2005 CHRYSLER VOYAGER ail

CARE OF UNDEPLOYED AIRBAGS
WARNING: 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 toward the body to mini-
mize possibility 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. 4).
(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)
WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to
do so may result in accidental airbag deployment,
personal injury or death.
(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 clockspring.
(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 clockspring and the instrument panel
wiring harness.
(13) Remove clockspring from column assembly by
removing the two retaining screws that attach the
clockspring to the column.
WARNING: The clockspring, steering wheel, and
complete steering column assembly w/lower steer-
ing column coupler must be replaced also in theevent of a driver airbag deployment. Personal injury
or death may result if not replaced.
UNDEPLOYED AIRBAG
(1) Release hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
WARNING: Wait two minutes for the system reserve
capacitor to discharge before beginning any airbag
component service. Personal injury or death may
result.
(3) Remove two screws retaining driver airbag to
steering wheel.
(4) Disconnect wire connectors from back of driver
airbag (Fig. 20).
(5) Disconnect the 2±way connector from remote
radio control harness.
(6) Disconnect the 4±way harness connector from
the speed control/horn harness to the clockspring.
(7) Remove driver airbag from vehicle.
WARNING: When carrying or handling an unde-
ployed airbag, the trim side of the airbag should be
pointing toward the body to minimize the possibility
of injury if accidental deployment occurs. Do not
place undeployed airbag face down on a solid sur-
face, the airbag will propel into the air if accidental
deployment occurs. Failure to do this may result in
personal injury or death.
Fig. 20 DRIVER AIRBAG WIRE CONNECTIONS
1 - AIRBAG SQUIB CONNECTORS
2 - DRIVER AIRBAG
3 - HORN/SPEED CONTROL CONNECTOR
4 - CLOCK SPRING
RSRESTRAINTS8O-17
DRIVER AIRBAG (Continued)

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 clockspring.
(4) Connect the 4-way and 6-way connectors
between the clockspring 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 clockspring.
(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 negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
UNDEPLOYED AIRBAG
(1) Connect the harness connector on the driver
airbag trim cover (horn, speed controls) to the clock-
spring.
(2) Connect the squib connectors to the driver air-
bag.
(3) Position the driver airbag into the steering
wheel.
(4) Install the two screws retaining the airbag.
Tighten screws to 10 N´m (90 in. lbs.)
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
IMPACT SENSOR
DESCRIPTION
FRONT IMPACT SENSORS
There are two front impact sensors (Fig. 21), one
on the left, and one on the right front sides of the
vehicle. These sensors are mounted remotely from
the impact sensor that is internal to the Occupant
Restraint Controller (ORC). The right and left front
and side impact sensors are identical in construction
and calibration and each front impact sensor is
secured with two screws. The front impact sensors
are secured with two screws to the outboard sides of
the right and left front rail tips.
The impact sensor housing has an integral connec-
tor and two mounting ears, each with a metal sleeve
to provide crush protection. A cavity in the center of
the molded black plastic impact sensor housing con-
tains the electronic circuitry of the sensor which
includes an electronic communication chip and an
electronic impact sensor. Potting material fills the
cavity to seal and protect the internal electronic cir-
cuitry and components. The front impact sensors are
each connected to the vehicle electrical system
through the headlamp to dash wire harness.
The front impact sensors cannot be repaired or
adjusted and, if damaged or faulty, they must be
replaced. If a front impact sensor is faulty, only the
sensor needs to be replaced. If the sensor is damaged
or faulty, or if proper tightening torque of the screws
that secure the sensor to the bracket cannot be
achieved, the sensor and bracket must be replaced.
Refer to the proper body diagnostic information for
diagnosis and testing.
Fig. 21 FRONT IMPACT SENSOR
8O - 18 RESTRAINTSRS
DRIVER AIRBAG (Continued)

SIDE IMPACT SENSORS
Three side impact sensors (Fig. 22) are used on
each side of the vehicle. These sensors are mounted
remotely from the bi-directional safing sensor that is
internal to the Occupant Restraint Controller (ORC).
The side and front impact sensors are identical in
construction and calibration and each impact sensor
is secured with two screws. Each side impact sensor
is secured with two screws. The first row side impact
sensor is located in the B-pillar, just above the front
seat belt retractor (Fig. 23). The second row side
impact sensor is located in the sliding door opening,in the lower door track area (Fig. 23). 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 (Fig. 23).
The impact sensor housing has an integral connec-
tor. 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 connector of the body
harness.
The side impact sensors cannot be repaired or
adjusted. If damaged or faulty, they must be
replaced. Refer to the proper body diagnostic infor-
mation for diagnosis and testing.
REMOVAL
FRONT IMPACT SENSOR
The right and left front impact sensors are
mounted identically on the front rail tips.
(1) Open hood, disconnect and isolate the battery
negative cable.
(2)
WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to
do so may result in accidental airbag deployment,
personal injury or death.
Fig. 23 SIDE IMPACT SENSOR LOCATION
1 - FRONT ROW SIDE IMPACT SENSOR 3 - THIRD ROW SIDE IMPACT SENSOR
2 - SECOND ROW SIDE IMPACT SENSOR
Fig. 22 SIDE IMPACT SENSOR
RSRESTRAINTS8O-19
IMPACT SENSOR (Continued)

(3) Hoist vehicle.
(4) Disconnect electrical connector (Fig. 24).
(5) Remove the two screws attaching front impact
sensor to outer rails (Fig. 24).
(6) Remove sensor from vehicle.
SIDE IMPACT SENSORS
B-PILLAR MOUNTED
The right and left front row side impact sensors,
are mounted identically, on opposite sides of the vehi-
cle, in the b-pillar.
(1) Open hood, disconnect and isolate the battery
negative cable.
(2)
WARNING: Wait two minutes for the system reserve
capacitor to discharge before beginning any airbag
component service. Personal injury or death may
result.
(3) Remove the B-pillar lower trim for the side of
the vehicle that you are replacing the side impact
sensor (Refer to 23 - BODY/INTERIOR/B-PILLAR
LOWER TRIM - REMOVAL).
(4) Disconnect the electrical connector from the
impact sensor (Fig. 25).
(5) Remove the four retaining screws to the impact
sensor bracket (Fig. 25).
(6) Remove impact sensor from vehicle (Fig. 26).
SLIDING DOOR OPENING MOUNTED
The right and left second row side impact sensors,
are mounted identically, on opposite sides of the vehi-cle, in the sliding door opening lower rear where the
lower roller arm mounts in the lower door track.
(1) Open hood, disconnect and isolate the battery
negative cable.
(2)
Fig. 24 FRONT IMPACT SENSOR REMOVE/INSTALL
1 - FRONT IMPACT SENSOR WIRE HARNESS RETAINER
2 - FRONT IMPACT SENSOR RETAINING SCREW
3 - FRONT IMPACT SENSOR WIRE HARNESS
4 - FRONT IMPACT SENSOR
5 - LOWER RADIATOR SUPPORT
Fig. 25 FRONT ROW SIDE IMPACT SENSOR AND
BRACKET
1 - B-PILLAR
2 - FRONT ROW SIDE IMPACT SENSOR ELECTRICAL
CONNECTOR
3 - FRONT ROW SIDE IMPACT SENSOR AND MOUNTING
BRACKET
4 - FRONT ROW SIDE IMPACT SENSOR RETAINING SCREW
Fig. 26 FRONT ROW SIDE IMPACT SENSOR/
BRACKET
1 - FRONT ROW SIDE IMPACT SENSOR
2 - SENSOR TO BRACKET ATTACHMENT
3 - FRONT ROW SIDE IMPACT SENSOR MOUNTING BRACKET
8O - 20 RESTRAINTSRS
IMPACT SENSOR (Continued)

REMOVAL
(1) Open hood, disconnect and isolate the battery
negative cable.
(2)
WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to
do so may result in accidental airbag deployment,
personal injury or death.
(3) Remove the steering column opening cover two
retaining screws (Fig. 31) and unsnap cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - REMOVAL).
(4) Disconnect the knee blocker airbag electrical
connector (Fig. 32).
(5) Remove five knee blocker airbag retaining bolts
from airbag (Fig. 33).
(6) Remove knee blocker airbag from vehicle.
INSTALLATION
(1) Place the knee blocker airbag into position in
the instrument panel opening (Fig. 33).
(2) Connect the one electrical connector (Fig. 32).
(3) Install the five knee blocker airbag retaining
bolts (Fig. 33).
(4) Position the steering column opening cover
over retaining slots and firmly snap into place (Fig.
31). Install the two retaining screws (Fig. 31) (Refer
to 23 - BODY/INSTRUMENT PANEL/STEERING
COLUMN OPENING COVER - INSTALLATION).
WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
(5) Verify vehicle and system operation.
(6) Close hood.
Fig. 30 KNEE BLOCKER AIRBAG LOCATION
1 - KNEE BLOCKER AIRBAG 3 - UNDER STEERING COLUMN COVER RETAINING SCREWS
2 - UNDER STEERING C0LUMN COVER
RSRESTRAINTS8O-23
KNEE BLOCKER AIRBAG (Continued)

OCCUPANT CLASSIFICATION
MODULE
DESCRIPTION
The Occupant Classification Module (OCM) (Fig.
34) is secured with two screws to a stamped steel
mounting bracket welded onto the underside of the
passenger front seat cushion frame near the inboard
front corner (Fig. 35). Concealed within a hollow in
the center of the molded plastic OCM housing is a
microprocessor and the other electronic circuitry of
the module. The module housing is sealed to enclose
and protect the internal electronic circuitry. The
OCM software is flash programmable.
A non-calibrated OCM is the only component of the
Occupant Classification System (OCS) that is avail-
able for separate service replacement. The OCS com-
ponents of the passenger side front seat cushion
including the cushion frame, insulator pad, seat
weight bladder and pressure sensor, seat cushion
foam, wiring harness and the OCM are a factory-cal-
ibrated and assembled unit. Once this unit is con-
nected to a vehicle electrically, the calibration
settings are uploaded from the calibrated OCM and
stored in the memory of the Occupant Restraint Con-
troller (ORC). If only the OCM is subsequently
replaced, the new, non-calibrated OCM learns the
proper calibration settings from the ORC after it is
connected to the vehicle electrically.The OCM cannot be adjusted or repaired and, if
damaged or faulty, it must be replaced. The compo-
nents of the passenger front seat cushion are ser-
viced only as a factory-calibrated, assembled and
tamper-evident unit. Only the OCM and the seat
cushion trim are available for separate service
replacement. Once a service replacement package has
been installed in a vehicle, the OCM can thereafter
be serviced only by replacing the entire passenger
front seat cushion with another complete service
replacement package.
OPERATION
The microprocessor in the Occupant Classification
Module (OCM) contains the Occupant Classification
System (OCS) logic circuits. The OCM uses On-Board
Diagnostics (OBD) and can communicate with other
electronic modules in the vehicle as well as with a
scan tool using the Programmable Communications
Interface (PCI) data bus network. This method of
communication is also used for OCS diagnosis and
testing through the 16-way Data Link Connector
(DLC), located on the driver side lower edge of the
instrument panel.
The OCM provides a nominal five volts to both the
pressure sensor of the seat weight bladder beneath
the passenger front seat cushion and to the belt ten-
sion sensor on the passenger front seat belt lower
Fig. 34 OCCUPANT CLASSIFICATION MODULE
(OCM) - TYPICAL
1 - OCCUPANT CLASSIFICATION MODULE
2 - CONNECTOR LOCK TOWER
3 - CONNECTOR RECEPTACLE
4 - MOUNTING TAB (2)
Fig. 35 OCM LOCATION
1 - OCCUPANT CLASSIFICATION MODULE (OCM)
2 - LOCK TOWER
3 - LOCK PIN
4 - CONNECTOR
5 - SCREW (2)
6 - BRACKET
RSRESTRAINTS8O-25

anchor. The OCM then monitors the return voltage
from each of the sensors. The bladder pressure sen-
sor input allows the OCM to determine whether the
passenger front seat is occupied and the relative size
of the occupant by providing a weight-sensing refer-
ence to the load on the seat cushion. The belt tension
sensor provides an additional logic input to the OCM
microprocessor that allows it to distinguish between
the lower seat belt cinch loads of a belted occupant
and the higher loads associated with a belted child
seat.
Pre-programmed decision algorithms and OCS cal-
ibration allow the OCM microprocessor to determine
when the seat cushion load as signaled by the blad-
der pressure sensor and the seat belt cinch load as
signaled by the belt tension sensor indicate that pas-
senger airbag protection is appropriate. When the
programmed conditions are met, the OCM sends the
proper electronic occupant classification messages
over the PCI data bus to the Occupant Restraint
Controller (ORC), and the ORC enables or disables
the deployment circuits for the passenger front sup-
plemental restraints. The ORC also provides a con-
trol output for the Passenger Airbag Disabled (PAD)
indicator in the instrument panel center stack, based
upon the electronic occupant classification messages
it receives from the OCM.
The OCM microprocessor continuously monitors all
of the OCS electrical circuits and components to
determine the system readiness. If the OCM detects
a monitored system fault, it sets an active and stored
Diagnostic Trouble Code (DTC) and sends the appro-
priate electronic messages to the ORC over the PCI
data bus. Then the ORC sets a DTC and sends mes-
sages to control the airbag indicator operation
accordingly. An active fault only remains for the
duration of the fault, or in some cases for the dura-
tion of the current ignition switch cycle, while a
stored fault causes a DTC to be stored in memory by
the OCM and the ORC. For some DTC's, if a fault
does not recur for a number of ignition cycles, the
OCM will automatically erase the stored DTC. For
other internal faults, the stored DTC is latched for-
ever.
The OCM receives battery current from an IPM
high side driver (Run/Start). The OCM receives
ground through a ground circuit of the body wire
harness, which it shares with the ORC. These con-
nections allow the OCM to be operational whenever
the ignition switch is in the Start or ON positions.
To diagnose and test the OCS, use a scan tool and
the appropriate diagnostic information.
REMOVAL
Once any of the original factory-installed compo-
nents except the Occupant Classification Module(OCM) have been replaced with the service replace-
ment package components, the OCM can only be ser-
viced by replacing the entire passenger front seat
cushion unit with another complete service replace-
ment package (Refer to 23 - BODY/SEATS/SEAT
CUSHION - FRONT - REMOVAL).
WARNING: Never replace both the Occupant
Restraint Controller (ORC) and the Occupant Clas-
sification Module (OCM) at the same time. If both
require replacement, replace one, then perform the
Airbag System test (Refer to 8 - ELECTRICAL/RE-
STRAINTS - 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 the same time, an irreversible fault will
be set in both modules and the OCS may malfunc-
tion and result in personal injury or death.
(1) Disconnect and isolate the battery negative
cable.
(2)
WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to
do so may result in accidental airbag deployment,
personal injury or death.
(3) Reach under the front edge of the passenger
side front seat cushion to access and remove the lock
pin from the connector lock tower on the Occupant
Classification Module (OCM) (Fig. 36).
(4) Disconnect the passenger front seat wire har-
ness connector for the OCM.
(5) Remove the two screws that secure the OCM to
the OCM bracket.
(6) Remove the OCM from under the passenger
front seat.
INSTALLATION
WARNING: To avoid personal injury or death on
vehicles equipped with the Occupant Classification
System (OCS), only the Occupant Classification
Module (OCM) and the seat cushion trim may be
serviced separately. All other components of the
passenger front seat cushion must be serviced only
as a complete factory-calibrated, assembled and
tamper-evident service replacement package.
Once any of the original factory-installed compo-
nents except the OCM have been replaced with the
service replacement package components, the OCM
can only be serviced by replacing the entire passen-
8O - 26 RESTRAINTSRS
OCCUPANT CLASSIFICATION MODULE (Continued)

The ORC is secured with screws to a stamped steel
mounting bracket welded onto the top of the floor
panel transmission tunnel just behind and under-
neath the instrument panel center stack in the pas-
senger compartment of the vehicle (Fig. 38).
Concealed within a hollow in the center of the die
cast aluminum ORC housing is the electronic cir-
cuitry of the ORC which includes a microprocessor,
an electronic impact sensor, an electronic safing sen-
sor, and an energy storage capacitor. A stamped
metal cover plate is secured to the bottom of the
ORC housing with four screws to enclose and protect
the internal electronic circuitry and components.
An arrow printed on the label on the top of the
ORC housing provides a visual verification of the
proper orientation of the unit, and should always be
pointed toward the front of the vehicle. The ORC
housing has integral mounting flanges. the ORC has
two molded plastic electrical connectors that exits the
right facing side of the ORC housing. These terminal
pins connect the ORC to the vehicle electrical system.
The impact sensor and safing sensor internal to
the ORC are calibrated for the specific vehicle, and
are only serviced as a unit with the ORC. In addi-
tion, there are unique versions of the ORC for vehi-
cles with or without curtain airbags. The ORC cannot
be repaired or adjusted and, if damaged or faulty, it
must be replaced.
OPERATION
The microprocessor in the Occupant Restraint Con-
troller (ORC) contains the supplemental restraint
system logic circuits and controls all of the supple-
mental restraint system components. The ORC uses
On-Board Diagnostics (OBD) and can communicatewith other electronic modules in the vehicle as well
as with the diagnostic scan tool using the Program-
mable Communication Interface (PCI) data bus. This
method of communication is used for control of the
airbag indicator in the ElectroMechanical Instrument
Cluster (EMIC) and for supplemental restraint sys-
tem diagnosis and testing through the 16-way Data
Link Connector (DLC) located on the driver side
lower edge of the instrument panel.
The ORC microprocessor continuously monitors all
of the supplemental restraint system electrical cir-
cuits to determine the system readiness. If the ORC
detects a monitored system fault, it sets an active
and stored Diagnostic Trouble Code (DTC) and sends
electronic messages to the EMIC over the PCI data
bus to turn on the airbag indicator. An active fault
only remains for the duration of the fault, or in some
cases for the duration of the current ignition switch
cycle, while a stored fault causes a DTC to be stored
in memory by the ORC. For some DTC's, if a fault
does not recur for a number of ignition cycles, the
ORC will automatically erase the stored DTC. For
other internal faults, the stored DTC is latched for-
ever.
On models equipped with the Occupant Classifica-
tion System (OCS), the ORC communicates with the
Occupant Classification Module (OCM) over the PCI
data bus. The ORC will internally disable the pas-
senger airbag and seat belt tensioner deployment cir-
cuits if the OCM detects that the passenger side
front seat is unoccupied or that it is occupied by a
load that is inappropriate for an airbag deployment.
The ORC also provides a control output to the Pas-
senger Airbag Disabled (PAD) indicator through the
passenger airbag indicator driver circuit. The OCM
notifies the ORC when it has detected a monitored
system fault and stored a DTC in its memory for any
faulty OCS component or circuit, then the ORC sets
a DTC and controls the airbag indicator operation
accordingly.
The ORC receives battery current through two cir-
cuits; a fused ignition switch output (RUN) circuit
through a fuse in the Junction Block (JB), and a
fused ignition switch output (RUN/START) circuit
through a second fuse in the JB. The ORC receives
ground through a ground circuit of the instrument
panel wire harness. These connections allow the ORC
to be operational whenever the ignition switch is in
the START or ON positions.
The ORC also contains an energy-storage capacitor.
When the ignition switch is in the START or ON
positions, this capacitor is continually being charged
with enough electrical energy to deploy the front sup-
plemental restraint components for up to one second
following a battery disconnect or failure. The purpose
of the capacitor is to provide backup supplemental
Fig. 38 ORC LOCATION
1 - ORC ELECTRICAL CONNECTORS
2 - ORC
3 - ORC MOUNTING SCREWS
8O - 28 RESTRAINTSRS
OCCUPANT RESTRAINT CONTROLLER (Continued)