2004 CHRYSLER VOYAGER battery

REMOVAL
WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
UTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.(1) Remove the appropriate seat from the vehicle
(Refer to 23 - BODY/SEATS/SEAT - REMOVAL). (2) Remove the rear fabric blocker trim panel from
the rear of the front seat. (3) Remove the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION SIDE COVERS - REMOVAL). (4) Disconnect all electrical connectors connecting
the power seat track to the seat assembly. (5) Pull the seat back trim cover up slightly to
access and remove the two seat back frame mounting
bolts and seat back recliner bolts. (6) Remove four seat track mounting bolts from
the seat cushion pan. (7) Remove the power seat track from the seat.
INSTALLATION
(1) Position the seat cushion on the seat track.
(2) Install the four seat track retaining bolts in the
seat cushion pan. Torque the bolts to 28.5 N´m. (3) Position the seat back and install the two seat
back frame mounting bolts and the two seat back
recliner bolts. Torque the bolts to 55 N´m. (4) Route and connect the electrical connectors
between the power seat track and the seat assembly. (5) Install the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION - INSTALLATION). (6) Install the rear fabric blocker trim panel on the
rear of the front seat. (7) Install the seat assembly in the vehicle (Refer
to 23 - BODY/SEATS/SEAT - INSTALLATION).
8Ns - 18 POWER SEAT SYSTEMRS
PASSENGER POWER SEAT TRACK (Continued)

RESTRAINTS
DESCRIPTION
This vehicle is equipped with a Frontal Impact Air-
bag System, which utilizes the driver/passenger air-
bags and seatbelt pretensioners. This system is
designed to protect occupants in the event of a front
impact collision. These airbags and seatbelt preten-
sioners are all serviceable parts. If these pyrotechnics
are deployed or defective, they must be replaced, as
well as the Occupant Restraint Controller (ORC)
must be diagnosed following procedures outlined in
the service/diagnostic manuals.
Vehicles equipped with the Side Impact Airbag
System, the seat back assembly must be replaced, as
well as the Side Impact Airbag Control Module
(SIACM) must be diagnosed following procedures
outlined in the service/diagnostic manuals.
OPERATION
The Occupant Restraint Controller (ORC) controls
the driver/passenger airbags and seat belt tensioners.
If the ORC determines that the impact is severe
enough, the driver/passenger/side airbags and seat
belt tensioners will deploy. Once a deployment
occurs, these devices, and all damaged parts must be
replaced, as well as the ORC must be diagnosed fol-
lowing procedures outlined in the service/diagnostic
manuals.
The Side Impact Airbag Control Module (SIACM),
the seat back assemblies and all damaged parts must
be replaced, as well as the SIACM must be diagnosed
following procedures outlined in the service/diagnos-
tic manuals.
WARNING
WARNING: THIS SYSTEM IS A SENSITIVE, COM-
PLEX ELECTRO±MECHANICAL UNIT. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE
BEFORE BEGINNING AIRBAG SYSTEM COMPO-
NENT REMOVAL OR INSTALLATION PROCEDURES.
THIS WILL DISABLE THE AIRBAG SYSTEM. FAIL-
URE TO DISCONNECT THE BATTERY COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT,
PERSONAL INJURY, OR DEATH.
ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR
TWO MINUTES BEFORE REMOVING AIRBAG COM-
PONENTS.
DO NOT PLACE AN INTACT UNDEPLOYED AIRBAG
FACE DOWN ON A SOLID SURFACE, THE AIRBAG
WILL PROPEL INTO THE AIR IF ACCIDENTALLY
DEPLOYED AND COULD RESULT IN PERSONAL
INJURY. WHEN CARRYING OR HANDLING AN
UNDEPLOYED AIRBAG MODULE, THE TRIM SIDE
OF THE AIRBAG SHOULD BE POINTING AWAYFROM THE BODY TO MINIMIZE POSSIBILITY OF
INJURY IF ACCIDENTAL DEPLOYMENT OCCURS.
REPLACE AIRBAG SYSTEM COMPONENTS WITH
MOPARTREPLACEMENT PARTS. SUBSTITUTE
PARTS MAY APPEAR INTERCHANGEABLE, BUT
INTERNAL DIFFERENCES MAY RESULT IN INFE-
RIOR OCCUPANT PROTECTION.
WEAR SAFETY GLASSES, RUBBER GLOVES, AND
LONG SLEEVED CLOTHING WHEN CLEANING
POWDER RESIDUE FROM VEHICLE AFTER AIRBAG
DEPLOYMENT. SODIUM HYDROXIDE POWDER
RESIDUE EMITTED FROM A DEPLOYED AIRBAG
CAN CAUSE SKIN IRRITATION. FLUSH AFFECTED
AREA WITH COOL WATER IF IRRITATION IS EXPE-
RIENCED. IF NASAL OR THROAT IRRITATION IS
EXPERIENCED, EXIT THE VEHICLE FOR FRESH AIR
UNTIL THE IRRITATION CEASES. IF IRRITATION
CONTINUES, SEE A PHYSICIAN.
DO NOT USE A REPLACEMENT AIRBAG THAT IS
NOT IN THE ORIGINAL PACKAGING, IMPROPER
DEPLOYMENT, PERSONAL INJURY, OR DEATH CAN
RESULT.
THE FACTORY INSTALLED FASTENERS, SCREWS
AND BOLTS USED TO FASTEN AIRBAG COMPO-
NENTS HAVE A SPECIAL COATING AND ARE SPE-
CIFICALLY DESIGNED FOR THE AIRBAG SYSTEM.
DO NOT USE SUBSTITUTE FASTENERS, USE ONLY
ORIGINAL EQUIPMENT FASTENERS LISTED IN THE
PARTS CATALOG WHEN FASTENER REPLACE-
MENT IS REQUIRED.
CAUTION:
Deployed and Nondeployed Air Bags may or may
not have live pyrotechnic material within the air bag
inflator. Do not dispose of Driver and Passenger
Airbags unless you are sure of complete deploy-
ment. Please refer to the Hazardous Substance
Control System for Proper Disposal. Dispose of
deployed air bags in a manner consistent with
state, provincial, local, and federal regulations.
WARNING: DURING, AND FOLLOWING, ANY CHILD
RESTRAINT ANCHOR SERVICE, DUE TO IMPACT
EVENT OR VEHICLE REPAIR, CAREFULLY INSPECT
ALL MOUNTING HARDWARE, TETHER STRAPS
AND ANCHORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. IF A CHILD RESTRAINT
ANCHOR IS FOUND DAMAGED IN ANY WAY, THE
ANCHOR MUST BE REPLACED OR IT COULD
RESULT IN PERSONAL INJURY OR DEATH.
DIAGNOSIS AND TESTING - AIRBAG SYSTEM
(1) With the battery negative remote cable discon-
nected, connect the DRB IIItscan tool to the Data
Link connector.
8O - 2 RESTRAINTSRS

(2) Turn the ignition key to the ON position. Exit
vehicle with the scan tool.
(3) After checking that no one is inside the vehicle,
connect the battery negative remote terminal.
(4) Read and record theACTIVEDiagnostic Trou-
ble Code (DTC) data.
(5) Read and record anySTOREDDTC's.
(6) Refer to the proper Body Diagnostic Procedures
manual if any DTC's are found in Step 4 and Step 5.
(7) If the airbag warning lamp either fails to light,
or goes ON and stays ON, there is a system malfunc-
tion. To test the airbag warning lamp (bulb) opera-
tion in the cluster, refer to Electrical, Instrument
Cluster, Diagnosis and Testing - Instrument Cluster.
Refer to the proper Body Diagnostic Procedures man-
ual for any other system problems.
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
AIRBAGS
DEPLOYED AIRBAG
The vehicle interior may contain a very small
amount of sodium hydroxide powder, a by-product of
airbag deployment. Sodium hydroxide powder can
irritate the skin, eyes, nose and throat. Wear safety
glasses, rubber gloves, and long sleeved clothing
when cleaning any of the powder residue from the
vehicle.
If you find that the cleanup is irritating your skin,
run cool water over the affected area. Also, if you
experience nasal or throat irritation, exit the vehicle
for fresh air until the irritation ceases. If irritation
continues, see a physician.
UNDEPLOYED AIRBAG
The airbags must be stored in its original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag module. When carrying or han-
dling an undeployed airbag module, the trim side of
the airbag should be pointing away from the body to
minimize possibility of injury if accidental deploy-
ment occurs. Do not place undeployed airbag face
down on a solid surface, the airbag will propel into
the air if accidental deployment occurs.
STANDARD PROCEDURE - SERVICE AFTER AN
AIRBAG DEPLOYMENT
DRIVER AIRBAG
After a Driver Airbag has been deployed due to a
collision, the followingMUSTbe replaced:
²Driver Airbag²Clock Spring Assembly
²Steering Wheel
²Complete Steering Column Assembly w/Lower
Steering Column Coupler
All other airbag and vehicle components should be
closely inspected following any airbag deployment,
and should be replaced when visible damage is
incurred.
PASSENGER AIRBAG
After a Passenger Airbag has been deployed due to
a collision. the followingMUSTbe replaced:
²Passenger Airbag
²Instrument Panel and Pad Assembly
All other airbag and vehicle components should be
closely inspected following any airbag deployment,
and should be replaced when visible damage is
incurred.
SEAT AIRBAG
After a Seat Airbag has been deployed due to a col-
lision. the followingMUSTbe replaced:
²Complete Seat Back Assembly
All other airbag and vehicle components should be
closely inspected following any airbag deployment,
and should be replaced when visible damage is
incurred.
SEAT BELTS AND TENSIONERS
After a frontal impact where an airbag has been
deployed due to a collision. the followingMUSTbe
replaced:
²Front Seat Belt Buckle (driver and passenger)
with integral Tensioners.
All other seat belts should be closely inspected for
cuts, tears, fraying, or damage in any way following
any frontal impact or airbag deployment. The other
seat belts are to be replaced when visible damage is
incurred. Inspect the Lower Anchors and Tether for
CHildren (LATCH) child restraint anchors for dam-
age after an impact event and replace as needed.
CLEAN UP PROCEDURE
Roll or fold the airbag towards its mounting point
(i.e. instrument panel, steering wheel, or seat back).
Then tape the ripped cover over the deployed airbag
if applicable.
Use a vacuum cleaner to remove any residual pow-
der from the vehicle interior. Work from the outside
in to avoid kneeling or sitting in a contaminated
area. Vacuum the heater and A/C outlets as well (Fig.
1). If the heater or air conditioner was in RECIRC
mode at time of airbag deployment, operate blower
motor on low speed and vacuum powder residue
expelled from the heater and A/C outlets. Multiple
RSRESTRAINTS8O-3
RESTRAINTS (Continued)

STANDARD PROCEDURE - CLOCK SPRING
CENTERING
If the rotating tape (wire coil) in the clock spring is
not positioned properly with the steering wheel and
the front wheels, the clock spring may fail. The fol-
lowing procedure MUST BE USED to center the
clock spring if it is not known to be properly posi-
tioned, or if the front wheels were moved from the
straight ahead position.
(1) Position steering wheel and front wheels
straight ahead.
(2) Release hood latch and open hood.
(3) Disconnect and isolate the battery negative
cable.
(4) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(5) Remove driver airbag from steering wheel
(Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER
AIRBAG - REMOVAL).
(6) Disconnect wire connectors from back of driver
airbag.
(7) Disconnect the 2±way connector from remote
radio control harness.
(8) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
(9) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(10) Rotate the clock spring rotor clockwise until
the rotor stops. Do not apply excessive force.
(11) From the end of travel, rotate the rotor two
turns counterclockwise until the wires end up at the
top.
(12) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(13) Connect the 4±way harness connector to the
speed control/horn harness to the clock spring.
(14) Connect the 2±way connector to the remote
radio control harness.
(15) Install the driver airbag (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION). Torque the two screws to 10 N´m (90 in.
lbs.).
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
REMOVAL
(1) Position steering wheel and front wheels
straight ahead.(2) Release hood latch and open hood.
(3) Disconnect and isolate the battery negative
cable.
(4) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(5) Remove driver airbag from steering wheel
(Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER
AIRBAG - REMOVAL).
(6) Disconnect wire connectors from back of driver
airbag.
(7) Disconnect the 2±way connector from remote
radio control harness.
(8) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
(9) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(10) Remove steering column shrouds and discon-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - REMOVAL).
(11) Disconnect 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(12) Remove clock spring from column assembly by
removing the two retaining screws that attach the
clock spring to the column.
INSTALLATION
(1) Install the clock spring on the column.
(2) Connect the 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(3) Install the steering column shrouds and con-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - INSTALLATION).
(4) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(5) Connect the 4±way harness connector to the
speed control/horn harness to the clock spring.
(6) Connect the 2±way connector to the remote
radio control harness.
(7) Install the driver airbag (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION). Torque the two screws to 10 N´m (90 in.
lbs.).
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
RSRESTRAINTS8O-5
CLOCK SPRING (Continued)

DRIVER AIRBAG
DESCRIPTION
The Driver Airbag is located in the center of the
steering wheel. The most visible part of the airbag is
the cover/horn switch. The Driver Airbag and Driver
Airbag Cover/Horn Pad are serviced separately from
each other.
OPERATION
The Driver Airbag cover contains the horn switch,
inflator device, and a fabric bag. The airbag cover/
horn switch is serviced separately from the inflator
and bag components.
When the front airbag system is deployed, the fol-
lowingMUSTbe replaced:
²Complete Steering Column Assembly.
²Lower Steering Column Coupler.
²Steering Wheel.
²Clock Spring.
²Driver Airbag
²Passenger Airbag
²Upper Instrument Panel with Pad.
CARE OF UNDEPLOYED AIRBAGS
Airbags must be stored in their original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag. When carrying or handling an
undeployed airbag, the trim side of the airbag should
be pointing away from the body to minimize possibil-
ity of injury if accidental deployment occurs. Do not
place undeployed airbag face down on a solid surface,
the airbag will propel into the air if accidental
deployment occurs.
REMOVAL
DEPLOYED AIRBAG
(1) Clean powder residue from interior of vehicle
(Fig. 1).
(2) Position steering wheel and front wheels
straight ahead.
(3) Release hood latch and open hood.
(4) Disconnect and isolate the battery negative
cable.
(5) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(6) Remove two screws retaining driver airbag to
steering wheel.
(7) Disconnect wire connectors from back of driver
airbag.
(8) Disconnect the 2±way connector from remote
radio control harness.(9) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
(10) Remove steering wheel (Refer to 19 - STEER-
ING/COLUMN/STEERING WHEEL - REMOVAL).
(11) Remove steering column shrouds and discon-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - REMOVAL).
(12) Disconnect 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(13) Remove clock spring from column assembly by
removing the two retaining screws that attach the
clock spring to the column.
NOTE: The clock spring, steering wheel, and com-
plete steering column assembly w/lower steering
column coupler must be replaced also in the event
of a driver airbag deployment
UNDEPLOYED AIRBAG
(1) Release hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service.
(4) Remove two screws retaining driver airbag to
steering wheel.
(5) Disconnect wire connectors from back of driver
airbag (Fig. 4).
(6) Disconnect the 2±way connector from remote
radio control harness.
Fig. 4 DRIVER AIRBAG WIRE CONNECTIONS
1 - AIRBAG SQUIB CONNECTORS
2 - DRIVER AIRBAG
3 - HORN/SPEED CONTROL CONNECTOR
4 - CLOCK SPRING
8O - 6 RESTRAINTSRS

(7) Disconnect the 4±way harness connector from
the speed control/horn harness to the clock spring.
INSTALLATION
DEPLOYED AIRBAG
(1) Perform clean up procedure (Refer to 8 - ELEC-
TRICAL/RESTRAINTS - STANDARD PROCEDURE
- SERVICE AFTER AN AIRBAG DEPLOYMENT).
(2) Install a new steering column assembly and
lower steering column coupler (Refer to 19 - STEER-
ING/COLUMN - INSTALLATION).
(3) Install the new clock spring.
(4) Connect the 4-way and 6-way connectors
between the clock spring and the instrument panel
wiring harness.
(5) Install the steering column shrouds and con-
nect traction control wire connector (if equipped)
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - INSTALLATION).
(6) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(7) Connect the 4±way harness connector to the
speed control/horn harness to the clock spring.
(8) Connect the 2±way connector to the remote
radio control harness.
(9) Install the driver airbag and the two screws
retaining the airbag. Tighten screws to 10 N´m (90
in. lbs.)
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
UNDEPLOYED AIRBAG
(1) Connect the harness connector on the DAB
cover (horn, speed controls) to the clock spring.
(2) Connect the squib connectors to the DAB.
(3) Position a new airbag into the airbag cavity.
(4) Install the two screws retaining the airbag.
Tighten screws to 10 N´m (90 in. lbs.)
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
DRIVER AIRBAG TRIM COVER
REMOVAL
The horn switch is integral to the driver airbag
trim cover. If either component is faulty or damaged,
the entire driver airbag trim cover and horn switch
unit must be replaced.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge.
(2) Remove the driver airbag from the steering
wheel (Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL).
(3) Remove the plastic wire retainer that captures
the horn switch feed pigtail wire between the upper
left inflator stud and the inflator on the back of the
driver airbag housing and disconnect the speed con-
trol switches (if equipped).
(4) Remove the four nuts that secure the trim
cover retainer to the studs on the back of the driver
airbag housing.
(5) Remove the horn switch ground pigtail wire
eyelet terminal from the upper left airbag housing
stud.
(6) Remove the trim cover retainer from the airbag
housing studs.
(7) Disengage the six trim cover locking blocks
from the lip around the outside edge of the driver
airbag housing and remove the housing from the
cover.
INSTALLATION
(1) Install the housing into the cover. Engage the
six trim cover locking blocks to the lip around the
outside edge of the driver airbag housing.
(2) Install the trim cover retainer to the airbag
housing studs.
(3) Install the horn switch ground pigtail wire eye-
let terminal to the upper left airbag housing stud.
(4) Install the four nuts that secure the upper and
lower trim cover retainers to the studs on the back of
the driver airbag housing. Torque nuts to 6.8 N´m (60
in. lbs.).
(5) Install the plastic wire retainer that captures
the horn switch feed pigtail wire between the upper
left inflator stud and the inflator on the back of the
driver airbag housing.
(6) Connect speed control switches (if equipped).
(7) Install the driver airbag onto the steering
wheel (Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - INSTALLATION).
RSRESTRAINTS8O-7
DRIVER AIRBAG (Continued)

WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
OCCUPANT RESTRAINT
CONTROLLER
DESCRIPTION
The front driver and passenger airbag system is
designed to reduce the risk of fatality or serious
injury, caused by a frontal impact of the vehicle.
The Occupant Restraint Controller (ORC) is also
sometimes referred to as the Airbag Control Module
(ACM). The ORC contains the impact sensor and
energy reserve capacitor. It is mounted on a bracket,
under the instrument panel, just forward of the stor-
age bin. The ORC monitors the system to determine
the system readiness. The ORC contains on-board
diagnostics and will light the AIRBAG warning lamp
in the message center when a problem occurs.
OPERATION
The impact sensor provides verification of the
direction and severity of the impact. One impact sen-
sor is used. It is located inside the Occupant
Restraint Controller (ORC). The impact sensor is an
accelerometer that senses deceleration. The decelera-
tion pulses are sent to a microprocessor which con-
tains a decision algorithm. When an impact is severe
enough to require airbag protection, the ORC micro-
processor sends a signal that completes the electrical
circuit to the driver and passenger airbags. The
impact sensor is calibrated for the specific vehicle
and reacts to the severity and direction of an impact.
REMOVAL
NOTE: Diagnose the ORC using the service/diag-
nostic manual.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove storage bin from instrument panel.
Refer to Body, Instrument Panel, Storage Bin,
Removal.
(3) Remove three bolts holding ORC to floor
bracket.
(4) Disconnect the wire connector from ORC.
(5) Remove the ORC assembly from vehicle.
INSTALLATION
WARNING: DO NOT INSTALL ORC IF MOUNTING
LOCATION IS DEFORMED OR DAMAGED. THIS
WILL CAUSE THE ORC TO BE IMPROPERLY
LOCATED AND COULD RESULT IN OCCUPANT
PERSONAL INJURY OR DEATH.
CAUTION: Use correct screws when installing the
ORC.
(1) Install the ORC assembly into vehicle.
(2) Connect the wire connector to the ORC.
(3) Install three bolts holding ORC to floor
bracket. Torque bolts to 7.3 - 9.6 N´m (65 to 85 in.
lbs.)
(4) Install the storage bin onto the instrument
panel. Refer to Body, Instrument Panel, Storage Bin,
Installation.
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING).
PERSONAL INJURY OR DEATH MAY RESULT IF
THE SYSTEM TEST IS NOT PERFORMED PROP-
ERLY.
PASSENGER AIRBAG
DESCRIPTION
WARNING: NEVER DISASSEMBLE THE PASSEN-
GER AIRBAG, THE PASSENGER AIRBAG HAS NO
SERVICEABLE PARTS. IF TAMPERED WITH INTER-
NALLY, THE AIRBAG COULD DEPLOY AND RESULT
IN PERSONAL INJURY OR DEATH.
The Passenger Airbag is located beneath the
instrument panel and pad assembly. The airbag is
mounted to the back side of the instrument panel
reinforcement.
The instrument panel top pad is the most visible
part of the passenger airbag system. Located under
the instrument panel top pad are the airbag door, the
passenger airbag cushion and the airbag cushion
supporting components.
The passenger airbag includes a magnesium hous-
ing within which the cushion and inflator are
mounted and sealed.
Following a passenger airbag deployment, the pas-
senger airbag and the instrument panel must be
replaced. The passenger airbag cannot be repaired,
and must be replaced if deployed or damaged in any
way.
8O - 8 RESTRAINTSRS
DRIVER AIRBAG TRIM COVER (Continued)

OPERATION
The passenger airbag is equipped with two infla-
tors, each with three levels of pressure output. The
inflators seal the hole in the airbag cushion so it can
discharge the gas it produces directly into the cush-
ion when supplied with the proper electrical signal.
Following an airbag deployment, the airbag cushion
quickly deflates by venting this gas through the
cushion material towards the instrument panel.
The passenger airbag is secured with screws to the
instrument panel beneath the instrument panel top
pad and above the glove box opening. The instrument
panel top pad above the glove box opening conceals
the airbag door and a predetermined hinge line
beneath its decorative cover. Upon airbag deploy-
ment, the top pad will bend at the hinge line and the
door will fold back out of the way onto the top of the
instrument panel.
When the front airbag system is deployed, the fol-
lowingMUSTbe replaced:
²Complete Steering Column Assembly.
²Lower Steering Column Coupler.
²Steering Wheel.
²Clock Spring.
²Driver Airbag.
²Passenger Airbag.
²Upper Instrument Panel with Pad.
CARE OF UNDEPLOYED AIRBAGS
Airbags must be stored in their original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag. When carrying or handling an
undeployed airbag, the trim side of the airbag should
be pointing away from the body to minimize possibil-
ity of injury if accidental deployment occurs. Do not
place undeployed airbag face down on a solid surface,
the airbag will propel into the air if accidental
deployment occurs.
REMOVAL
DEPLOYED AIRBAG
(1) Clean powder residue from interior of vehicle
(Refer to 8 - ELECTRICAL/RESTRAINTS - STAN-
DARD PROCEDURE - SERVICE AFTER AN AIR-
BAG DEPLOYMENT).
(2) Remove instrument panel (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
ASSEMBLY - REMOVAL).
(3) Remove all reusable components from the
upper instrument panel and transfer to the new
instrument panel.
UNDEPLOYED AIRBAG
(1) Open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Wait two minutes for the airbag system reserve
capacitor to discharge before attempting any airbag
or instrument panel service.
(4) Remove center console bin between front seats.
(5) Remove left front door sill plate using a trim
stick (special tool #C-4755) or equivalent, and gently
prying up on sill plate.
(6) Remove left cowl panel using a trim stick or
equivalent, and gently prying out on cowl panel.
(7) Remove four screws to lower steering column
cover and remove cover.
(8) Unsnap parking brake lever from knee blocker
reinforcement.
(9) Remove Data Link Connector (DLC) from knee
blocker.
(10) Remove screws to knee blocker.
(11) Unsnap left A-pillar lower extension trim
using a trim stick or equivalent.
(12) Remove three left side instrument panel A-pil-
lar retaining bolts and loosen the instrument panel
roll down bolt.
(13) Remove four nuts at brake pedal support
bracket to instrument panel.
(14) Using a trim stick or equivalent, gently pry
off left side upper A-pillar trim.
(15) Remove six screws and two wiring connectors
to lower instrument panel cubby bin at bottom of
center stack.
(16) Remove two left side nuts at instrument panel
center stack support to floor.
(17) Remove two right side nuts at instrument
panel center stack support to floor.
(18) Remove right front door sill plate using a trim
stick or equivalent, and gently prying up on sill
plate.
(19) Remove right cowl panel using a trim stick or
equivalent, and gently prying out on cowl panel.
(20) Using a trim stick or equivalent, gently pry
out on right instrument panel end cap.
(21) Unsnap right A-pillar lower extension trim
using a trim stick or equivalent.
(22) Remove three right side instrument panel
A-pillar retaining bolts and loosen the instrument
panel roll down bolt.
(23) Using a trim stick or equivalent, gently pry
off right side upper A-pillar trim.
(24) Open glove box, pinch in sides and roll down
towards floor. With a firm pull, snap glove box door
off hinges and remove.
(25) Using a trim stick or equivalent, gently pry
up on rear of instrument panel top cover and then
pull rearward and out.
RSRESTRAINTS8O-9
PASSENGER AIRBAG (Continued)