clock MERCEDES-BENZ SPRINTER 2005 Service Owner's Manual

(3) Rotate the bulb holder counterclockwise about
30 degrees and pull it straight out from the lamp
housing (Fig. 25).
(4) Remove the bulb from the front turn/park/side
marker bulb holder.
INSTALLATION
(1) Install the bulb into the front turn/park/side
marker bulb holder.
(2) Insert the bulb holder straight into the front
lamp unit housing and rotate the bulb holder clock-
wise about 30 degrees to lock it into place (Fig. 25).
(3) Reconnect the battery negative cable.
HEADLAMP LEVELING MOTOR
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disengage and swing the retainers that secure
the front lamp unit rear cover to each side of the
lamp housing and remove the cover (Fig. 26).
(3) Disconnect the front lamp unit wire harness
connector from the connector receptacle for the head-
lamp leveling motor (Fig. 27).
Fig. 25 Front Turn/Park/Side Marker Bulb Remove/
Install
1 - LAMP HOUSING
2 - BULB HOLDER
Fig. 26 Front Lamp Unit Bulbs Remove/Install
1 - COVER RETAINER (2)
2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
4 - COVER
5 - LOW BEAM BULB
6 - POSITION BULB
7 - HIGH BEAM BULB
8 - TURN/PARK/SIDE MARKER BULB
9 - FRONT LAMP UNIT
Fig. 27 Headlamp Leveling Motor
1 - HOUSING
2 - REFLECTOR
3 - CONNECTOR
4 - MOTOR
5 - MOUNT
VALAMPS/LIGHTING - EXTERIOR 8L - 15
FRONT TURN/PARK/SIDE MARKER LAMP BULB (Continued)

(4)Rotate the headlamp leveling motor counterclock-
wise about 30 degrees and pull it straight out from the
mount integral to the front lamp unit housing (Fig. 28).
(5) Stabilize the front lamp unit reflector with one
hand, then use the other hand to pull the headlamp
leveling motor away from the reflector until the ball
on the end of the motor pushrod unsnaps from the
bracket on the reflector.
(6) Remove the headlamp leveling motor from the
mount on the front lamp unit housing.
INSTALLATION
(1) Position the headlamp leveling motor to the
mount on the front lamp unit housing (Fig. 28).
(2) Snap the ball on the end of the headlamp lev-
eling motor into the bracket on the front lamp unit
reflector.
(3) Push the headlamp leveling motor into the
mount integral to the front lamp unit housing until it
is fully seated, then rotate the motor clockwise about
30 degrees to lock it into place (Fig. 27).
(4) Reconnect the front lamp unit wire harness
connector to the connector receptacle for the head-
lamp leveling motor.
(5) Position the front lamp unit rear cover onto the
lamp housing and engage the retainers over each
side of the cover to secure it (Fig. 26).
(6) Reconnect the battery negative cable.
HEADLAMP LEVELING SWITCH
REMOVAL
(1)Disconnect and isolate the battery negative cable.
(2) Remove the cluster bezel from the instrument
panel (Fig. 29). (Refer to 23 - BODY/INSTRUMENT
PANEL/CLUSTER BEZEL - REMOVAL).
(3) From the back of the cluster bezel, squeeze the
two latches on the headlamp leveling switch body
and push the switch out through the face of the bezel
(Fig. 30).
(4) Remove the headlamp leveling switch from the
face of the cluster bezel.
Fig. 28 Headlamp Leveling Motor Remove/Install
1 - PUSHROD
2 - MOTOR
3 - MOUNT
4 - BRACKET
5 - REFLECTORFig. 29 Headlamp Leveling Switch
1 - HEADLAMP LEVELING SWITCH
2 - SCREW (2)
3 - CLUSTER BEZEL
4 - TO REAR WINDOW DEFOGGER SWITCH (OPTIONAL)
5 - TO HEADLAMP LEVELING SWITCH
6 - TO FOG LAMP SWITCH (OPTIONAL)
Fig. 30 Headlamp Leveling Switch Remove/Install
1 - FOG LAMP SWITCH
2 - LATCH (2)
3 - CLUSTER BEZEL
8L - 16 LAMPS/LIGHTING - EXTERIORVA
HEADLAMP LEVELING MOTOR (Continued)

(3) Disconnect the front lamp unit wire harness
connector from the low beam headlamp bulb base
(Fig. 36).
(4) Disengage the low beam headlamp bulb
retainer by pushing it slightly toward the front lamp
unit housing and downward from the bulb base, then
pivot the retainer off of the bulb base.
(5) Remove the low beam headlamp bulb from the
integral bulb holder on the front lamp unit reflector.
INSTALLATION
(1) Position the low beam headlamp bulb into the
integral bulb holder on the front lamp unit reflector.
Be certain that the lugs on the bulb base are
engaged in the recesses of the bulb holder (Fig. 36).
(2) Engage the low beam headlamp bulb retainer
by pivoting it over the bulb base, pressing it slightly
toward the front lamp unit housing and upward
toward the side of the bulb base.
(3) Reconnect the front lamp unit wire harness
connector to the low beam headlamp bulb base.
(4) Position the front lamp unit rear cover onto the
lamp housing and engage the retainers over each
side of the cover to secure it (Fig. 35).
(5) Reconnect the battery negative cable.
MULTI-FUNCTION SWITCH
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,PASSENGER AIRBAG, SEAT BELT TENSIONER, 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.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the fuse block from the underside of
the steering column. (Refer to 8 - ELECTRICAL/
POWER DISTRIBUTION/FUSE BLOCK - REMOV-
AL).
(3) Remove the clockspring from the steering col-
umn. (Refer to 8 - ELECTRICAL/RESTRAINTS/
CLOCKSPRING - REMOVAL).
(4) Remove the two screws that secure the upper
shroud to the top of the multi-function switch (Fig.
37).
(5) Remove the upper shroud from the top of the
multi-function switch.
(6) Remove the two screws that secure the multi-
function switch to the steering column.
(7) Remove the multi-function switch from the
steering column.
(8) Remove the speed control switch from the back
of the multi-function switch. (Refer to 8 - ELECTRI-
CAL/SPEED CONTROL/SWITCH - REMOVAL).
Fig. 36 Low Beam Headlamp Bulb Remove/Install
1 - LAMP HOUSING
2 - BULB BASE
3 - CONNECTOR
4 - BULB RETAINER
Fig. 37 Multi-Function Switch Remove/Install
1 - SCREW (2)
2 - UPPER SHROUD
3 - SWITCH
4 - SCREW (2)
VALAMPS/LIGHTING - EXTERIOR 8L - 19
LOW BEAM HEADLAMP BULB (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, SEAT BELT TENSIONER, 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.
(1) Reinstall the speed control switch onto the
back of the multi-function switch. (Refer to 8 - ELEC-
TRICAL/SPEED CONTROL/SWITCH - INSTALLA-
TION).
(2) Position the multi-function switch onto the
steering column (Fig. 37).
(3) Install and tighten the two screws that secure
the multi-function switch to the steering column.
(4) Position the upper shroud onto the top of the
multi-function switch.
(5) Install and tighten the two screws that secure
the upper shroud to the top of the multi-function
switch.
(6) Reinstall the clockspring onto the steering col-
umn. (Refer to 8 - ELECTRICAL/RESTRAINTS/
CLOCKSPRING - INSTALLATION).
(7) Reinstall the fuse block onto the underside of
the steering column. (Refer to 8 - ELECTRICAL/
POWER DISTRIBUTION/FUSE BLOCK - INSTAL-
LATION).
(8) Reconnect the battery negative cable.
PARK BRAKE SWITCH
REMOVAL
(1) Remove the trim cover from the park brake
lever (Fig. 38). (Refer to 5 - BRAKES/PARKING
BRAKE/LEVER - REMOVAL).(2) Remove the screw that secures the park brake
switch and the ground eyelet terminal to the park
brake lever.
(3) Disengage the park brake switch from the park
brake lever.
(4) Disconnect the vehicle wire harness connector
for the park brake switch from the switch terminal.
(5) Remove the park brake switch from the park
brake lever.
INSTALLATION
(1) Position the park brake switch near the park
brake lever (Fig. 38).
(2) Reconnect the vehicle wire harness connector
for the park brake switch to the switch terminal.
(3) Engage the park brake switch into the park
brake lever.
(4) Install and tighten the screw that secures the
park brake switch and the ground eyelet terminal to
the park brake lever.
(5) Reinstall the trim cover onto the park brake
lever. (Refer to 5 - BRAKES/PARKING BRAKE/LE-
VER - INSTALLATION).
Fig. 38 Park Brake Switch Remove/Install
1 - LEVER
2 - SWITCH
3 - WIRE HARNESS
4 - SCREW
8L - 20 LAMPS/LIGHTING - EXTERIORVA
MULTI-FUNCTION SWITCH (Continued)

DOME/READING LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Insert the tip of a small flat-bladed screwdriver
into the notch on one edge of the dome/reading lamp
housing to depress the retainer clip and pull that
edge of the lamp away from its mounting location
(Fig. 6).
(3) Pull the dome/reading lamp unit from its
mounting location far enough to access and discon-
nect the vehicle wire harness from the lamp connec-
tor receptacle.
(4) Remove the dome/reading lamp unit from its
mounting location.
INSTALLATION
(1) Position the dome/reading lamp unit to its
mounting location.
(2) Reconnect the vehicle wire harness connector
to the dome/reading lamp connector receptacle (Fig.
6).
(3) Position the edge of the dome/reading lamp
housing opposite from the retainer clip into the
mounting hole.
(4) Push firmly and evenly on the notched edge of
the dome/reading lamp housing until the retainer
clip latches into place.
(5) Reconnect the battery negative cable.
DOME LAMP/INTRUSION
SENSOR BULB
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the dome lamp/intrusion sensor unit
from its mounting location, but do not disconnect the
vehicle wire harness from the lamp connector recep-
tacle. (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING
- INTERIOR/DOME LAMP/INTRUSION SENSOR
UNIT - REMOVAL).
(3) Grasp the lamp housing in one hand and rotate
the bulb holder and bulb unit counterclockwise about
30 degrees on the circuit board (Fig. 7).
(4) Pull the bulb holder and bulb unit straight out
from the mounting hole in the circuit board.
INSTALLATION
(1) Grasp the dome lamp/intrusion sensor unit
housing in one hand and align the bulb holder and
bulb unit with the bulb mounting hole in the circuit
board with the other hand (Fig. 7).
(2) Insert the bulb holder and bulb unit straight
into the circuit board bulb mounting hole until it is
firmly seated.
(3) Rotate the bulb holder and bulb unit clockwise
about 30 degrees on the circuit board.
(4) Reinstall the dome lamp/intrusion sensor unit
into its mounting location. (Refer to 8 - ELECTRI-
CAL/LAMPS/LIGHTING - INTERIOR/DOME LAMP/
INTRUSION SENSOR UNIT - INSTALLATION).
(5) Reconnect the battery negative cable.
Fig. 6 Dome/Reading Lamp Unit Remove/Install
1 - LAMP HOUSING
2 - SWITCH BUTTON
3 - NOTCH
4 - SUN VISOR (2)
5 - HEADLINER
Fig. 7 Dome Lamp/Intrusion Sensor Bulb Remove/
Install
1 - BULB HOLDER/BULB (4)
2 - LAMP HOUSING
8L - 30 LAMPS/LIGHTING - INTERIORVA

DOME LAMP/INTRUSION
SENSOR
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Insert the tip of a small flat-bladed screwdriver
into the notch on one edge of the dome lamp/intru-
sion sensor unit housing to depress the retainer clip
and pull that edge of the lamp away from its mount-
ing location (Fig. 8).
(3) Pull the dome lamp/intrusion sensor unit from
its mounting location far enough to access and dis-
connect the vehicle wire harness from the lamp con-
nector receptacle.
(4) Remove the dome lamp/intrusion sensor unit
from its mounting location.
INSTALLATION
(1) Position the dome lamp/intrusion sensor unit to
its mounting location (Fig. 8).
(2) Reconnect the vehicle wire harness connector
to the dome lamp/intrusion sensor unit connector
receptacle.
(3) Position the edge of the dome lamp/intrusion
sensor unit housing opposite from the retainer clip
into the mounting hole.
(4) Push firmly and evenly on the notched edge of
the dome lamp/intrusion sensor unit housing until
the retainer clip latches into place.
(5) Reconnect the battery negative cable.
DOOR JAMB SWITCH
REMOVAL
(1) Disconnect and isolate the battery negative
cable.(2) Open the door and remove the screw that
secures the door jamb switch to the hinge pillar of
the door opening (Fig. 9).
(3) Pull the door jamb switch away from the
mounting hole in the pillar far enough to access and
disconnect the vehicle wire harness connector from
the back of the switch.
INSTALLATION
(1) Position the door jamb switch close enough to
the mounting hole in the hinge pillar of the door
opening to reconnect the vehicle wire harness connec-
tor to the back of the switch.
(2) Position the door jamb switch into the mount-
ing hole in the hinge pillar (Fig. 9).
(3) Install and tighten the screw that secures the
door jamb switch to the hinge pillar.
(4) Reconnect the battery negative cable.
ENTRY/EXIT LAMP BULB
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the entry/exit lamp unit from its
mounting location. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - INTERIOR/ENTRY/EXIT
LAMP UNIT - REMOVAL).
(3) Grasp the lamp housing firmly in one hand,
then rotate the bulb holder counterclockwise and pull
it straight out from the housing with the other hand
(Fig. 10).
(4) Remove the bulb from the bulb holder.
Fig. 8 Dome Lamp/Intrusion Sensor Unit Remove/
Install
1 - NOTCH
2 - SENSOR (3)
3 - HOUSING
4 - SWITCH (2)
Fig. 9 Door Jamb Switch Remove/Install
1 - DOOR JAMB SWITCH
2 - PLUNGER
3 - PILLAR
4 - SCREW
VALAMPS/LIGHTING - INTERIOR 8L - 31

INSTALLATION
(1) Insert the bulb into the entry/exit lamp bulb
holder (Fig. 10).
(2) Grasp the entry/exit lamp housing firmly in
one hand, then insert the bulb holder into the hous-
ing and rotate it clockwise to lock it in place with the
other hand.
(3) Reinstall the entry/exit lamp unit into its
mounting location. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - INTERIOR/ENTRY/EXIT
LAMP UNIT - INSTALLATION).
(4) Reconnect the battery negative cable.
ENTRY/EXIT LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Insert the tip of a small flat-bladed screwdriver
into the notch on one edge of the entry/exit lamp
housing to depress the retainer clip and pull that
edge of the lamp away from its mounting location
(Fig. 11).
(3) Pull the entry/exit lamp unit from its mounting
location far enough to access and disconnect the vehi-
cle wire harness from the lamp connector receptacle.(4) Remove the entry/exit lamp unit from its
mounting location.
INSTALLATION
(1) Position the entry/exit lamp unit to its mount-
ing location.
(2) Reconnect the vehicle wire harness connector
to the entry/exit lamp connector receptacle (Fig. 11).
(3) Position the edge of the entry/exit lamp hous-
ing opposite from the retainer clip into the mounting
hole.
(4) Push firmly and evenly on the notched edge of
the entry/exit lamp housing until the retainer clip
latches into place.
(5) Reconnect the battery negative cable.
TIME DELAY RELAY
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Move the driver side front seat to its most for-
ward position for easiest access to the seat riser
cover panel.
(3) Remove the two screws that secure the cover
panel to the top of the seat riser under the driver
side front seat (Fig. 12).
(4) Remove the cover panel from the top of the
driver side seat riser.
(5) Remove the time delay relay from its vehicle
wire harness connector by grasping it firmly and
pulling it straight out from the connector within the
driver side seat riser.
Fig. 10 Entry/Exit Lamp Bulb Remove/Install
1 - LAMP HOUSING
2 - BULB HOLDER
3 - CONNECTOR
Fig. 11 Entry/Exit Lamp Unit Remove/Install
1 - STEP WELL SCUFF PAD
2 - NOTCH
3 - ENTRY/EXIT LAMP UNIT
Fig. 12 Seat Riser Cover
1 - DRIVER SEAT BACK
2 - COVER PANEL
3 - SCREW (2)
4 - SEAT RISER
8L - 32 LAMPS/LIGHTING - INTERIORVA
ENTRY/EXIT LAMP BULB (Continued)

RESTRAINTS
TABLE OF CONTENTS
page page
RESTRAINTS
DESCRIPTION..........................2
OPERATION............................4
WARNING
WARNINGS - RESTRAINT SYSTEM........5
DIAGNOSIS AND TESTING - SUPPLEMENTAL
RESTRAINT SYSTEM...................5
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS.........................6
STANDARD PROCEDURE - SERVICE
AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT.........................6
STANDARD PROCEDURE - VERIFICATION
TEST................................7
AIRBAG CONTROL MODULE
DESCRIPTION..........................8
OPERATION............................9
REMOVAL.............................10
INSTALLATION.........................11
CLOCKSPRING
DESCRIPTION.........................12
OPERATION...........................13
STANDARD PROCEDURE - CLOCKSPRING
CENTERING.........................13
REMOVAL.............................14
INSTALLATION.........................15
DRIVER AIRBAG
DESCRIPTION.........................16
OPERATION...........................17
REMOVAL.............................17
INSTALLATION.........................18FRONT SEAT BELT & RETRACTOR
REMOVAL.............................19
INSTALLATION.........................21
FRONT SEAT BELT BUCKLE
REMOVAL.............................22
INSTALLATION.........................23
PASSENGER AIRBAG
DESCRIPTION.........................23
OPERATION...........................24
REMOVAL.............................24
INSTALLATION.........................26
PASSENGER AIRBAG BRACKET
REMOVAL.............................27
INSTALLATION.........................27
REAR SEAT BELT & RETRACTOR
REMOVAL.............................27
INSTALLATION.........................29
REAR SEAT BELT BUCKLE
REMOVAL
REMOVAL - INBOARD..................29
REMOVAL - OUTBOARD................30
INSTALLATION
INSTALLATION - INBOARD..............30
INSTALLATION - OUTBOARD............31
SEAT BELT SWITCH
DESCRIPTION.........................31
OPERATION...........................31
SEAT BELT TENSIONER
DESCRIPTION.........................31
OPERATION...........................32
SEAT BELT TURNING LOOP ADJUSTER
REMOVAL.............................33
INSTALLATION.........................34
VARESTRAINTS 8O - 1

ACTIVE RESTRAINTS
The active restraints for this model include:
²Front Seat Belts- Both outboard front seating
positions are equipped with three-point seat belt sys-
tems employing a lower B-pillar mounted inertia
latch-type retractors, height-adjustable upper B-pil-
lar mounted turning loops, travelling lower seat belt
anchors secured to the outboard seat tracks, and
travelling end-release seat belt buckles secured to
the inboard seat track. The driver side front seat belt
buckle of all models includes an integral seat belt
switch that detects whether its seat belt has been
fastened.
²Rear Seat Belts- All rear seating positions are
equipped with three-point seat belt systems. Each
rear seating position belt employs an integral seat
cushion frame mounted inertia latch-type retractor, a
fixed position upper seat back frame mounted turn-
ing loop, and a fixed lower seat belt anchor secured
to the seat cushion frame. All rear seat belts have
fixed end-release seat belt buckles that are also
secured to the seat cushion frame.
PASSIVE RESTRAINTS
A Next Generation driver airbag is standard facto-
ry-installed safety equipment on this model, while a
passenger side front airbag is optional. This airbag
system is a passive, inflatable, Supplemental
Restraint System (SRS) and vehicles with this equip-
ment can be readily identified by the ªSRS - AIR-
BAGº logo molded into the driver airbag trim cover
in the center of the steering wheel and, if the vehicle
is so equipped, also into the passenger airbag door on
the instrument panel above the glove box (Fig. 2).
Vehicles with the airbag system can also be identified
by the airbag indicator, which will illuminate in the
instrument cluster for about six seconds as a bulb
test each time the ignition switch is turned to the On
position. A pyrotechnic-type seat belt tensioner is
integral to the front seat belt retractor mounted on
the lower B-pillar on the driver side, and to the pas-
senger side retractor of vehicles equipped with the
optional passenger side airbag.
The supplemental restraint system includes the
following major components, which are described in
further detail elsewhere in this service information:
²Airbag Control Module- The Airbag Control
Module (ACM) is located on a mount on the floor
panel within the driver side seat riser, beneath the
driver seat in the passenger compartment.
²Airbag (SRS) Indicator- The airbag indicator
is integral to the ElectroMechanical Instrument Clus-
ter (EMIC), which is located on the instrument panel
in front of the driver.²Clockspring- The clockspring is located near
the top of the steering column, directly beneath the
steering wheel.
²Driver Airbag- The driver airbag is located in
the center of the steering wheel, beneath the driver
airbag trim cover.
²Driver Knee Blocker- The structure of the
lower instrument panel serves as a knee blocker for
the driver.
²Passenger Airbag- The optional passenger air-
bag is located within the instrument panel, behind
the passenger airbag door on the instrument panel
above the glove box on the passenger side of the vehi-
cle.
²Passenger Knee Blocker- The structure of
the glove box door and the lower instrument panel
serve as a knee blocker for the front seat passenger.
²Seat Belt Tensioner- A seat belt tensioner is
integral to the driver side front seat belt retractor
unit, and to the passenger side front seat belt retrac-
tor unit on vehicles equipped with an optional pas-
senger airbag.
The ACM contains a central processing unit and
programming that allows it to communicate on a
serial data bus diagnostic circuit connected to the
16-way Data Link Connector (DLC) located below the
left end of the instrument panel. This method of com-
munication is used for initialization of the ACM and
for diagnosis of the SRS circuits and components
using a DRBIIItscan tool.
Hard wired circuitry connects the supplemental
restraint system components to each other through
the electrical system of the vehicle. These hard wired
circuits are integral to several wire harnesses, which
are routed throughout the vehicle and retained by
many different methods. These circuits may be con-
nected to each other, to the vehicle electrical system,
and to the supplemental restraint system compo-
nents through the use of a combination of soldered
Fig. 2 SRS Logo
VARESTRAINTS 8O - 3
RESTRAINTS (Continued)

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER, 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.
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
NON-DEPLOYED SUPPLEMENTAL RESTRAINTS
At no time should any source of electricity be per-
mitted near the inflator on the back of a non-de-
ployed airbag or seat belt tensioner. When carrying a
non-deployed airbag, the trim cover or airbag cushion
side of the unit should be pointed away from the
body to minimize injury in the event of an accidental
deployment. If the airbag unit is placed on a bench or
any other surface, the trim cover or airbag cushion
side of the unit should be face up to minimize move-
ment in the event of an accidental deployment. When
handling a non-deployed seat belt tensioner, take
proper care to keep fingers out from under the
retractor cover and away from the seat belt webbing
where it exits from the retractor cover. In addition,
the supplemental restraint system should be dis-
armed whenever any steering wheel, steering col-
umn, seat belt tensioner, driver airbag, passenger
airbag, or instrument panel components require diag-
nosis or service. Failure to observe this warning
could result in accidental deployment and possible
personal injury.
All damaged, faulty or non-deployed airbags and
seat belt tensioners which are replaced on vehicles
are to be handled and disposed of properly. If an air-
bag or seat belt tensioner unit is faulty or damaged
and non-deployed, refer to the Hazardous Substance
Control System for proper disposal. Dispose of all
non-deployed and deployed airbags and seat belt ten-
sioners in a manner consistent with state, provincial,
local and federal regulations.
SUPPLEMENTAL RESTRAINT STORAGE
Airbags and seat belt tensioners must be stored in
their original, special container until they are used
for service. Also, they must be stored in a clean, dry
environment; away from sources of extreme heat,
sparks, and high electrical energy. Always place or
store any airbag on a surface with its trim cover or
airbag cushion side facing up, to minimize movement
in case of an accidental deployment.
STANDARD PROCEDURE - SERVICE AFTER A
SUPPLEMENTAL RESTRAINT DEPLOYMENT
Any vehicle which is to be returned to use follow-
ing a supplemental restraint deployment, must have
the deployed restraints replaced. In addition, if the
driver airbag has been deployed, the clockspring and
the steering wheel must be replaced. The seat belt
tensioners are deployed by the same signal that
deploys the driver and passenger airbags and must
also be replaced if either airbag has been deployed.
These components are not intended for reuse and
will be damaged or weakened as a result of a supple-
mental restraint deployment, which may or may not
be obvious during a visual inspection.
It is also critical that the mounting surfaces and/or
mounting brackets for the Airbag Control Module
(ACM) be closely inspected and restored to their orig-
inal conditions following any vehicle impact damage.
Because the ACM contains the impact sensor that is
used by the supplemental restraint system to moni-
tor or confirm the direction and severity of a vehicle
impact, improper orientation or insecure fastening of
this component may cause airbags not to deploy
when required, or to deploy when not required. All
other vehicle components should be closely inspected
following any supplemental restraint deployment, but
are to be replaced only as required by the extent of
the visible damage incurred.
CLEANUP PROCEDURE
Following a supplemental restraint deployment,
the vehicle interior will contain a powdery residue.
This residue consists primarily of harmless particu-
late by-products of the small pyrotechnic charge that
initiates the propellant used to deploy a supplemen-
tal restraint. However, this residue may also contain
traces of sodium hydroxide powder, a chemical
by-product of the propellant material that is used to
generate the inert gas that inflates the airbag. Since
sodium hydroxide powder can irritate the skin, eyes,
nose, or throat, be certain to wear safety glasses,
rubber gloves, and a long-sleeved shirt during
cleanup (Fig. 3).
8O - 6 RESTRAINTSVA
RESTRAINTS (Continued)