the driver airbag from the steering
wheel (Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL).
(3) Remove the plastic wire retainer that captures
the horn switch feed pigtail wire between the upper
left inflator stud and the inflator on the back of the
driver airbag housing and disconnect the speed con-
trol switches (if equipped).
(4) Remove the four nuts that secure the trim
cover retainer to the studs on the back of the driver
airbag housing.
(5) Remove the horn switch ground pigtail wire
eyelet terminal from the upper left airbag housing
stud.
(6) Remove the trim cover retainer from the airbag
housing studs.
(7) Disengage the six trim cover locking blocks
from the lip around the outside edge of the driver
airbag housing and remove the housing from the
cover.
INSTALLATION
(1) Install the housing into the cover. Engage the
six trim cover locking blocks to the lip around the
outside edge of the driver airbag housing.
(2) Install the trim cover retainer to the airbag
housing studs.
(3) Install the horn switch ground pigtail wire eye-
let terminal to the upper left airbag housing stud.
(4) Install the four nuts that secure the upper and
lower trim cover retainers to the studs on the back of
the driver airbag housing. Torque nuts to 6.8 N´m (60
in. lbs.).
(5) Install the plastic wire retainer that captures
the horn switch feed pigtail wire between the upper
left inflator stud and the inflator on the back of the
driver airbag housing.
(6) Connect speed control switches (if equipped).
(7) Install the driver airbag onto the steering
wheel (Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - INSTALLATION).
RSRESTRAINTS8O-7
DRIVER AIRBAG (Continued)

WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
OCCUPANT RESTRAINT
CONTROLLER
DESCRIPTION
The front driver and passenger airbag system is
designed to reduce the risk of fatality or serious
injury, caused by a frontal impact of the vehicle.
The Occupant Restraint Controller (ORC) is also
sometimes referred to as the Airbag Control Module
(ACM). The ORC contains the impact sensor and
energy reserve capacitor. It is mounted on a bracket,
under the instrument panel, just forward of the stor-
age bin. The ORC monitors the system to determine
the system readiness. The ORC contains on-board
diagnostics and will light the AIRBAG warning lamp
in the message center when a problem occurs.
OPERATION
The impact sensor provides verification of the
direction and severity of the impact. One impact sen-
sor is used. It is located inside the Occupant
Restraint Controller (ORC). The impact sensor is an
accelerometer that senses deceleration. The decelera-
tion pulses are sent to a microprocessor which con-
tains a decision algorithm. When an impact is severe
enough to require airbag protection, the ORC micro-
processor sends a signal that completes the electrical
circuit to the driver and passenger airbags. The
impact sensor is calibrated for the specific vehicle
and reacts to the severity and direction of an impact.
REMOVAL
NOTE: Diagnose the ORC using the service/diag-
nostic manual.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove storage bin from instrument panel.
Refer to Body, Instrument Panel, Storage Bin,
Removal.
(3) Remove three bolts holding ORC to floor
bracket.
(4) Disconnect the wire connector from ORC.
(5) Remove the ORC assembly from vehicle.
INSTALLATION
WARNING: DO NOT INSTALL ORC IF MOUNTING
LOCATION IS DEFORMED OR DAMAGED. THIS
WILL CAUSE THE ORC TO BE IMPROPERLY
LOCATED AND COULD RESULT IN OCCUPANT
PERSONAL INJURY OR DEATH.
CAUTION: Use correct screws when installing the
ORC.
(1) Install the ORC assembly into vehicle.
(2) Connect the wire connector to the ORC.
(3) Install three bolts holding ORC to floor
bracket. Torque bolts to 7.3 - 9.6 N´m (65 to 85 in.
lbs.)
(4) Install the storage bin onto the instrument
panel. Refer to Body, Instrument Panel, Storage Bin,
Installation.
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
PASSENGER AIRBAG
DESCRIPTION
WARNING: NEVER DISASSEMBLE THE PASSEN-
GER AIRBAG, THE PASSENGER AIRBAG HAS NO
SERVICEABLE PARTS. IF TAMPERED WITH INTER-
NALLY, THE AIRBAG COULD DEPLOY AND RESULT
IN PERSONAL INJURY OR DEATH.
The Passenger Airbag is located beneath the
instrument panel and pad assembly. The airbag is
mounted to the back side of the instrument panel
reinforcement.
The instrument panel top pad is the most visible
part of the passenger airbag system. Located under
the instrument panel top pad are the airbag door, the
passenger airbag cushion and the airbag cushion
supporting components.
The passenger airbag includes a magnesium hous-
ing within which the cushion and inflator are
mounted and sealed.
Following a passenger airbag deployment, the pas-
senger airbag and the instrument panel must be
replaced. The passenger airbag cannot be repaired,
and must be replaced if deployed or damaged in any
way.
8O - 8 RESTRAINTSRS
DRIVER AIRBAG TRIM COVER (Continued)

OPERATION
The passenger airbag is equipped with two infla-
tors, each with three levels of pressure output. The
inflators seal the hole in the airbag cushion so it can
discharge the gas it produces directly into the cush-
ion when supplied with the proper electrical signal.
Following an airbag deployment, the airbag cushion
quickly deflates by venting this gas through the
cushion material towards the instrument panel.
The passenger airbag is secured with screws to the
instrument panel beneath the instrument panel top
pad and above the glove box opening. The instrument
panel top pad above the glove box opening conceals
the airbag door and a predetermined hinge line
beneath its decorative cover. Upon airbag deploy-
ment, the top pad will bend at the hinge line and the
door will fold back out of the way onto the top of the
instrument panel.
When the front airbag system is deployed, the fol-
lowingMUSTbe replaced:
²Complete Steering Column Assembly.
²Lower Steering Column Coupler.
²Steering Wheel.
²Clock Spring.
²Driver Airbag.
²Passenger Airbag.
²Upper Instrument Panel with Pad.
CARE OF UNDEPLOYED AIRBAGS
Airbags must be stored in their original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag. When carrying or handling an
undeployed airbag, the trim side of the airbag should
be pointing away from the body to minimize possibil-
ity of injury if accidental deployment occurs. Do not
place undeployed airbag face down on a solid surface,
the airbag will propel into the air if accidental
deployment occurs.
REMOVAL
DEPLOYED AIRBAG
(1) Clean powder residue from interior of vehicle
(Refer to 8 - ELECTRICAL/RESTRAINTS - STAN-
DARD PROCEDURE - SERVICE AFTER AN AIR-
BAG DEPLOYMENT).
(2) Remove instrument panel (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
ASSEMBLY - REMOVAL).
(3) Remove all reusable components from the
upper instrument panel and transfer to the new
instrument panel.
UNDEPLOYED AIRBAG
(1) Open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Wait two minutes for the airbag system reserve
capacitor to discharge before attempting any airbag
or instrument panel service.
(4) Remove center console bin between front seats.
(5) Remove left front door sill plate using a trim
stick (special tool #C-4755) or equivalent, and gently
prying up on sill plate.
(6) Remove left cowl panel using a trim stick or
equivalent, and gently prying out on cowl panel.
(7) Remove four screws to lower steering column
cover and remove cover.
(8) Unsnap parking brake lever from knee blocker
reinforcement.
(9) Remove Data Link Connector (DLC) from knee
blocker.
(10) Remove screws to knee blocker.
(11) Unsnap left A-pillar lower extension trim
using a trim stick or equivalent.
(12) Remove three left side instrument panel A-pil-
lar retaining bolts and loosen the instrument panel
roll down bolt.
(13) Remove four nuts at brake pedal support
bracket to instrument panel.
(14) Using a trim stick or equivalent, gently pry
off left side upper A-pillar trim.
(15) Remove six screws and two wiring connectors
to lower instrument panel cubby bin at bottom of
center stack.
(16) Remove two left side nuts at instrument panel
center stack support to floor.
(17) Remove two right side nuts at instrument
panel center stack support to floor.
(18) Remove right front door sill plate using a trim
stick or equivalent, and gently prying up on sill
plate.
(19) Remove right cowl panel using a trim stick or
equivalent, and gently prying out on cowl panel.
(20) Using a trim stick or equivalent, gently pry
out on right instrument panel end cap.
(21) Unsnap right A-pillar lower extension trim
using a trim stick or equivalent.
(22) Remove three right side instrument panel
A-pillar retaining bolts and loosen the instrument
panel roll down bolt.
(23) Using a trim stick or equivalent, gently pry
off right side upper A-pillar trim.
(24) Open glove box, pinch in sides and roll down
towards floor. With a firm pull, snap glove box door
off hinges and remove.
(25) Using a trim stick or equivalent, gently pry
up on rear of instrument panel top cover and then
pull rearward and out.
RSRESTRAINTS8O-9
PASSENGER AIRBAG (Continued)

(26) Using a trim stick or equivalent, gently pry
off the filler bezel just above the cup holder to expose
the lower screws to center bezel.
(27) Remove two screws and then using a trim
stick or equivalent, gently pry off instrument panel
center bezel.
(28) Remove center bezel wiring connectors to
HVAC control and switch assembly (hazard, rear
wiper/washer, heated seats) and remove bezel.
(29) Slide cup holder assembly from instrument
panel.
(30) Remove nineteen screws to right lower instru-
ment panel trim (glove box surround), unplug glove
box lamp wire connector, and remove panel.
(31) Remove four screws and wiring connectors to
radio and remove radio.
(32) Remove one far left instrument panel speaker
retaining screw.
(33) Remove four screws along top front edge of
instrument panel cover/pad.
(34) Remove seven lower instrument panel cover/
pad retaining screws starting from right of vehicle
and only removing these seven, not all of them.
(35) Remove six upper fence line instrument panel
retaining bolts.
(36) Roll back instrument panel just enough to
increase access to the passenger airbag retaining
bolts at the reinforcement. Lift the instrument panel
up slightly so as not to damage the air distribution to
HVAC unit seal.
(37) Disconnect the passenger airbag electrical
connector. Using a trim stick or equivalent, gently
pry electrical connector off of instrument panel rein-
forcement.
(38) Remove the two passenger airbag to instru-
ment panel cover/pad retaining screws.
(39) Remove the three passenger airbag to instru-
ment panel reinforcement retaining bolts.
(40) Pull rearward slightly on the instrument
panel cover/pad to maneuver passenger airbag out
from reinforcement and instrument panel.
INSTALLATION
DEPLOYED AIRBAG
Transfer all reusable components to the new
instrument panel.
(1) Install new Passenger Airbag into instrument
panel.
(2) Install airbag attaching bolts to the instrument
panel.
(a) Torque the two bolts at instrument panel
retainer bosses to 2.7   .5 N´m (24   5 in. lbs.).
(b) Torque the three bolts that attach the pas-
senger airbag to cross-car beam to 10   2 N´m (90
  15 in. lbs.).(3) Connect yellow wire connector to passenger air-
bag and affix connector to instrument panel rein-
forcement with push pins.
(4) Install Instrument panel (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
ASSEMBLY - INSTALLATION).
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
UNDEPLOYED AIRBAG
(1) Pull rearward slightly on the instrument panel
cover/pad to maneuver passenger airbag up onto
reinforcement and instrument panel.
(2) Install the three passenger airbag to instru-
ment panel reinforcement retaining bolts but leave
loose. This will help align the passenger airbag for
the cover/pad fit.
(3) Install the two passenger airbag to instrument
panel cover/pad retaining screws. Torque screws to
2.7  .5 N´m (24   5 in. lbs.).
NOTE: Insure that the instrument panel cover/pad
locator pins are indexed properly at center stack
area prior to reassembly.
(4) Tighten the three passenger airbag to instru-
ment panel reinforcement retaining bolts. Torque
bolts to 10   2 N´m (90   15 in. lbs.).
(5) Connect the passenger airbag electrical connec-
tor. Install the connector onto the instrument panel
reinforcement with the push-pin fasteners.
(6) Roll the instrument panel forward lifting
slightly so as to seat the instrument panel air distri-
bution duct on top of the HVAC unit properly to
avoid any leaks or damage to the seal.
(7) Install six upper fence line instrument panel
retaining bolts.
(8) Install three right side instrument panel A-pil-
lar retaining bolts and tighten the right instrument
panel roll down bolt. Install the smaller 10 mm bolt
first to align the instrument panel properly.
(9) Install three left side instrument panel A-pillar
retaining bolts and tighten the left instrument panel
roll down bolt. Install the smaller 10 mm bolt first to
align the instrument panel properly.
(10) Install seven lower instrument panel cover/
pad retaining screws.
(11) Install four screws along top front edge of
instrument panel cover/pad.
(12) Install one far left instrument panel speaker
retaining screw.
8O - 10 RESTRAINTSRS
PASSENGER AIRBAG (Continued)

(13) Install wiring connectors to radio. Install
radio and four retaining screws.
(14) Connect glove box lamp wiring connector and
place right lower instrument panel trim (glove box
surround) into position.
(15) Install nineteen right lower instrument panel
trim (glove box surround) and install panel screws.
(16) Slide cup holder assembly into instrument
panel.
(17) Install center bezel wiring connectors to
HVAC control and switch assembly (hazard, rear
wiper/washer, heated seats).
(18) Install instrument panel center bezel by align-
ing slots and firmly snapping into place.
(19) Install two screws to instrument panel center
bezel.
(20) Align filler bezel above cup holder over retain-
ing slots and firmly snap into place.
(21) Place instrument panel top cover into position
and firmly snap down rear edge of top cover.
(22) Install glove box. Align hinges, snap into
place, roll glove box upwards and push in sides to
fully install.
(23) Align right side upper A-pillar trim over
retaining slots and firmly snap into place.
(24) Align right A-pillar lower extension trim over
retaining slots and firmly snap into place.
(25) Align right instrument panel end cap over
retaining slots and firmly snap into place.
(26) Align right cowl panel over retaining slots and
firmly snap into place.
(27) Align right front door sill plate over retaining
slots and firmly snap into place.
(28) Install two right side nuts at instrument
panel center stack support to floor.
(29) Install two left side nuts at instrument panel
center stack support to floor.
(30) Connect the two wiring connectors to lower
instrument panel cubby bin at bottom of center stack
and install six screws.
(31) Align left side upper A-pillar trim over retain-
ing slots and firmly snap into place.
(32) Install four nuts at brake pedal support
bracket to instrument panel.
(33) Align left A-pillar lower extension trim over
retaining slots and firmly snap into place.
(34) Install knee blocker and retaining screws.
(35) Install Data Link Connector (DLC) into bot-
tom of knee blocker.
(36) Align parking brake lever and snap into place
on knee blocker reinforcement.
(37) Install lower steering column cover and four
retaining screws
(38) Align left cowl panel over retaining slots and
firmly snap into place.(39) Align left front door sill plate over retaining
slots and firmly snap into place.
(40) Install center console bin between front seats.
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
(41) Close hood.
(42) Verify system and vehicle operation.
SEAT AIRBAG
DESCRIPTION
The side impact airbag system Seat Airbags are
located in the outboard side of the front seat backs.
One in each front seat. The seat airbag inflator
assembly is within the airbag housing (Fig. 5). Each
airbag is mounted to the seat back frame. If deployed
or defective, the entire seat back assembly must be
replaced.
OPERATION
Only the Side Impact Airbag Control Module
(SIACM) can deploy the side airbags. When supplied
with the proper electrical signal, the seat airbag
inflator will produce a gas and discharge the bag
directly between the occupant and the side of the
vehicle, protecting the occupant. Upon deployment,
Fig. 5 SEAT AIRBAG - TYPICAL
RSRESTRAINTS8O-11
PASSENGER AIRBAG (Continued)