DODGE CARAVAN 2006 4.G Repair Manual

•TheDriver and Passenger Airbag/Inflator Unitsare
located in the center of the steering wheel and the right
side of the instrument panel. When the ORC and
impact sensors detects a collision requiring the air-
bags, it signals the inflator units. A large quantity of
nontoxic gas is generated to inflate the front airbags.
Different airbag inflation rates may be possible based
on collision severity and occupant size. The steering
wheel hub trim cover and the upper right side of the
instrument panel separate and fold out of the way as
the airbags inflate to their full size. The airbags fully
inflate in about 50–70 milliseconds. This is about half
of the time it takes to blink your eyes. The airbags then
quickly deflate while helping to restrain the driver and
front passenger.
The driver’s and passenger’s front airbag gas is vented
through the airbag material towards the instrument
panel. In this way the airbags do not interfere with
your control of the vehicle.•TheSide Impact SRS Window Bagsare designed to
activate only in certain side collisions. When the ORC
and the side impact sensors (with side impact option)
detects a collision requiring the window bags to
inflate, it signals the inflators on the crash side of the
vehicle. A quantity of nontoxic gas is generated to
inflate the window bag. The inflating window bag
pushes the outside edge of the headliner out of the
way and covers the window. The airbag inflates in
about 30 milliseconds (about one quarter of the time it
takes to blink your eyes) with enough force to injure
you if you are not belted and seated properly, or if
items are positioned in the area where the window bag
inflates. This especially applies to children. The win-
dow bag is only about 3
12inches (9 cm) thick when it
is inflated.
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 61
2

•When the ORC and the side impact sensors (with side
impact option) detects a collision requiring theDriver
Inflatable Knee Blocker, it signals the inflator unit. A
quantity of nontoxic gas is generated to inflate the
Driver Inflatable Knee Blocker. The Driver Inflatable
Knee Blocker inflates rearward towards the driver’s
knees to help protect the knees and position you for
the best interaction with the front airbag. The Driver
Inflatable Knee Blocker fully inflates in about 50
milliseconds, this is only about half of the time it takes
you to blink your eyes. It then quickly deflates while
helping to protect the driver’s knees.
•TheKnee Impact Bolstershelp protect the knees, and
position everyone for the best interaction with the
front airbag.
•If your vehicle contains a Passenger Airbag Disable
indicator light, it will be equipped with theOccupant
Classification System (OCS).The OCS system willclassify an occupant into a size category based on
sensor readings from within the seat cushion. Occu-
pants should try to remain in a normally seated
position. If the occupant’s weight is transferred to
another object in the vehicle (i.e. feet on the dash-
board), the OCS may not be able to properly approxi-
mate occupant size. Furthermore, the occupant size
may appear to increase or decrease due to objects
hanging on the seat, other passengers pushing on the
seat, or objects lodged underneath the seat. Ensure
that the front passenger seat back does not touch
anything placed on the back seat because this can also
affect occupant classification. Also, if you fold down
the rear seat, check to be sure it doesn’t touch the front
passenger seat.If there is a rapid change in temperature or humidity,
the OCS may not be able to properly approximate
occupant size. If your seat including your trim cover
and cushion needs to be serviced in any way (including
62 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

removal or loosening/tightening of seat attachment
bolts), take the vehicle to your authorized dealer. Only
manufacturer approved seat accessories may be used.
If there is a fault present in the system, the AIRBAG
warning light will illuminate indicating that you should
take the vehicle to an authorized dealer. In the presence
of an occupant in the passenger seat, if both the PAD
indicator light and AIRBAG warning light are illumi-
nated the airbag will be disabled.
The ORC will not allow front airbag deployment in the
event of a collision for occupants classified into the empty
or child size categories. The PAD indicator light will
illuminate indicating that the Passenger Airbag is OFF
when the OCS has determined that the occupant size
category is a child. Also, when the seat is empty or an
object that weighs less than a predetermined threshold is
placed on the seat, the light will remain OFF. (The PAD
indicator light is an amber light located on the center of the
instrument panel above the radio.)
For almost all sizes of properly seated adults, the airbag
will be enabled in the event of a collision. For small
teenagers and some small adults, depending on size, the
airbag may or may not be enabled in the event of a
collision. Both drivers and passengers should always use
the PAD indicator light as an indication if the front
passenger is properly positioned or not. If the PAD
indicator light comes on when an adult is in the passen-
ger seat, have the passenger re-position themselves in the
seat until the light goes out.
Passenger Airbag Disabled Light
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 63
2

Remember, if the PAD indicator light is illuminated the
passenger front airbag will not inflate. For almost all
properly installed child restraints, the“PAD Indicator
Light”will be illuminated indicating that the front pas-
senger airbag is turned off and will not inflate. If the
“PAD Indicator Light”is not illuminated, DO NOT
assume the airbag is turned off and move the child
restraint to the rear seat. A deploying passenger airbag
can cause death or serious injury to a child in a rear
facing infant seat.
NOTE:Even though this vehicle is equipped with an
Occupant Classification System, children 12 years and
under should always ride buckled up in a rear seat in an
appropriate child restraint.
•TheOccupant Classification Module (OCM)—If
Equippedis located beneath the front passenger seat.
The OCM classifies the occupant into one of three sizecategories based on the input from the Bladder Assem-
bly and Belt Tension Sensor. The size categories in-
clude empty, child, and adult. The OCM sends the
Occupant Classification to the ORC to identify if a
front passenger airbag is allowed. If a fault is present,
the AIRBAG warning light is illuminated.
•ThePassenger Airbag Disabled (PAD) Indicator
Light—If Equippedindicates to the driver and
passenger when the airbag is turned OFF in the
presence of a properly seated occupant. When the PAD
indicator light is illuminated, the airbag is OFF. Also,
when the Occupant Classification System detects ei-
ther an empty seat or a weight less than the predeter-
mined occupant threshold, the ORC will not illumi-
nate the PAD indicator light even though the airbag is
turned OFF. When the ocs system detects an adult the
PAD indicator light will be off, and the airbag will be
enabled.
64 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

•TheBelt Tension Sensor (BTS)—If Equippedis
located at the outboard passenger lap belt anchor. The
BTS generates a signal based on outboard lap belt
tension. This signal is sent to the OCM to ensure that
the resultant bladder pressure increase due to applied
lap belt tension does not cause a small occupant to be
classified as a larger occupant.
•TheBladder Assembly—If Equippedis located
beneath the seat cushion foam. The pressure sensor
sends a signal to the OCM.
The front passenger seat assembly contains critical com-
ponents that affect the front passenger airbag deploy-
ment. Correctly functioning front passenger seat compo-
nents are critical for the Occupant Classification System
(OCS) to properly classify the front passenger and calcu-
late the proper airbag deployment. Do not make any
modifications to the front passenger seat components,
assembly, or to the seat cover.
WARNING!
Unapproved modifications or service procedures to
the front passenger seat assembly, its related compo-
nents, or seat cover may inadvertently change the
airbag deployment in case of a frontal crash. This
could result in death or serious injury to the front
seat passenger if the vehicle is involved in an acci-
dent. A modified vehicle may not comply with
required Federal Motor Vehicle Safety Standards
(FMVSS).
The following requirements must be strictly adhered to:
•Do not modify the front passenger seat assembly or
components in any way.
•Do not modify the front seat center console or center
position seat in any way.
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 65
2

•Do not use prior or future model year seat covers not
designated for the specific model being repaired. Al-
ways use the correct seat cover specified for the
vehicle.
•Do not replace the seat cover with an aftermarket seat
cover.
•Do not add a secondary seat cover other than those
approved by DaimlerChrysler/Mopar.
•At no time should any supplemental restraint system
(SRS) component or SRS related component or fas-
tener be modified or replaced with any part except
those which are approved by DaimlerChrysler/
Mopar.
•For replacement of the bladder or seat cover assembly,
always use the DaimlerChrysler service kit which
includes the seat cover and bladder riveted together.
If A Deployment Occurs
The airbag system is designed to deploy the airbags
when the ORC and impact sensors detect a moderate-to-
severe collision, to help restrain the vehicle passengers,
and then immediately deflate.
NOTE:A collision that is not severe enough to need
airbag protection will not activate the system. This does
not mean something is wrong with the airbag system.
If you do have a collision which deploys the airbags, any
or all of the following may occur:
•The nylon airbag material may sometimes cause abra-
sions and/or skin reddening to the driver and front
passenger as the airbags deploy and unfold. The
abrasions are similar to friction rope burns or those
you might get sliding along a carpet or gymnasium
floor. They are not caused by contact with chemicals.
They are not permanent and normally heal quickly.
66 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

However, if you haven’t healed significantly within a
few days, or if you have any blistering, see your doctor
immediately.
•As the airbags deflate you may see some smoke-like
particles. The particles are a normal by-product of the
process that generates the nontoxic gas used for airbag
inflation. These airborne particles may irritate the skin,
eyes, nose, or throat. If you have skin or eye irritation,
rinse the area with cool water. For nose or throat
irritation, move to fresh air. If the irritation continues,
see your doctor. If these particles settle on your
clothing, follow the garment manufacturer’s instruc-
tions for cleaning.
•It is not advisable to drive your vehicle after the
airbags have deployed. If you are involved in another
collision, the airbags will not be in place to protect you.
WARNING!
Deployed airbags, front seat belt buckle pretension-
ers and driver inflatable knee blocker cannot protect
you in another collision. Have the airbags, front seat
belt buckle pretensioners and driver inflatable knee
blocker replaced by an authorized dealer as soon as
possible. Also, have the Occupant Classification
System serviced as well.
Enhanced Accident Response
If the airbags and seat belt pertensioners deploy after an
impact and the electrical system remains functional,
vehicles equipped with power door locks will unlock
automatically. In addition, approximately 10 seconds
after the vehicle has stopped moving, the interior lights
will illuminate until the ignition switch is turned off.
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 67
2

Maintaining Your Airbag System
WARNING!
•Modifications to any part of the airbag system could cause
it to fail when you need it. You could be injured because the
airbags are not there to protect you. Do not modify the
components or wiring, including adding any kind of
badges or stickers to the steering wheel hub trim cover or
the upper right side of the instrument panel. Do not modify
the front bumper, vehicle body structure, or frame.
•Do not attempt to modify any part of your advanced airbag
system. The airbag may inflate accidentally or may not
function properly if modifications are made. Take your
vehicle to an authorized dealer for any advanced airbag
system service. If your seat including your trim cover and
cushion needs to be serviced in any way (including removal
or loosening/tightening of seat attachment bolts), take the
vehicle to your authorized dealer. Only manufacturer ap-
proved seat accessories may be used. If it is necessary to
modify an advanced airbag system for persons with dis-
abilities, contact your authorized dealer.
WARNING!
•You need proper knee impact protection in a
collision. Do not mount or locate any aftermarket
equipment on or behind the knee bolsters.
•It is dangerous to try to repair any part of the
airbag system yourself. Be sure to tell anyone who
works on your vehicle that it has airbags.
Airbag Light
You will want to have the airbags ready to
inflate for your protection in a collision. While
the airbag system is designed to be mainte-
nance free, if any of the following occurs, have
an authorized dealer service the system immediately.
•The AIRBAG light does not come on or flickers during
the 6 to 8 seconds when the ignition switch is first
turned on.
68 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

•The light remains on or flickers after the 6 to 8 second
interval.
•The light flickers or comes on and remains on while
driving.
DaimlerChrysler Corporation Integrated Child
Seat—If Equipped
Operating instructions for this seat are included with the
seat. If the instructions are not with the seat or in the
Owner’s Manual Package, replacement instructions can
be obtained.
To obtain Integrated Child Seat replacement
instructions:
Use the order form at the back of this manual and specify
publication number 81-016-1950.
Child Restraint
Everyone in your vehicle needs to be buckled up at all
times—babies and children, too. Every state in the
United States and all Canadian provinces require that
small children ride in proper restraint systems. This is the
law, and you can be prosecuted for ignoring it.
Children 12 years and under should ride properly buck-
led up in a rear seat. According to crash statistics,
children are safer when properly restrained in the rear
seats, rather than in the front.
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 69
2

WARNING!
In a collision, an unrestrained child, even a tiny
baby, can become a missile inside the vehicle. The
force required to hold even an infant on your lap
could become so great that you could not hold the
child, no matter how strong you are. The child and
others could be badly injured. Any child riding in
your vehicle should be in a proper restraint for the
child’s size.
There are different sizes and types of restraints for
children from newborn size to the child almost large
enough for an adult safety belt. Always check the child
seat owner’s manual to ensure you have the right seat for
your child. Use the restraint that is correct for your child.
Infants and Child Restraints
•
Safety experts recommend that children ride
rearward-facing in the vehicle until they are at least
one year old and weigh at least 20 lbs (9 kg). Two types
of child restraints can be used rearward-facing: infant
carriers andconvertiblechild seats. Both types of
child restraints are held in the vehicle by the lap/
shoulder belt or the LATCH child restraint anchorage
system. Refer to“Lower Anchors and Tether for CHil-
dren (LATCH)”later in this section.
•The infant carrier is only used rearward-facing in the
vehicle. It is recommended for children who weigh up
to about 20 lbs (9 kg).Convertiblechild seats can be
used either rearward-facing or forward-facing in the
vehicle. Convertible child seats often have a higher
weight limit in the rearward-facing direction than
70 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE