warning CHRYSLER VOYAGER 2005 Owners Manual

WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
(5) Verify vehicle and system operation.
(6) Close hood.
SLIDING DOOR OPENING MOUNTED
(1) Connect electrical connector (Fig. 27).
(2) Position sensor in vehicle (Fig. 27).
(3) Install the two retaining screws to the impact
sensor (Fig. 27). Torque screws to 7 N´m (62 in. lbs.).
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
(4) Verify vehicle and system operation.
(5) Close hood.
QUARTER PANEL MOUNTED
(1) Position sensor in vehicle (Fig. 28).
(2) Connect electrical connector (Fig. 28).
(3) Install the two retaining screws to the impact
sensor (Fig. 28). Torque screws to 7 N´m (62 in. lbs.).
(4) Install the quarter trim panel for the side of
the vehicle that you are replacing the side impact
sensor (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - INSTALLATION).
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
(5) Verify vehicle and system operation.
(6) Close hood.
KNEE BLOCKER AIRBAG
DESCRIPTION
The Knee Blocker Airbag (Fig. 29) is located on the
driver side of the vehicle beneath the instrument
panel under steering column cover (Fig. 30).
The knee blocker airbag includes one reaction plate
and one load plate, within which the cushion and
inflator are mounted and sealed. Following a knee
blocker airbag deployment, the knee blocker airbag
and instrument panel assembly must be replaced.
Refer to the proper diagnostic information for diagno-
sis and testing.
OPERATION
The knee blocker airbag is equipped with a single
inflator. When the Occupant Restraint Controller
(ORC) sends the proper electrical signals to the initi-
ator, the electrical energy generates enough heat to
initiate a small pyrotechnic charge which, in turn
ignites chemical pellets within the inflator. Once
ignited, these chemical pellets burn rapidly and pro-
duce a large quantity of inert gas. The inflator is
sealed to the back of the airbag housing and a dif-
fuser in the inflator directs all of the inert gas into
the airbag cushion, causing the cushion to inflate. As
the cushion inflates, the knee blocker airbag trim
deploy. Following an airbag deployment, the airbag
cushion quickly deflates by venting the inert gas
towards the instrument panel through vent holes
within the fabric used to construct the back panel of
the airbag cushion.
Some of the chemicals used to create the inert gas
may be considered hazardous while in their solid
state before they are burned, but they are securely
sealed within the airbag inflator. Typically, the poten-
tially hazardous chemicals are burned during an air-
bag deployment event.
WARNING: The inert gas that is produced when the
chemicals are burned is harmless. However, a small
amount of residue from the burned chemicals may
cause some temporary discomfort if it contacts the
skin, eyes, or breathing passages. If skin or eye irri-
tation is noted, rinse the affected area with plenty
of cool, clean water. If breathing passages are irri-
tated, move to another area where there is plenty of
clean, fresh air to breath. If the irritation is not alle-
viated by these actions, contact a physician.
Fig. 29 KNEE BLOCKER AIRBAG
8O - 22 RESTRAINTSRS
IMPACT SENSOR (Continued)

REMOVAL
(1) Open hood, disconnect and isolate the battery
negative cable.
(2)
WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to
do so may result in accidental airbag deployment,
personal injury or death.
(3) Remove the steering column opening cover two
retaining screws (Fig. 31) and unsnap cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - REMOVAL).
(4) Disconnect the knee blocker airbag electrical
connector (Fig. 32).
(5) Remove five knee blocker airbag retaining bolts
from airbag (Fig. 33).
(6) Remove knee blocker airbag from vehicle.
INSTALLATION
(1) Place the knee blocker airbag into position in
the instrument panel opening (Fig. 33).
(2) Connect the one electrical connector (Fig. 32).
(3) Install the five knee blocker airbag retaining
bolts (Fig. 33).
(4) Position the steering column opening cover
over retaining slots and firmly snap into place (Fig.
31). Install the two retaining screws (Fig. 31) (Refer
to 23 - BODY/INSTRUMENT PANEL/STEERING
COLUMN OPENING COVER - INSTALLATION).
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
(5) Verify vehicle and system operation.
(6) Close hood.
Fig. 30 KNEE BLOCKER AIRBAG LOCATION
1 - KNEE BLOCKER AIRBAG 3 - UNDER STEERING COLUMN COVER RETAINING SCREWS
2 - UNDER STEERING C0LUMN COVER
RSRESTRAINTS8O-23
KNEE BLOCKER AIRBAG (Continued)

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

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

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

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

WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to
do so may result in accidental airbag deployment,
personal injury or death.
(4) Clean powder residue from interior of vehicle
(Refer to 8 - ELECTRICAL/RESTRAINTS - STAN-
DARD PROCEDURE - SERVICE AFTER AN AIR-
BAG DEPLOYMENT).
(5) Remove instrument panel (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
ASSEMBLY - REMOVAL).
(6) 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)
WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to
do so may result in accidental airbag deployment,
personal injury or death.
(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.
(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.
RSRESTRAINTS8O-31
PASSENGER AIRBAG (Continued)

(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 negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
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.
(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.
8O - 32 RESTRAINTSRS
PASSENGER AIRBAG (Continued)

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

²The ORC receives an occupant classification
message indicating that the passenger front seat is
empty.
²The seat is occupied by a load equal to or
greater than a fifth percentile female.
²OR, until the ignition switch is turned to the
OFF position, whichever of these three occurs first.
²Load Undetermined Occupant Classifica-
tion Message- Each time the ORC receives a mes-
sage from the OCM indicating that a load cannot be
determined in the passenger front seat, the passen-
ger airbag and seat belt tensioner deployment cir-
cuits are deactivated and the PAD indicator will be
illuminated. The indicator remains illuminated until:
²The ORC receives an occupant classification
message indicating that the passenger front seat is
empty.
²The seat is occupied by a load equal to or
greater than a fifth percentile female.
²OR, until the ignition switch is turned to the
OFF position, whichever of these three occurs first.
²Communication Error- If the ORC receives
invalid occupant classification messages or no mes-
sages from the OCM, the PAD indicator is illumi-
nated. The indicator remains illuminated until:
²The ORC receives an occupant classification
message indicating that the passenger front seat is
empty.
²The seat is occupied by a load equal to or
greater than a fifth percentile female.
²OR, until the ignition switch is turned to the
OFF position, whichever of these three occurs first.
The ORC continually monitors the occupant classi-
fication messages from the OCM to decide whether
the passenger airbag and seat belt tensioner deploy-
ment circuits should be activated or deactivated.
Note that there may be several seconds of delay
between changes in the detected occupant status and
PAD indications. This is a programmed feature of the
OCM used to prevent a flashing indicator condition
resulting from the normal shifting of occupant weight
on the passenger seat cushion. The ORC then pro-
vides the proper control output to turn the PAD indi-
cator ON or OFF.
The ORC will store a Diagnostic Trouble Code
(DTC) for any malfunction it detects. For proper
diagnosis of the OCM, the ORC, the PCI data bus, or
the electronic message inputs to the ORC that con-
trol the PAD indicator, use a scan tool and the appro-
priate diagnostic information.REMOVAL
(1) Open hood.
(2) Disconnect and isolate the battery negative
cable.
(3)
WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to
do so may result in accidental airbag deployment,
personal injury or death.
(4) Remove instrument panel center bezel (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL CENTER BEZEL - REMOVAL).
(5) From the back of the center bezel, depress the
two latches toward the indicator housing and push
the indicator out through the face of the center bezel.
INSTALLATION
(1) From the face of the instrument panel center
bezel, align the Passenger Airbag Disabled (PAD)
indicator housing with the mounting hole.
(2) Firmly push the indicator into the center bezel
until the two latches are fully engaged on the back of
the cap and are snapped in.
(3) Install the instrument panel center bezel (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL CENTER BEZEL - INSTALLATION).
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
WARNING: Following successful completion of the
Airbag System test procedure, the Occupant Classi-
fication System Verification Test must be done
using a scan tool and the appropriate diagnostic
information.
(4) Close hood.
(5) Verify system and vehicle operation.
8O - 34 RESTRAINTSRS
PASSENGER AIRBAG DISABLED INDICATOR (Continued)