DODGE CARAVAN 2007 4.G Repair Manual

You should read the instructions provided with your
child restraint to make sure that you are using it properly.
2. All occupants should wear their lap and shoulder
belts properly.
3. The driver and front passenger seats should be
moved back as far as practical to allow the front airbags
room to inflate.
4. If your vehicle has window bags, do not lean against
the door, airbags will inflate forcefully into the space
between you and the door.
5. If the airbag system in this vehicle needs to be
modified to accommodate a disabled person, contact
the Customer Center. Phone numbers are provided in
the If You Need Customer Assistance section in this
manual.WARNING!
•Relying on the airbags alone could lead to more
severe injuries in a collision. The airbags work
with your seat belt to restrain you properly. In
some collisions the airbags won’t deploy at all.
Always wear your seat belts even though you
have airbags.
•Being too close to the steering wheel or instru-
ment panel during front airbag deployment could
cause serious injury. Airbags need room to inflate.
Sit back, comfortably extending your arms to
reach the steering wheel or instrument panel.
•If the vehicle has window bags, they also need
room to inflate. Do not lean against the door or
window. Sit upright in the center of the seat.
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Airbag System Components
The airbag system consists of the following:
•Occupant Restraint Controller (ORC)
•AIRBAG Light
•Driver Airbag
•Front Passenger Airbag
•Supplemental Side Curtain Airbags (If Equipped)
•Front Impact Sensors
•Side Impact Sensors (If Equipped)
•Steering Wheel and Column
•Instrument Panel
•Seat Belt Reminder Light
•Knee Impact Bolster
•Driver Inflatable Knee Blocker
•Front Passenger Seat Occupant Classification System
(OCS) — If Equipped
Occupant Classification Module
Passenger Airbag Disabled (PAD) Indicator Light
Interconnecting Wiring
Bladder Assembly
Belt Tension Sensor
•Front Seat Belt Buckle Pretensioners
How The Airbag System Works
•
The Occupant Restraint Controller (ORC) determines
if a frontal collision is severe enough to require the
airbags to inflate. Based on the level of collision
severity, the front control module determines the
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proper rate of inflation. The front airbag inflators are
designed to provide different rates of airbag inflation.
•The ORC may modify the rate of inflation based on the
occupant size provided by the Occupant Classification
Module.
•The ORC will not detect side, roll over, or rear impacts.
•The ORC monitors the readiness of the electronic parts
of the system whenever the ignition switch is in the
START or RUN positions. These include all of the
items listed above except the steering wheel and
column, instrument panel and passenger knee bol-
sters. If the key is in the OFF position, in the ACC
position, or not in the ignition, the airbags are not on
and will not inflate.
•Also, the ORC turns on the AIRBAG warn-
ing light and PAD indicator light in the
center of the instrument panel for 6 to 8
seconds for a self-check when the ignition is first turned on. After the self-check, the AIRBAG
warning light will turn off. The PAD indicator light
will function normally (Refer to “Passenger Airbag
Disable (PAD) Indicator Light” in this section). If the
ORC detects a malfunction in any part of the system, it
turns on the AIRBAG warning light either momen-
tarily or continuously. A single chime will sound if the
light comes on again after initial start up.
WARNING!
Ignoring the AIRBAG warning light in your instru-
ment panel could mean you won’t have the airbags
to protect you in a collision. If the light does not
come on, stays on after you start the vehicle, or if it
comes on as you drive, have the airbag system
checked right away.
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•TheDriver and Passenger Airbag/Inflator Units are
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.•The Side Impact SRS Side Curtain Bags are 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.
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•When the ORC and the side impact sensors (with side
impact option) detects a collision requiring the Driver
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.
•The Knee Impact Bolsters help 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 the Occupant
Classification System (OCS). The OCS system will classify 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
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and cushion needs to be serviced in any way (includ-
ing removal or loosening/tightening of seat attach-
ment 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
Passenger Airbag Disabled Light
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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.
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.•The Occupant Classification Module (OCM) — If
Equipped is located beneath the front passenger seat.
The OCM classifies the occupant into one of three size
categories 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.
•The Passenger Airbag Disabled (PAD) Indicator
Light — If Equipped indicates 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
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turned OFF. When the OCS system detects an adult the
PAD indicator light will be off, and the airbag will be
enabled.
•The Belt Tension Sensor (BTS) — If Equipped is
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.
•The Bladder Assembly — If Equipped is 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).
68 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

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.
•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.
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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.
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.
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