2005 CHRYSLER CARAVAN classification

²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API)
²National Lubricating Grease Institute (NLGI)
API CERTIFICATION AND LICENSE SYMBOL
Use an engine oil that is API Certified (GF-3) and
Licensed to display the certification mark (Fig. 2).
MOPARtprovides engine oils that meet or exceed,
Material Standard MS-6395 requirement.
SAE VISCOSITY
SAE 5W-20 and SAE 5W-30 engine oils are rec-
ommended for all operating temperatures.
These engine oils are designed to improve low
temperature starting and vehicle fuel economy.
Refer to the engine oil filler cap for the pre-
ferred engine oil viscosity grade for each vehi-
cle (Fig. 3).SAE viscosity grades are used to specify
the correct viscosity oil for an engine. Use only Multi-
Viscosity oils such as SAE 5W-20 or 5W-30. These
are specified with a dual SAE viscosity grade which
indicates the cold (5W) to hot (20, 30) temperature
performance range of the oil.
CONTAINER IDENTIFICATION
The Engine Oil Certificarion Mark was developed
and trademarked by the API to refer customers to
those engine oils preferred by the automobile manu-
facturers. This symbol means that the oil has been
certified and licensed by the American Petroleum
Institute (API). This certification mark will only be
found on the front of the oil containers. Those oilsthat do not display the ªMarkº on the front of the
container should not be used (Fig. 2).
DiamlerChrysler only recommends API Certified
engine oils that meet the requirements of Material
Standard MS-6395. Use Mopar or an equivalent oil
meeting the specification MS-6395.
SYNTHETIC ENGINE OILS
There are a number of engine oils being promoted
as either synthetic or semi-synthetic. If you chose to
use such a product, useonlythose oils that are cer-
tified by the American Petroleum Institute (API) to
display the ªCertification Markº and show SAE vis-
cosity grade recommended for each vehicle. Follow
the service schedule that describes your driving type.
ENGINE OIL ADDITIVES/SUPPLEMENTS
The manufacturerdoes not recommendthe addi-
tion of any engine oil additives/supplements to the
specified engine oil. Engine oil additives/supplements
should not be used to enhance engine oil perfor-
mance. Engine oil additives/supplements should not
be used to extend engine oil change intervals. No
additive is known to be safe for engine durability and
can degrade emission components. Additives can con-
tain undesirable materials that harm the long term
durability of engines by:
²Increasing the level of Phosphorus and Sulfur in
the engine oil. The API Certified Engine Oils control
the Phosphorus and Sulfur contents of the oil to lev-
els that reduce the contamination effect on the vehi-
cles emission control system.
²Altering the viscosity characteristics of the
engine oil so that it no longer meets the require-
ments of the specified viscosity grade.
²Creating potential for an undesirable additive
compatibility interaction in the engine crankcase.
The engine oils contain a performance additive sys-
tem carefully developed to optimize the oils perfor-
mance in the engine. The addition of supplements
may cause the oil to thicken prematurely, cause
excessive deposit build up and potentially shorten
engine life.
AXLE LUBRICANTS
SAE ratings also apply to multigrade gear lubri-
cants. In addition, API classification defines the
lubricants usage. Such as API GL-5 and SAE 75W-
90.
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 4) on the label. At the bottom of the
NLGI symbol is the usage and quality identification
letters. Wheel bearing lubricant is identified by the
Fig. 2 API Certification Mark
Fig. 3 5W-30 Oil Filler Cap
0 - 2 LUBRICATION & MAINTENANCERS
FLUID TYPES (Continued)

DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE
WARNING: DO NOT USE ALCOHOL OR GASOLINE
AS A FUEL BLENDING AGENT. THEY CAN BE
UNSTABLE UNDER CERTAIN CONDITIONS AND
HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH
DIESEL FUEL.
Use good quality diesel fuel from a reputable sup-
plier. For most year-round service, number 2 diesel
fuel meeting DIN EN 590 (Class0-4)will provide
good performance. If the vehicle is exposed to
extreme cold (below -18ÉC/0ÉF) or is required to oper-
ate at colder than normal conditions for prolonged
periods, use climatize No. 2 diesel fuel or dilute the
No. 2 diesel fuel with 50% No. 1 diesel fuel as long as
it meets ASTM D 975: 1D and 2D and the quality of
lubrication behavior is in accordance with DIN EN
590. This will provide better protection from fuel gel-
ling or wax plugging of the fuel filters.
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez-
ing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good quality fuel and follow
the cold weather advice above, fuel conditioners should
not be required in your vehicle. If available in your
area, a high cetane ªpremiumº diesel fuel may offer
improved cold starting and warm up performance.
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES
Use only Diesel Engine Oil meeting standardMIL-
2104Cor API ClassificationCD or higherorCCML
D4, D5.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.
To assure of properly formulated engine oils, it is
recommended that SAE Grade 10W-40 engine oils
that meet Chrysler material standard MS-6395, be
used in accordance to ACEA B3, B4 specification.
European Grade 10W-40 oils are also acceptable.
Oils of the SAE 5W-40 grade number are preferred
when minimum temperatures consistently fall below
-15ÉC.
DESCRIPTION - AWD REAR DRIVELINE
MODULE FLUIDS
The AWD Rear Driveline Module Assembly consists
of two subassemblies, the Overrunning Clutch Hous-
ing (front) and the Differential Carrier (rear).The recommended lubricant for the Overrunning
Clutch Housing is MopartATF+4. The recommended
lubricant for the Differential Carrier is Mopart
80W-90 Gear and Axle Lubricant.
DESCRIPTION - AWD POWER TRANSFER UNIT
FLUID
The recommended lubricant for the AWD Power
Transfer Unit is MopartGear and Axle Lubricant
80W-90.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
Fuel Tank (Gas) 75 L (20 gal.)
Fuel Tank (Diesel) 75 L (20 gal.)
Engine Oil* - 2.4 L 4.7 L (5.0 qts.)
Engine Oil* - 3.3/3.8 L 4.7 L (5.0 qts.)
Engine Oil* - 2.5 L
(Diesel)6.0 L (6.3 qts.)
Cooling System** - 2.4 L 10.7 L (11.4 qts.)
Cooling System** - 2.5 L
Turbo Diesel with
Auxiliary Heater13.8 L (14.6 qts.)
Cooling System** -
3.3/3.8 L without Auxiliary
Heater12.6 L (13.4 qts.)
Cooling System** -
3.3/3.8 L with Auxiliary
Heater15.4 L (16.3 qts.)
Automatic Transaxle -
Service Fill3.8 L (4.0 qts.)
Automatic Transaxle -
4XTE Overhaul Fill9.2 L (9.7 qts.)
Manual Transaxle (T850
5-Speed)2.4-2.7 L (2.5-2.9 qts.)
AWD Power Transfer Unit 1.15 L (2.4 pts.)
Power Steering 1.2 L (2.5 pts.)
AWD Bi-directional
Overrunning Clutch0.575 L (1.22 pts.)
AWD Rear Carrier 0.7 L (1.48 pts.)
* (includes oil filter)
** (includes heater and recovery/reserve bottle)
0 - 6 LUBRICATION & MAINTENANCERS
FLUID TYPES (Continued)

(5) Inspect the battery built-in test indicator sight
glass (if equipped) for an indication of the battery
condition. If the battery is discharged, charge as
required. (Refer to 8 - ELECTRICAL/BATTERY SYS-
TEM/BATTERY - STANDARD PROCEDURE - BAT-
TERY CHARGING) for the proper battery charging
procedures.
SPECIFICATIONS
BATTERY
The battery Group Size number, the Cold Cranking
Amperage (CCA) rating, and the Reserve Capacity(RC) rating or Ampere-Hours (AH) rating can be
found on the original equipment battery label. Be
certain that a replacement battery has the correct
Group Size number, as well as CCA, and RC or AH
ratings that equal or exceed the original equipment
specification for the vehicle being serviced. Battery
sizes and ratings are discussed in more detail below.
²Group Size- The outside dimensions and ter-
minal placement of the battery conform to standards
established by the Battery Council International
(BCI). Each battery is assigned a BCI Group Size
number to help identify a correctly-sized replace-
ment.
²Cold Cranking Amperage- The Cold Crank-
ing Amperage (CCA) rating specifies how much cur-
rent (in amperes) the battery can deliver for thirty
seconds at -18É C (0É F). Terminal voltage must not
fall below 7.2 volts during or after the thirty second
discharge period. The CCA required is generally
higher as engine displacement increases, depending
also upon the starter current draw requirements.
²Reserve Capacity- The Reserve Capacity (RC)
rating specifies the time (in minutes) it takes for bat-
tery terminal voltage to fall below 10.5 volts, at a
discharge rate of 25 amperes. RC is determined with
the battery fully-charged at 26.7É C (80É F). This rat-
ing estimates how long the battery might last after a
charging system failure, under minimum electrical
load.
²Ampere-Hours- The Ampere-Hours (AH) rat-
ing specifies the current (in amperes) that a battery
can deliver steadily for twenty hours, with the volt-
age in the battery not falling below 10.5 volts. This
rating is also sometimes identified as the twenty-
hour discharge rating.
BATTERY CLASSIFICATIONS & RATINGS
Part NumberBCI Group Size
ClassificationCold Cranking
AmperageReserve
CapacityAmpere -
HoursLoad Test
Amperage
4686158AD 34 500 110 Minutes 60 250
4727159AD 34 600 120 Minutes 66 300
4727242AD DIN H6 600 120 Minutes 66 300
4868999AA 34 700 90 Minutes 50 350
Fig. 3 Clean Battery Terminal Post - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
8F - 6 BATTERY SYSTEMRS
BATTERY SYSTEM (Continued)

RESTRAINTS
TABLE OF CONTENTS
page page
RESTRAINTS
DESCRIPTION..........................2
OPERATION............................4
WARNING
WARNINGS...........................5
DIAGNOSIS AND TESTING - AIRBAG SYSTEM . 6
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
AIRBAGS.............................6
STANDARD PROCEDURE - SERVICE
AFTER AN AIRBAG DEPLOYMENT.........7
BELT TENSION SENSOR
DESCRIPTION..........................8
OPERATION............................9
CHILD RESTRAINT ANCHOR
DESCRIPTION..........................9
OPERATION...........................10
CLOCKSPRING
DESCRIPTION.........................10
OPERATION...........................11
STANDARD PROCEDURE - CLOCKSPRING
CENTERING.........................11
REMOVAL.............................12
INSTALLATION.........................12
CURTAIN AIRBAG
DESCRIPTION.........................12
OPERATION...........................13
REMOVAL.............................14
INSTALLATION.........................16
DRIVER AIRBAG
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................17
INSTALLATION.........................18
IMPACT SENSOR
DESCRIPTION.........................18
REMOVAL.............................19
INSTALLATION.........................21
KNEE BLOCKER AIRBAG
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................23
INSTALLATION.........................23
OCCUPANT CLASSIFICATION MODULE
DESCRIPTION.........................25
OPERATION...........................25
REMOVAL.............................26
INSTALLATION.........................26OCCUPANT RESTRAINT CONTROLLER
DESCRIPTION.........................27
OPERATION...........................28
REMOVAL.............................29
INSTALLATION.........................29
PASSENGER AIRBAG
DESCRIPTION.........................30
OPERATION...........................30
REMOVAL.............................30
INSTALLATION.........................32
PASSENGER AIRBAG DISABLED INDICATOR
DESCRIPTION.........................33
OPERATION...........................33
REMOVAL.............................34
INSTALLATION.........................34
SEAT BELT BUCKLE - FRONT INBOARD
REMOVAL.............................35
INSTALLATION.........................35
SEAT BELT BUCKLE - FIRST ROW INBOARD -
QUAD BUCKET
REMOVAL.............................35
INSTALLATION.........................36
SEAT BELT BUCKLE - FIRST ROW - BENCH
REMOVAL.............................36
INSTALLATION.........................37
SEAT BELT BUCKLE - SECOND ROW
INBOARD - 50/50 BENCH
REMOVAL.............................37
INSTALLATION.........................38
SEAT BELT HEIGHT ADJUSTER-BOR
C-PILLAR
REMOVAL.............................38
INSTALLATION.........................38
SEAT BELT HEIGHT ADJUSTER KNOB
REMOVAL.............................38
INSTALLATION.........................38
SEAT BELT & RETRACTOR - OUTBOARD -
FRONT
REMOVAL.............................38
INSTALLATION.........................39
SEAT BELT & RETRACTOR - FIRST ROW -
OUTBOARD
REMOVAL.............................39
INSTALLATION.........................40
SEAT BELT BUCKLE - SECOND ROW - THREE
PASSENGER BENCH
REMOVAL.............................40
INSTALLATION.........................40
RSRESTRAINTS8O-1

²Occupant Classification System- These
vehicles also include an Occupant Classification Sys-
tem (OCS) with components that are located on or in
the passenger front seat cushion. These components
include an Occupant Classification Module (OCM)
and a seat weight bladder and pressure sensor
assembly. In addition, this system includes a belt
tension sensor integral to the lower anchor of the
passenger side front seat belt. Vehicles equipped with
the OCS can be readily identified by a Passenger Air-
bag Disabled (PAD) indicator (Fig. 1) located in the
center stack on the instrument panel above HVAC
control head and radio.
²Curtain Airbags- Curtain airbags are avail-
able for this model when it is also equipped with
dual front airbags. This airbag system is a passive,
inflatable, Supplemental Restraint System (SRS) and
vehicles with this equipment can be readily identified
by a molded identification trim button with the ªSRS
- AIRBAGº logo (Fig. 2) located on the headliner
above each B-pillar.
This vehicle is equipped with a Frontal Impact Air-
bag System, which utilizes the driver/passenger air-
bags, driver knee blocker airbag, and seat belt
tensioners. This system is designed to protect occu-
pants in the event of a front impact collision. These
airbags and seat belt tensioners are all serviceable
parts. If these pyrotechnics are deployed or defective,
they must be replaced, as well as the OccupantRestraint Controller (ORC) must be diagnosed follow-
ing procedures outlined in the diagnostic information.
The Driver and Passenger Airbag System was
designed to reduce the likelihood of injury or death
in frontal collisions. Each separate system is supple-
mental (Fig. 2) orPassiveto the primary restraint
device, which are the seat belts.
²Airbag Indicator- The airbag indicator is inte-
gral to the Instrument Cluster, which is located on
the instrument panel in front of the driver.
²Belt Tension Sensor- Vehicles equipped with
the Occupant Classification System (OCS) include a
belt tension sensor. This sensor is integral to the pas-
senger side front seat belt lower anchor which is
secured to the floor, out board and rear of the front
passenger seat. -.....concealed beneath an access cover
on the seat belt assembly.
²Clockspring- The clockspring is located near
the top of the steering column, directly beneath the
steering wheel (Fig. 3).
²Curtain Airbag- A side curtain airbag is
located on each inside roof side rail above the head-
liner, and extends from the A-pillar to just beyond
the D-pillar.
²Driver Airbag- The driver airbag is located in
the center of the steering wheel, beneath the driver
airbag trim cover (Fig. 3).
²Front Impact Sensor- Two front impact sen-
sors are used on vehicles equipped with dual front
airbags, one left side and one right side. The sensors
are located on the rail tips, rearward of the bumper
attachments.
²Knee Blocker Airbag- The driver knee blocker
airbag is secured to the instrument panel behind the
steering column opening cover (Fig. 3).
Fig. 1 PAD INDICATOR
Fig. 2 SRS LOGO
Fig. 3 AIRBAG COMPONENT LOCATION -
INSTRUMENT PANEL
1 - DRIVER AIRBAG
2 - PASSENGER AIRBAG DISABLED (PAD) INDICATOR
3 - PASSENGER AIRBAG
4 - OCCUPANT RESTRAINT CONTROLLER (ORC)
5 - KNEE BLOCKER AIRBAG
RSRESTRAINTS8O-3
RESTRAINTS (Continued)

²Occupant Classification Module- Vehicles
equipped with the Occupant Classification System
(OCS) include an Occupant Classification Module
(OCM) which is secured to a stamped steel mounting
bracket on the underside of the passenger side front
seat cushion frame.
²Occupant Restraint Controller- The Occu-
pant Restraint Controller (ORC) is also sometimes
referred to as the Airbag Control Module (ACM). The
ORC is located on a mount on the floor transmission
tunnel just underneath the instrument panel center
stack (Fig. 3).
²Passenger Airbag- The passenger airbag is
located on the instrument panel, beneath the instru-
ment panel top pad and above the glove box on the
passenger side of the vehicle (Fig. 3).
²Passenger Airbag Disabled (PAD) Indicator
- Vehicles equipped with the Occupant Classification
System (OCS) include a passenger airbag disabled
(PAD) indicator which is located in the instrument
panel center stack (Fig. 3).
²Passenger Knee Blocker- The passenger knee
blocker is a structural reinforcement that is integral
to and concealed within the glove box door (Fig. 3).
²Seat Belt Tensioner- A seat belt tensioner is
integral to both front seat belt buckles. The seat belt
buckles are secured to the inner seat frame sides,
beneath a cushion trim panel.
²Seat Weight Bladder and Pressure Sensor
Assembly- Vehicles equipped with the Occupant
Classification System (OCS) include a seat weight
bladder that is sandwiched between an insulator pad
on the top of the passenger side front seat pan and
the seat cushion foam padding. A short hose connects
the bladder to a pressure sensor which is secured to
the Occupant Classification Module (OCM) mounting
bracket on the underside of the passenger side front
seat cushion frame.
²Side Impact Sensors- Six side impact sensors
are used on vehicles equipped with the curtain air-
bags, three left side and three right side. The first
row side impact sensor is located in the B-pillar, just
above the front seat belt retractor. The second row
side impact sensor is located in the sliding side door
track opening, just in front of the C-pillar. The third
row side impact sensor is located behind the quarter
trim panel, above the rear tire wheel well, between
the C and D-pillars.
The ORC, the OCM, and the cluster each contain a
microprocessor and programming that allow them to
communicate with each other using the Programma-
ble Communications Interface (PCI) data bus net-
work. This method of communication is used by the
ORC for control of the airbag indicators.OPERATION
ACTIVE RESTRAINTS
The primary passenger restraints in this or any
other vehicle are the seat belts and child restraint
anchors. Seat belts and child restraint anchors are
referred to as an active restraint because the vehicle
occupants are required to physically fasten and prop-
erly adjust these restraints in order to benefit from
them. See the owner's manual in the vehicle glove
box for more information on the features, use and
operation of all of the active restraints.
PASSIVE RESTRAINTS
The passive restraints are referred to as a supple-
mental restraint system because they were designed
and are intended to enhance the protection for the
occupants of the vehicleONLYwhen used in con-
junction with the seat belts. They are referred to as
passive restraints because the vehicle occupants are
not required to do anything to make them operate;
however, the vehicle occupants must be wearing their
seat belts in order to obtain the maximum safety
benefit from the supplemental restraint system.
The supplemental restraint system electrical cir-
cuits are continuously monitored and controlled by a
microprocessor and software contained within the
Occupant Restraint Controller (ORC). An airbag indi-
cator in the ElectroMechanical Instrument Cluster
(EMIC) illuminates for about seven seconds as a bulb
test each time the ignition switch is turned to the
ON or START positions. Following the bulb test, the
airbag indicator is turned ON or OFF by the ORC to
indicate the status of the supplemental restraint sys-
tem. If the airbag indicator comes ON at any time
other than during the bulb test, it indicates that
there is a problem in the supplemental restraint sys-
tem electrical circuits. Such a problem may cause air-
bags not to deploy when required, or to deploy when
not required.
Deployment of the supplemental restraints
depends upon the angle and severity of an impact.
Deployment is not based upon vehicle speed; rather,
deployment is based upon the rate of deceleration as
measured by the forces of gravity (G force) upon the
impact sensors. When an impact is severe enough,
the microprocessor in the ORC signals the inflator of
the appropriate airbag units to deploy their airbag
cushions. The front seat belt tensioners are provided
with a deployment signal by the ORC in conjunction
with the front airbags. During a frontal vehicle
impact, the knee blockers work in concert with prop-
erly fastened and adjusted seat belts to restrain both
the driver and the front seat passenger in the proper
position for an airbag deployment. The knee blockers
also absorb and distribute the crash energy from the
8O - 4 RESTRAINTSRS
RESTRAINTS (Continued)

driver and the front seat passenger to the structure
of the instrument panel (Refer to 8 - ELECTRICAL/
RESTRAINTS/KNEE BLOCKER AIRBAG -
DESCRIPTION). The seat belt tensioners remove the
slack from the front seat belts to provide further
assurance that the driver and front seat passenger
are properly positioned and restrained for an airbag
deployment.
When the ORC monitors a problem in any of the
dual front airbag system circuits or components,
including the seat belt tensioners, it stores a Diag-
nostic Trouble Code (DTC) in its memory and sends
an electronic message to the EMIC to turn on the
airbag indicator. Proper testing of the supplemental
restraint system components, the Programmable
Communications Interface (PCI) data bus, the elec-
tronic message inputs to and outputs from the EMIC
or the ORC, as well as the retrieval or erasure of a
DTC from the ORC or the EMIC requires the use of
a scan tool. Refer to the appropriate diagnostic infor-
mation.
OCCUPANT CLASSIFICATION SYSTEM
The Occupant Classification System (OCS) auto-
matically suppresses or enables passenger airbag and
seat belt tensioner operation based upon whether or
not the passenger side front seat is occupied and, if
the seat is occupied, classifies the size of the occu-
pant and whether the seat is occupied by a child
seat.
The OCS has an Occupant Classification Module
(OCM) that monitors inputs from the seat weight
bladder pressure sensor under the passenger side
front seat cushion and from the belt tension sensor
on the passenger side front seat belt lower anchor.
Based upon those inputs the microprocessor within
the OCM classifies the occupant of the passenger
side front seat. The OCM then sends electronic occu-
pant classification messages to the ORC. The micro-
processor and programming of the ORC uses these
occupant classification messages to determine
whether to enable or disable the deployment circuits
for the passenger airbag and seat belt tensioner.
The OCS electrical circuits and components are
continuously monitored by the OCM, and the OCM is
continuously monitored by the ORC. A passenger air-
bag ON/OFF indicator is located in the instrument
panel center stack area. This indicator receives bat-
tery current whenever the ignition switch is in the
ON or START positions, and illuminates only when
the ORC pulls the indicator control circuit to ground.
The indicator illuminates for about seven seconds as
a bulb test each time the ignition switch is turned to
the ON or START positions. Following the bulb test,
the indicator is turned ON or OFF by the ORC based
upon the electronic occupant classification messagesreceived from the OCM. This indicator is illuminated
whenever the passenger airbag and seat belt ten-
sioner operation has been suppressed, and is turned
OFF whenever they are enabled or when the passen-
ger seat is classified as empty.
When the OCM monitors a problem in any of the
OCS circuits or components, it stores a fault code or
DTC in its memory circuit and sends an electronic
message to the ORC. The ORC then sends an elec-
tronic message to the EMIC to turn ON the airbag
indicator. If for any reason the OCM is unable to
classify the occupant it sends an electronic message
to the ORC, and the ORC suppresses passenger air-
bag and seat belt tensioner operation. Proper testing
of the OCS components, the Programmable Commu-
nications Interface (PCI) data bus, the electronic
message inputs to and outputs from the OCM, the
EMIC or the ORC, as well as the retrieval or erasure
of a DTC's, requires the use of a scan tool. Refer to
the appropriate diagnostic information.
WARNING
WARNINGS
Disconnect and isolate the battery negative
cable before beginning any airbag system com-
ponent diagnosis, testing, removal, or installa-
tion procedures. Allow system capacitor to
discharge for two minutes before beginning any
component testing or service. This will disable
the airbag system. Failure to disconnect the
battery negative cable may result in accidental
airbag deployment, personal injury, or death.
Do not place an intact undeployed airbag
face down on a solid surface. The airbag will
propel into the air if accidentally deployed and
may result in personal injury or death.
When carrying or handling an undeployed
airbag, the trim side (face) of the airbag should
be pointing towards the body to minimize pos-
sibility of injury if accidental deployment
occurs. Failure to do this may result in per-
sonal injury or death.
Replace airbag system components with
Mopartreplacement parts. Substitute parts
may appear interchangeable, but internal dif-
ferences may result in inferior occupant protec-
tion. Failure to do so may result in occupant
personal injury or death.
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 experienced. If nasal or throat irritation is
RSRESTRAINTS8O-5
RESTRAINTS (Continued)

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. This may result in
improper deployment, personal injury, or
death.
The factory installed fasteners, screws and
bolts used to fasten airbag components have a
special coating and are specifically designed
for the airbag system. Do not use substitute fas-
teners. Use only original equipment fasteners
listed in the parts catalog when fastener
replacement is required.
During, and following, any child restraint
anchor service, due to impact event or vehicle
repair, carefully inspect all mounting hard-
ware, 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. Failure to do this
may result in personal injury or death.
Deployed and nondeployed airbags may or
may not have live pyrotechnic material within
the airbag inflator. Do not dispose of driver/
passenger/seat/curtain/knee blocker airbags or
seat belt tensioners unless you are sure of com-
plete deployment. Refer to the Hazardous Sub-
stance Control System for proper disposal.
Dispose of deployed airbags and tensioners
consistent with state, provincial, local, and fed-
eral regulations.
After any airbag component testing or ser-
vice, do not connect the battery negative cable
(Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM).
Personal injury or death may result if the sys-
tem test is not performed first.
If the vehicle is equipped with the Occupant
Classification System (OCS), do not connect the
battery negative cable before performing the
OCS Verification Test using the scan tool and
the appropriate diagnostic information. Per-
sonal injury or death may result if the system
test is not performed properly.
Never replace both the Occupant Restraint
Controller (ORC) and the Occupant Classifica-
tion Module (OCM) at the same time. If both
require replacement, replace one, then perform
the Airbag System test (Refer to 8 - ELECTRI-
CAL/RESTRAINTS - DIAGNOSIS AND TESTING
- AIRBAG SYSTEM) before replacing the other.
Both the ORC and the OCM store Occupant
Classification System (OCS) calibration data,
which they transfer to one another when one of
them is replaced. If both are replaced at thesame time, an irreversible fault will be set in
both modules and the OCS may malfunction
and cause personal injury or death.
DIAGNOSIS AND TESTING - AIRBAG SYSTEM
(1) With the battery negative remote cable discon-
nected, connect the scan tool to the Data Link Con-
nector (DLC).
(2) Turn the ignition key to the ON position, then
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 diagnostic information 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 8 - ELECTRICAL/
INSTRUMENT CLUSTER - DIAGNOSIS AND
TESTING). Refer to the proper diagnostic informa-
tion for any other system problems.
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
AIRBAGS
DEPLOYED AIRBAG
WARNING: The vehicle interior may contain a very
small amount of powder, a by-product of airbag
deployment. This 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.
8O - 6 RESTRAINTSRS
RESTRAINTS (Continued)