obs JEEP GRAND CHEROKEE 2003 WJ / 2.G Service Manual

WARNING: THE FRONT IMPACT SENSOR ENABLES
THE SYSTEM TO DEPLOY THE FRONT SUPPLE-
MENTAL RESTRAINTS. NEVER STRIKE OR DROP
THE FRONT IMPACT SENSOR, AS IT CAN DAMAGE
THE IMPACT SENSOR OR AFFECT ITS CALIBRA-
TION. IF AN IMPACT SENSOR IS ACCIDENTALLY
DROPPED DURING SERVICE, THE SENSOR MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER FRONT SUPPLEMENTAL RESTRAINT
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(2) Remove the headlamp mounting module from
the front of the vehicle. (Refer to 23 - BODY/EXTE-
RIOR/HEADLAMP MOUNTING MODULE -
REMOVAL).
(3) Disconnect the right or left headlamp and dash
wire harness connector for the front impact sensor
from the sensor connector receptacle.
(4) Remove the three screws that secure the right
or left front impact sensor and bracket unit to the
right or left radiator support vertical member (Fig.
26).
(5) Remove the right or left front impact sensor
and bracket unit from the front of the vehicle.INSTALLATION
The front and side impact sensors are interchange-
able except that the front impact sensors are serviced
with a right or left mounting bracket, while the side
impact sensors use no mounting bracket. If a front
impact sensor is faulty, but not damaged, the sensor
may be removed from the sensor mounting bracket
and replaced with a side impact sensor. If the front
impact sensor or the sensor mounting bracket are
damaged in any way, or if proper tightening torque of
the screws that secure the sensor to the bracket can-
not be achieved, the front impact sensor and bracket
must be replaced as a unit.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: THE FRONT IMPACT SENSOR ENABLES
THE SYSTEM TO DEPLOY THE FRONT SUPPLE-
MENTAL RESTRAINTS. NEVER STRIKE OR DROP
THE FRONT IMPACT SENSOR, AS IT CAN DAMAGE
THE IMPACT SENSOR OR AFFECT ITS CALIBRA-
TION. IF AN IMPACT SENSOR IS ACCIDENTALLY
DROPPED DURING SERVICE, THE SENSOR MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER FRONT SUPPLEMENTAL RESTRAINT
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) Position the right or left front impact sensor
and bracket unit to the front of the vehicle (Fig. 26).
(2) Position the right or left front impact sensor
and bracket unit to the right or left radiator support
vertical member.
(3) Loosely install the three screws that secure the
right or left front impact sensor and bracket unit
right or left radiator support vertical member.
Fig. 26 Front Impact Sensor & B Remove/Install
1 - RADIATOR SUPPORT
2 - SCREW (3)
3 - BRACKET
4 - WIRE HARNESS CONNECTOR
5 - IMPACT SENSOR
8O - 26 RESTRAINTSWJ
FRONT IMPACT SENSOR & BRACKET (Continued)

INSTALLATION
The following procedure is for replacement of a
faulty or damaged passenger airbag. If the airbag is
faulty or damaged, but not deployed, review the rec-
ommended procedures for handling non-deployed
supplemental restraints. (Refer to 8 - ELECTRICAL/
RESTRAINTS - STANDARD PROCEDURE - HAN-
DLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the passenger airbag has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the airbag from the vehicle. (Refer to
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
CEDURE - SERVICE AFTER A SUPPLEMENTAL
RESTRAINT DEPLOYMENT).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: WHEN REMOVING A DEPLOYED AIR-
BAG, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE PAS-
SENGER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE INSTRUMENT PANEL TOP PAD. FAILURE
TO OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.WARNING: THE INSTRUMENT PANEL TOP PAD
MUST NEVER BE PAINTED. REPLACEMENT TOP
PADS ARE SERVICED IN THE ORIGINAL COLORS.
PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TOP PAD RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
(1) Carefully position the passenger airbag onto
the instrument panel structural duct (Fig. 32).
(2) Install and tighten the four screws that secure
the passenger airbag to the instrument panel struc-
tural duct. Tighten the screws to 11.8 N´m (105 in.
lbs.).
(3) Reconnect the instrument panel wire harness
connector for the passenger airbag to the passenger
airbag pigtail wire connector. This connector is
secured to the outside of the outboard airbag unit
end bracket. Be certain that the latch on the connec-
tor and the red Connector Position Assurance (CPA)
lock are each fully engaged.
(4) Reinstall the top pad onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL TOP PAD - INSTALLA-
TION).
(5) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).
REAR CENTER SEAT BELT &
RETRACTOR
REMOVAL
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
8O - 32 RESTRAINTSWJ
PASSENGER AIRBAG (Continued)

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: WHEN REMOVING A DEPLOYED AIR-
BAG, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE SIDE
CURTAIN AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE SIDE CURTAIN AIRBAG CUSHION
AND THE HEADLINER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(2) Remove the headliner from the vehicle. (Refer
to 23 - BODY/INTERIOR/HEADLINER - REMOV-
AL).
(3) Disconnect the body wire harness connector for
the side curtain airbag inflator from the inflator con-
nector receptacle (Fig. 44).
(4) Disengage the side curtain airbag rear tether
hook and plastic retainer clip from the slot in the
roof rail near the D-pillar.
(5) Disengage the side curtain airbag front tether
hook and plastic retainer clip from the slot in the
lower A-pillar (Fig. 45).
(6) Disengage the side curtain airbag front tether
plastic retainer from the hole in the upper A-pillar.
Fig. 43 Side Curtain Airbag
1 - NUT (9)
2 - REAR TETHER
3 - SCREW (9)
4 - INFLATOR5 - MANIFOLD
6 - PUSH-IN FASTENER (4)
7 - CHANNEL
8 - FRONT TETHER
8O - 40 RESTRAINTSWJ
SIDE CURTAIN AIRBAG (Continued)

INSTALLATION
The following procedure is for replacement of a
faulty or damaged side curtain airbag. If the airbag
is faulty or damaged, but not deployed, review the
recommended procedures for handling non-deployed
supplemental restraints. (Refer to 8 - ELECTRICAL/
RESTRAINTS - STANDARD PROCEDURE - HAN-
DLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the side curtain airbag has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the airbag from the vehicle. (Refer to
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
CEDURE - SERVICE AFTER A SUPPLEMENTAL
RESTRAINT DEPLOYMENT).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: WHEN REMOVING A DEPLOYED AIR-
BAG, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE SIDE
CURTAIN AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE SIDE CURTAIN AIRBAG CUSHION
AND THE HEADLINER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
(1) Position the side curtain airbag into the vehicle
as a unit.(2) Align the push-in fastener that secures the
inflator of the side curtain airbag to the locating hole
in the roof side rail and, using hand pressure, push
firmly on the retainer until it is fully seated (Fig. 45).
(3) Align the three push-in fasteners that secure
the extruded plastic channel of the side curtain air-
bag to the locating holes in the roof side rail and,
using hand pressure, push firmly on each retainer
until it is fully seated.
(4) Install and tighten the nine screws that secure
the side curtain airbag channel and inflator mount-
ing bracket to the spring nuts in the roof side rail.
Tighten the screws to 6 N´m (50 in. lbs.).
(5) Align the side curtain airbag front tether plas-
tic retainer with the hole in the upper A-pillar and,
using hand pressure, push firmly on the retainer
until it is fully seated.
(6) Engage the side curtain airbag front tether
hook and plastic retainer clip into the slot in the
lower A-pillar.
(7) Engage the side curtain airbag rear tether
hook and plastic retainer clip into the slot in the roof
rail near the D-pillar (Fig. 44).
(8) Reconnect the body wire harness connector for
the side curtain airbag inflator to the inflator connec-
tor receptacle.
(9) Reinstall the headliner into the vehicle. (Refer
to 23 - BODY/INTERIOR/HEADLINER - INSTALLA-
TION).
(10) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).
SIDE IMPACT SENSOR
DESCRIPTION
Two side impact sensors are used on this model
when it is equipped with the optional side curtain
airbags, one each for the left and right sides of the
vehicle (Fig. 46). These sensors are mounted
remotely from the bi-directional safing sensor that is
internal to the Airbag Control Module (ACM). The
side and front impact sensors are identical in con-
struction and calibration with the exception of the
right-hand and left-hand die cast aluminum mount-
ing brackets to which each front impact sensor is
secured with two screws. The side impact sensors are
secured with two screws to the base of the right and
left B-pillars just below the front seat belt retractors
and behind the lower B-pillar trim within the pas-
senger compartment.
8O - 42 RESTRAINTSWJ
SIDE CURTAIN AIRBAG (Continued)

The impact sensor housing has an integral connec-
tor receptacle and two integral mounting ears, each
with a metal sleeve to provide crush protection. 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 dedicated take out and
connector of the airbag overlay wire harness.
The side impact sensors cannot be repaired or
adjusted and, if damaged or faulty, they must be
replaced.
OPERATION
The side impact sensors are electronic accelerome-
ters that sense the rate of vehicle deceleration, which
provides verification of the direction and severity of
an impact. Each sensor also contains an electronic
communication chip that allows the unit to commu-
nicate the sensor status as well as sensor fault infor-
mation to the microprocessor in the Airbag Control
Module (ACM). The ACM microprocessor continu-
ously monitors all of the passive restraint system
electrical circuits to determine the system readiness.
If the ACM detects a monitored system fault, it sets
a Diagnostic Trouble Code (DTC) and controls the
airbag indicator operation accordingly.
The impact sensors each receive battery current and
ground through dedicated left and right sensor plus
and minus circuits from the ACM. The impact sensors
and the ACM communicate by modulating the voltage
in the sensor plus circuit. The hard wired circuits
between the side impact sensors and the ACM may bediagnosed and tested using conventional diagnostic
tools and procedures. However, conventional diagnos-
tic methods will not prove conclusive in the diagnosis
of the ACM or the impact sensors. The most reliable,
efficient, and accurate means to diagnose the impact
sensors, the ACM, and the electronic message commu-
nication between the sensors and the ACM requires
the use of a DRBIIItscan tool. Refer to the appropri-
ate diagnostic information.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: THE SIDE IMPACT SENSOR ENABLES
THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIR-
BAG. NEVER STRIKE OR DROP THE SIDE IMPACT
SENSOR, AS IT CAN DAMAGE THE IMPACT SEN-
SOR OR AFFECT ITS CALIBRATION. IF AN IMPACT
SENSOR IS ACCIDENTALLY DROPPED DURING
SERVICE, THE SENSOR MUST BE SCRAPPED AND
REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER SIDE CUR-
TAIN AIRBAG DEPLOYMENT AND POSSIBLE
OCCUPANT INJURIES.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(2) Remove the trim from the lower right or left
B-pillar. (Refer to 23 - BODY/INTERIOR/B-PILLAR
LOWER TRIM - REMOVAL).
(3) Disconnect the airbag overlay wire harness
connector for the right or left side impact sensor from
the sensor connector receptacle (Fig. 47).
(4) Remove the two screws that secure the right or
left side impact sensor to the B-pillar.
(5) Remove the side impact sensor from the B-pil-
lar.
Fig. 46 Side Impact Sensor
1 - SENSOR
2 - CONNECTOR RECEPTACLE
WJRESTRAINTS 8O - 43
SIDE IMPACT SENSOR (Continued)

INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTALRESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: THE SIDE IMPACT SENSOR ENABLES
THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIR-
BAG. NEVER STRIKE OR DROP THE SIDE IMPACT
SENSOR, AS IT CAN DAMAGE THE IMPACT SEN-
SOR OR AFFECT ITS CALIBRATION. IF AN IMPACT
SENSOR IS ACCIDENTALLY DROPPED DURING
SERVICE, THE SENSOR MUST BE SCRAPPED AND
REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER SIDE CUR-
TAIN AIRBAG DEPLOYMENT AND POSSIBLE
OCCUPANT INJURIES.
(1) Position the right or left side impact sensor
onto the B-pillar (Fig. 47).
(2) Install and tighten the two screws that secure
the right or left side impact sensor to the B-pillar.
Tighten the screws to 12 N´m (105 in. lbs.).
(3) Reconnect the airbag overlay wire harness con-
nector for the right or left side impact sensor to the
sensor connector receptacle.
(4) Reinstall the trim onto the lower right or left
B-pillar. (Refer to 23 - BODY/INTERIOR/B-PILLAR
LOWER TRIM - INSTALLATION).
(5) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).
Fig. 47 Side Impact Sensor Remove/Install
1 - B-PILLAR
2 - SIDE IMPACT SENSOR
3 - SCREW (2)
4 - WIRE HARNESS CONNECTOR
8O - 44 RESTRAINTSWJ
SIDE IMPACT SENSOR (Continued)

(4) Install airbag module. Refer to Group 8M, Pas-
sive Restraint Systems.
(5) Connect negative battery cable.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoir is a plastic storage tank con-
nected to an engine vacuum source by vacuum lines.
OPERATION
The vacuum reservoir is used to supply the vac-
uum needed to maintain proper speed control opera-
tion when engine vacuum drops, such as in climbing
a grade while driving. A one-way check valve is used
in the vacuum line between the reservoir and the
vacuum source. This check valve is used to trap
engine vacuum in the reservoir. On certain vehicle
applications, this reservoir is shared with the heat-
ing/air-conditioning system. The vacuum reservoir
cannot be repaired and must be replaced if faulty.
DIAGNOSIS AND TESTING - VACUUM
RESERVOIR
(1) Disconnect vacuum hose at speed control servo
and install a vacuum gauge into the disconnected
hose.
(2) Start engine and observe gauge at idle. Vac-
uum gauge should read at least ten inches of mer-
cury.
(3) If vacuum is less than ten inches of mercury,
determine source of leak. Check vacuum line to
engine for leaks. Also check actual engine intake
manifold vacuum. If manifold vacuum does not meet
this requirement, check for poor engine performance
and repair as necessary.
(4) If vacuum line to engine is not leaking, check
for leak at vacuum reservoir. To locate and gain
access to reservoir, refer to Vacuum Reservoir Remov-
al/Installation in this group. Disconnect vacuum line
at reservoir and connect a hand-operated vacuum
pump to reservoir fitting. Apply vacuum. Reservoir
vacuum should not bleed off. If vacuum is being lost,
replace reservoir.
(5) Verify operation of one-way check valve and
check it for leaks.
(a) Locate one-way check valve. The valve is
located in vacuum line between vacuum reservoir
and engine vacuum source. Disconnect vacuum
hoses (lines) at each end of valve.
(b) Connect a hand-operated vacuum pump to
reservoir end of check valve. Apply vacuum. Vac-
uum should not bleed off. If vacuum is being lost,
replace one-way check valve.
(c) Connect a hand-operated vacuum pump to
vacuum source end of check valve. Apply vacuum.
Vacuum should flow through valve. If vacuum is
not flowing, replace one-way check valve. Seal the
fitting at opposite end of valve with a finger and
apply vacuum. If vacuum will not hold, diaphragm
within check valve has ruptured. Replace valve.
REMOVAL
The vacuum reservoir is located in the right/front
corner of the vehicle behind the front bumper fascia
(Fig. 8).
(1) Remove front bumper and grill assembly.
(2) Remove 1 support bolt near front of reservoir
(Fig. 8).
(3) Remove 2 reservoir mounting bolts.
(4) Remove reservoir from vehicle to gain access to
vacuum hose (Fig. 9). Disconnect vacuum hose from
reservoir fitting at rear of reservoir.
Fig. 7 Speed Control Switches
1 - MOUNTING SCREW
2 - SPEED CONTROL SWITCHES
8P - 8 SPEED CONTROLWJ
SWITCH (Continued)

switch, check for battery voltage at the washer pump
switch sense circuit cavity of the instrument panel
wire harness connector (Connector C2) for the BCM.
If OK, use a DRBIIItscan tool to diagnose the BCM.
Refer to the appropriate diagnostic information. If
not OK, repair the open washer pump switch sense
circuit between the right (wiper) multi-function
switch and the BCM as required.
CLEANING - FRONT WIPER & WASHER
SYSTEM
WIPER SYSTEM
The squeegees of wiper blades exposed to the ele-
ments for a long time tend to lose their wiping effec-
tiveness. Periodic cleaning of the squeegees is
suggested to remove any deposits of salt or road film.
The wiper blades, arms, and windshield glass should
only be cleaned using a sponge or soft cloth and
windshield washer fluid, a mild detergent, or a non-
abrasive cleaner. If the wiper blades continue to
leave streaks, smears, hazing, or beading on the
glass after thorough cleaning of the squeegees and
the glass, the entire wiper blade assembly must be
replaced.
CAUTION: Protect the rubber squeegees of the
wiper blades from any petroleum-based cleaners,
solvents, or contaminants. These products can rap-
idly deteriorate the rubber squeegees.
WASHER SYSTEM
If the washer system is contaminated with foreign
material, drain the washer reservoir by removing the
front washer pump/motor from the reservoir. Clean
foreign material from the inside of the washer reser-
voir using clean washer fluid, a mild detergent, or a
non-abrasive cleaner. Flush foreign material from the
washer system plumbing by first disconnecting the
washer hoses from the washer nozzles, then running
the washer pump/motor to run clean washer fluid or
water through the system. Plugged or restricted
washer nozzles should be carefully back-flushed
using compressed air. If the washer nozzle obstruc-
tion cannot be cleared, replace the washer nozzle.
CAUTION: Never introduce petroleum-based clean-
ers, solvents, or contaminants into the washer sys-
tem. These products can rapidly deteriorate the
rubber seals and hoses of the washer system, as
well as the rubber squeegees of the wiper blades.
CAUTION: Never use compressed air to flush the
washer system plumbing. Compressed air pres-
sures are too great for the washer system plumbingcomponents and will result in further system dam-
age. Never use sharp instruments to clear a
plugged washer nozzle or damage to the nozzle ori-
fice and improper nozzle spray patterns will result.
INSPECTION - FRONT WIPER & WASHER
SYSTEM
WIPER SYSTEM
The front wiper blades and wiper arms should be
inspected periodically, not just when wiper perfor-
mance problems are experienced. This inspection
should include the following points:
(1) Inspect the wiper arms for any indications of
damage, or contamination. If the wiper arms are con-
taminated with any foreign material, clean them as
required. (Refer to 8 - ELECTRICAL/FRONT WIP-
ERS/WASHERS - CLEANING). If a wiper arm is
damaged or corrosion is evident, replace the wiper
arm with a new unit. Do not attempt to repair a
wiper arm that is damaged or corroded.
(2) Carefully lift the wiper blade off of the glass.
Note the action of the wiper arm hinge. The wiper
arm should pivot freely at the hinge, but with no lat-
eral looseness evident. If there is any binding evident
in the wiper arm hinge, or there is evident lateral
play in the wiper arm hinge, replace the wiper arm.
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(3) Once proper hinge action of the wiper arm is
confirmed, check the hinge for proper spring tension.
Remove the wiper blade from the wiper arm. Either
place a small postal scale between the blade end of
the wiper arm and the glass, or carefully lift the
blade end of the arm away from the glass using a
small fish scale. Compare the scale readings between
the right and left wiper arms. Replace a wiper arm if
it has comparatively lower spring tension, as evi-
denced by a lower scale reading.
(4) Inspect the wiper blades and squeegees for any
indications of damage, contamination, or rubber dete-
rioration (Fig. 2). If the wiper blades or squeegees
are contaminated with any foreign material, clean
them and the glass as required. (Refer to 8 - ELEC-
TRICAL/FRONT WIPERS/WASHERS - CLEANING).
After cleaning the wiper blade and the glass, if the
wiper blade still fails to clear the glass without
smearing, streaking, chattering, hazing, or beading,
replace the wiper blade. Also, if a wiper blade is
damaged or the squeegee rubber is damaged or dete-
riorated, replace the wiper blade with a new unit. Do
not attempt to repair a wiper blade that is damaged.
8R - 8 FRONT WIPERS/WASHERSWJ
FRONT WIPERS/WASHERS (Continued)

(2) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the left headlamp and dash wire harness
connector for the rear washer pump/motor unit from
the pump/motor unit connector receptacle. Check for
continuity between the ground circuit cavity of the
left headlamp and dash wire harness connector for
the rear washer pump/motor unit and a good ground.
There should be continuity. If OK, go to Step 3. If not
OK, repair the open ground circuit to ground (G106)
as required.
(3) Reconnect the battery negative cable. Turn the
ignition switch to the On position. Push the right
multi-function switch control stalk toward the instru-
ment panel to actuate the rear washer switch. With
the rear washer switch actuated, check for battery
voltage at the rear washer switch output circuit cav-
ity of the left headlamp and dash wire harness con-
nector for the rear washer pump/motor unit. If OK,
replace the faulty rear washer pump/motor unit. If
not OK, repair the open rear washer switch output
circuit between the rear washer pump/motor unit
and the right multi-function switch as required.
CLEANING - REAR WIPER & WASHER SYSTEM
WIPER SYSTEM
The squeegee of a wiper blade exposed to the ele-
ments for a long time tends to lose its wiping effec-
tiveness. Periodic cleaning of the squeegee is
suggested to remove any deposits of salt or road film.
The wiper blade, arm, and liftgate glass should only
be cleaned using a sponge or soft cloth and wind-
shield washer fluid, a mild detergent, or a non-abra-
sive cleaner. If the wiper blade continues to leave
streaks, smears, hazing, or beading on the glass after
thorough cleaning of the squeegees and the glass, the
entire wiper blade assembly must be replaced.
CAUTION: Protect the rubber squeegee of the wiper
blade from any petroleum-based cleaners, solvents,
or contaminants. These products can rapidly deteri-
orate the rubber squeegee.
WASHER SYSTEM
If the washer system is contaminated with foreign
material, drain the washer reservoir by removing the
front washer pump/motor from the reservoir. Clean
foreign material from the inside of the washer reser-
voir using clean washer fluid, a mild detergent, or a
non-abrasive cleaner. Flush foreign material from the
washer system plumbing by first disconnecting the
washer hose from the washer nozzle, then running
the washer pump/motor to run clean washer fluid or
water through the system. A plugged or restricted
washer nozzle should be carefully back-flushed usingcompressed air. If the washer nozzle obstruction can-
not be cleared, replace the washer nozzle.
CAUTION: Never introduce petroleum-based clean-
ers, solvents, or contaminants into the washer sys-
tem. These products can rapidly deteriorate the
rubber seals and hoses of the washer system, as
well as the rubber squeegee of the wiper blade.
CAUTION: Never use compressed air to flush the
washer system plumbing. Compressed air pres-
sures are too great for the washer system plumbing
components and will result in further system dam-
age. Never use sharp instruments to clear a
plugged washer nozzle or damage to the nozzle ori-
fice and improper nozzle spray patterns will result.
INSPECTION - REAR WIPER & WASHER
SYSTEM
WIPER SYSTEM
The rear wiper blade and wiper arm should be
inspected periodically, not just when wiper perfor-
mance problems are experienced. This inspection
should include the following points:
(1) Inspect the wiper arm for any indications of
damage, or contamination. If the wiper arm is con-
taminated with any foreign material, clean as
required. (Refer to 8 - ELECTRICAL/REAR WIPERS/
WASHERS - CLEANING). If a wiper arm is damaged
or corrosion is evident, replace the wiper arm with a
new unit. Do not attempt to repair a wiper arm that
is damaged or corroded.
(2) Carefully lift the wiper arm off of the ramp.
Note the action of the wiper arm hinge. The wiper
arm should pivot freely at the hinge, but with no lat-
eral looseness evident. If there is any binding evident
in the wiper arm hinge, or there is evident lateral
play in the wiper arm hinge, replace the wiper arm.
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(3) Once proper hinge action of the wiper arm is
confirmed, check the hinge for proper spring tension.
The spring tension of the wiper arm should be suffi-
cient to cause the rubber squeegee to conform to the
curvature of the glass. Replace a wiper arm if it has
low or no spring tension.
(4) Inspect the wiper blade and squeegee for any
indications of damage, contamination, or rubber dete-
rioration (Fig. 1). If the wiper blade or squeegee is
contaminated with any foreign material, clean them
and the glass as required. (Refer to 8 - ELECTRI-
WJREAR WIPERS/WASHERS 8R - 37
REAR WIPERS/WASHERS (Continued)

DIAGNOSIS AND TESTINGÐREAR SEAL AREA
LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, distributor seal,
camshaft bore cup plugs, oil galley pipe plugs, oil
filter runoff, and main bearing cap to cylinder
block mating surfaces.
(4) If no leaks are detected, pressurized the crank-
case as outlined in (Refer to 9 - ENGINE/LUBRICA-
TION - DIAGNOSIS AND TESTING)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled. Refer to the service DiagnosisÐMechani-
cal, under the Oil Leak row, for components
inspections on possible causes and corrections.
(7) After the oil leak root cause and appropriate
corrective action have been identified, (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL), for proper replacement
procedures.
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtGASKET SEALANT
MopartGasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This mate-
rial is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will pre-
vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
WJENGINE - 4.0L 9 - 9
ENGINE - 4.0L (Continued)