Front door CHRYSLER VOYAGER 2005 Owner's Guide

²Occupant Classification Module- Vehicles
equipped with the Occupant Classification System
(OCS) include an Occupant Classification Module
(OCM) which is secured to a stamped steel mounting
bracket on the underside of the passenger side front
seat cushion frame.
²Occupant Restraint Controller- The Occu-
pant Restraint Controller (ORC) is also sometimes
referred to as the Airbag Control Module (ACM). The
ORC is located on a mount on the floor transmission
tunnel just underneath the instrument panel center
stack (Fig. 3).
²Passenger Airbag- The passenger airbag is
located on the instrument panel, beneath the instru-
ment panel top pad and above the glove box on the
passenger side of the vehicle (Fig. 3).
²Passenger Airbag Disabled (PAD) Indicator
- Vehicles equipped with the Occupant Classification
System (OCS) include a passenger airbag disabled
(PAD) indicator which is located in the instrument
panel center stack (Fig. 3).
²Passenger Knee Blocker- The passenger knee
blocker is a structural reinforcement that is integral
to and concealed within the glove box door (Fig. 3).
²Seat Belt Tensioner- A seat belt tensioner is
integral to both front seat belt buckles. The seat belt
buckles are secured to the inner seat frame sides,
beneath a cushion trim panel.
²Seat Weight Bladder and Pressure Sensor
Assembly- Vehicles equipped with the Occupant
Classification System (OCS) include a seat weight
bladder that is sandwiched between an insulator pad
on the top of the passenger side front seat pan and
the seat cushion foam padding. A short hose connects
the bladder to a pressure sensor which is secured to
the Occupant Classification Module (OCM) mounting
bracket on the underside of the passenger side front
seat cushion frame.
²Side Impact Sensors- Six side impact sensors
are used on vehicles equipped with the curtain air-
bags, three left side and three right side. The first
row side impact sensor is located in the B-pillar, just
above the front seat belt retractor. The second row
side impact sensor is located in the sliding side door
track opening, just in front of the C-pillar. The third
row side impact sensor is located behind the quarter
trim panel, above the rear tire wheel well, between
the C and D-pillars.
The ORC, the OCM, and the cluster each contain a
microprocessor and programming that allow them to
communicate with each other using the Programma-
ble Communications Interface (PCI) data bus net-
work. This method of communication is used by the
ORC for control of the airbag indicators.OPERATION
ACTIVE RESTRAINTS
The primary passenger restraints in this or any
other vehicle are the seat belts and child restraint
anchors. Seat belts and child restraint anchors are
referred to as an active restraint because the vehicle
occupants are required to physically fasten and prop-
erly adjust these restraints in order to benefit from
them. See the owner's manual in the vehicle glove
box for more information on the features, use and
operation of all of the active restraints.
PASSIVE RESTRAINTS
The passive restraints are referred to as a supple-
mental restraint system because they were designed
and are intended to enhance the protection for the
occupants of the vehicleONLYwhen used in con-
junction with the seat belts. They are referred to as
passive restraints because the vehicle occupants are
not required to do anything to make them operate;
however, the vehicle occupants must be wearing their
seat belts in order to obtain the maximum safety
benefit from the supplemental restraint system.
The supplemental restraint system electrical cir-
cuits are continuously monitored and controlled by a
microprocessor and software contained within the
Occupant Restraint Controller (ORC). An airbag indi-
cator in the ElectroMechanical Instrument Cluster
(EMIC) illuminates for about seven seconds as a bulb
test each time the ignition switch is turned to the
ON or START positions. Following the bulb test, the
airbag indicator is turned ON or OFF by the ORC to
indicate the status of the supplemental restraint sys-
tem. If the airbag indicator comes ON at any time
other than during the bulb test, it indicates that
there is a problem in the supplemental restraint sys-
tem electrical circuits. Such a problem may cause air-
bags not to deploy when required, or to deploy when
not required.
Deployment of the supplemental restraints
depends upon the angle and severity of an impact.
Deployment is not based upon vehicle speed; rather,
deployment is based upon the rate of deceleration as
measured by the forces of gravity (G force) upon the
impact sensors. When an impact is severe enough,
the microprocessor in the ORC signals the inflator of
the appropriate airbag units to deploy their airbag
cushions. The front seat belt tensioners are provided
with a deployment signal by the ORC in conjunction
with the front airbags. During a frontal vehicle
impact, the knee blockers work in concert with prop-
erly fastened and adjusted seat belts to restrain both
the driver and the front seat passenger in the proper
position for an airbag deployment. The knee blockers
also absorb and distribute the crash energy from the
8O - 4 RESTRAINTSRS
RESTRAINTS (Continued)

As the airbag cushion inflates it will drop down
from the roof rail between the edge of the headliner
and the side glass/body pillars to form a curtain-like
cushion to protect the vehicle occupants during a side
impact collision. The front and rear tethers keep the
side curtain bag taut, thus ensuring that the bag will
deploy in the proper position. Following the airbag
deployment, the airbag cushion quickly deflates by
venting the inert gas through the loose weave of the
cushion fabric, and the deflated cushion hangs down
loosely from the roof rail.
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.
Fig. 13 CURTAIN AIRBAG LOCATION - TYPICAL
Fig. 14 HEAD IMPACT COUNTER MEASURES
1 - SLIDING DOOR OPENING/ROOF RAIL
2 - CURTIAN AIRBAG
3 - HEAD IMPACT COUNTER MEASURES
8O - 14 RESTRAINTSRS
CURTAIN AIRBAG (Continued)

(3) Remove the headliner from the vehicle (Refer
to 23 - BODY/INTERIOR/HEADLINER -
REMOVAL).
(4) Disconnect the curtain airbag squib connector
(Fig. 15).
(5) Remove the bolt from the curtain airbag front
tether and unclip from the A-pillar (Fig. 16).(6) Remove the screws that secure the curtain air-
bag to the spring nuts in the roof side rail (Fig. 17).
(7) Remove the bolt from the curtain airbag infla-
tor mounting bracket (Fig. 18).
(8) Remove the bolts retaining the curtain airbag
to the roof rail in the d-pillar area (Fig. 19).
(9) Grasp the curtain airbag, using a trim stick
(special tool #C-4755) or equivalent, gently pry out on
push fasteners to disengage the curtain airbag and
remove it from its mounting location in the side roof
rail (Fig. 17).
(10) Remove the curtain airbag from the vehicle as
a unit.
Fig. 15 CURTAIN AIRBAG SQUIB CONNECTION
1 - CURTAIN AIRBAG INFLATOR
2 - CURTAIN AIRBAG SQUIB CONNECTOR
3 - C-PILLAR
Fig. 16 CURTAIN AIRBAG FRONT TETHER
ATTACHMENT
1 - A-PILLAR
2 - CURTAIN AIRBAG PUSH FASTENER
3 - CURTAIN AIRBAG FRONT TETHER
4 - CURTAIN AIRBAG FRONT TETHER ATTACHMENT HOOK/
BOLT
Fig. 17 CURTAIN AIRBAG REMOVE/INSTALL
1 - CURTAIN AIRBAG ATTACHMENT LOCATIONS
2 - SLIDING DOOR OPENING/ROOF RAIL
3 - CURTAIN AIRBAG
Fig. 18 CURTAIN AIRBAG INFLATOR MOUNTING
BRACKET ATTACHMENT
1 - CURTAIN AIRBAG INFLATOR MOUNTING BRACKET
2 - CURTAIN AIRBAG SQUIB CONNECTOR
3 - C-PILLAR
RSRESTRAINTS8O-15
CURTAIN AIRBAG (Continued)

SIDE IMPACT SENSORS
Three side impact sensors (Fig. 22) are used on
each side of the vehicle. These sensors are mounted
remotely from the bi-directional safing sensor that is
internal to the Occupant Restraint Controller (ORC).
The side and front impact sensors are identical in
construction and calibration and each impact sensor
is secured with two screws. Each side impact sensor
is secured with two screws. The first row side impact
sensor is located in the B-pillar, just above the front
seat belt retractor (Fig. 23). The second row side
impact sensor is located in the sliding door opening,in the lower door track area (Fig. 23). The third row
side impact sensor is located behind the quarter trim
panel, above the rear tire wheel well, between the C
and D-pillars (Fig. 23).
The impact sensor housing has an integral connec-
tor. A cavity in the center of the molded black plastic
impact sensor housing contains the electronic cir-
cuitry of the sensor which includes an electronic com-
munication chip and an electronic impact sensor.
Potting material fills the cavity to seal and protect
the internal electronic circuitry and components. The
side impact sensors are each connected to the vehicle
electrical system through a connector of the body
harness.
The side impact sensors cannot be repaired or
adjusted. If damaged or faulty, they must be
replaced. Refer to the proper body diagnostic infor-
mation for diagnosis and testing.
REMOVAL
FRONT IMPACT SENSOR
The right and left front impact sensors are
mounted identically on the front rail tips.
(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.
Fig. 23 SIDE IMPACT SENSOR LOCATION
1 - FRONT ROW SIDE IMPACT SENSOR 3 - THIRD ROW SIDE IMPACT SENSOR
2 - SECOND ROW SIDE IMPACT SENSOR
Fig. 22 SIDE IMPACT SENSOR
RSRESTRAINTS8O-19
IMPACT SENSOR (Continued)

(3) Hoist vehicle.
(4) Disconnect electrical connector (Fig. 24).
(5) Remove the two screws attaching front impact
sensor to outer rails (Fig. 24).
(6) Remove sensor from vehicle.
SIDE IMPACT SENSORS
B-PILLAR MOUNTED
The right and left front row side impact sensors,
are mounted identically, on opposite sides of the vehi-
cle, in the b-pillar.
(1) Open hood, disconnect and isolate the battery
negative cable.
(2)
WARNING: Wait two minutes for the system reserve
capacitor to discharge before beginning any airbag
component service. Personal injury or death may
result.
(3) Remove the B-pillar lower trim for the side of
the vehicle that you are replacing the side impact
sensor (Refer to 23 - BODY/INTERIOR/B-PILLAR
LOWER TRIM - REMOVAL).
(4) Disconnect the electrical connector from the
impact sensor (Fig. 25).
(5) Remove the four retaining screws to the impact
sensor bracket (Fig. 25).
(6) Remove impact sensor from vehicle (Fig. 26).
SLIDING DOOR OPENING MOUNTED
The right and left second row side impact sensors,
are mounted identically, on opposite sides of the vehi-cle, in the sliding door opening lower rear where the
lower roller arm mounts in the lower door track.
(1) Open hood, disconnect and isolate the battery
negative cable.
(2)
Fig. 24 FRONT IMPACT SENSOR REMOVE/INSTALL
1 - FRONT IMPACT SENSOR WIRE HARNESS RETAINER
2 - FRONT IMPACT SENSOR RETAINING SCREW
3 - FRONT IMPACT SENSOR WIRE HARNESS
4 - FRONT IMPACT SENSOR
5 - LOWER RADIATOR SUPPORT
Fig. 25 FRONT ROW SIDE IMPACT SENSOR AND
BRACKET
1 - B-PILLAR
2 - FRONT ROW SIDE IMPACT SENSOR ELECTRICAL
CONNECTOR
3 - FRONT ROW SIDE IMPACT SENSOR AND MOUNTING
BRACKET
4 - FRONT ROW SIDE IMPACT SENSOR RETAINING SCREW
Fig. 26 FRONT ROW SIDE IMPACT SENSOR/
BRACKET
1 - FRONT ROW SIDE IMPACT SENSOR
2 - SENSOR TO BRACKET ATTACHMENT
3 - FRONT ROW SIDE IMPACT SENSOR MOUNTING BRACKET
8O - 20 RESTRAINTSRS
IMPACT SENSOR (Continued)

WARNING: Wait two minutes for the system reserve
capacitor to discharge before beginning any airbag
component service. Personal injury or death may
result.
(3) Open sliding door to the fullest open position.
(4) Remove the two retaining screws to the impact
sensor (Fig. 27).
(5) Disconnect the electrical connector from the
impact sensor and remove from vehicle (Fig. 27).
QUARTER PANEL MOUNTED
(1) Open hood, disconnect and isolate the battery
negative cable.
(2)
WARNING: Wait two minutes for the system reserve
capacitor to discharge before beginning any airbag
component service. Personal injury or death may
result.
(3) Remove 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 - REMOVAL).
(4) Remove the two retaining screws to the impact
sensor (Fig. 28).
(5) Disconnect the electrical connector from the
impact sensor and remove from vehicle (Fig. 28).
INSTALLATION
FRONT IMPACT SENSOR
(1) Position sensor in vehicle (Fig. 24).
(2) Install the two retaining screws to the impact
sensor (Fig. 24). Torque screws to 7 N´m (62 in. lbs.).
(3) Connect electrical connector (Fig. 24).
(4) Lower vehicle from hoist.
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.
SIDE IMPACT SENSORS
B-PILLAR MOUNTED
(1) Position sensor bracket in vehicle (Fig. 25).
(2) Install the four retaining screws to the impact
sensor bracket (Fig. 25). Torque screws to 7 N´m (62
in. lbs.).
(3) Connect the electrical connector (Fig. 25).
(4) Install the B-pillar lower trim for the side of
the vehicle that you are replacing the side impact
sensor (Refer to 23 - BODY/INTERIOR/B-PILLAR
LOWER TRIM - INSTALLATION).
Fig. 27 2ND ROW SIDE IMPACT SENSOR
1 - 2ND ROW SIDE IMPACT SENSOR ELECTRICAL CONNECTOR
2 - 2ND ROW SIDE IMPACT SENSOR RETAINING SCREWS
3 - SLIDING DOOR LOWER ROLLER ARM
Fig. 28 3RD ROW SIDE IMPACT SENSOR
1 - 3RD ROW SIDE IMPACT SENSOR
2 - 3RD ROW SIDE IMPACT SENSOR MOUNTING SCREWS
3 - REAR SPEAKER
4 - REAR WHEEL WELL
RSRESTRAINTS8O-21
IMPACT SENSOR (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)