2005 MERCEDES-BENZ SPRINTER battery replacement

WARNING: IF YOU EXPERIENCE SKIN IRRITATION
DURING CLEANUP, RUN COOL WATER OVER THE
AFFECTED AREA. ALSO, IF YOU EXPERIENCE
IRRITATION OF THE NOSE OR THROAT, EXIT THE
VEHICLE FOR FRESH AIR UNTIL THE IRRITATION
CEASES. IF IRRITATION CONTINUES, SEE A PHYSI-
CIAN.
(1) Begin the cleanup by using a vacuum cleaner
to remove any residual powder from the vehicle inte-
rior. Clean from outside the vehicle and work your
way inside, so that you avoid kneeling or sitting on a
non-cleaned area.
(2) Be certain to vacuum the heater and air condi-
tioning outlets as well (Fig. 4). Run the heater and
air conditioner blower on the lowest speed setting
and vacuum any powder expelled from the outlets.
CAUTION: All damaged, faulty, or non-deployed
supplemental restraints which are replaced on vehi-
cles are to be handled and disposed of properly. If
an airbag unit or seat belt tensioner unit is faulty ordamaged and non-deployed, refer to the Hazardous
Substance Control System for proper disposal. Be
certain to dispose of all non-deployed and deployed
supplemental restraints in a manner consistent with
state, provincial, local and federal regulations.
(3) Next, remove the deployed supplemental
restraints from the vehicle. Refer to the appropriate
service removal procedures.
(4) You may need to vacuum the interior of the
vehicle a second time to recover all of the powder.
STANDARD PROCEDURE - VERIFICATION TEST
The following procedure should be performed using
a DRBIIItscan tool to verify proper supplemental
restraint system operation following the service or
replacement of any supplemental restraint system
component.
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) During the following test, the battery negative
cable remains disconnected and isolated, as it was
during the supplemental restraint system component
removal and installation procedures.
(2) Be certain that the DRBIIItscan tool contains
the latest version of the proper DRBIIItsoftware.
Connect the DRBIIItto the 16-way Data Link Con-
nector (DLC). The DLC is located on the dash panel
beneath the driver side lower edge of the instrument
panel, outboard of the steering column (Fig. 5).
(3) Turn the ignition switch to the On position and
exit the vehicle with the DRBIIItscan tool.
(4) Check to be certain that nobody is in the vehi-
cle, then reconnect the battery negative cable.
(5) Using the DRBIIIt, read and record the active
(current) Diagnostic Trouble Code (DTC) data.
(6) Next, use the DRBIIItto read and record any
stored (historical) DTC data.
(7) If any DTC is found in Step 5 or Step 6, refer
to the appropriate diagnostic information.
(8) Use the DRBIIItto erase the stored DTC data.
If any problems remain, the stored DTC data will not
Fig. 3 Wear Safety Glasses and Rubber Gloves -
Typical
Fig. 4 Vacuum Heater and A/C Outlets - Typical
VARESTRAINTS 8O - 7
RESTRAINTS (Continued)

(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(2) From the underside of the steering wheel,
remove the two screws that secure the driver airbag
to the horn switch armature within the hub cavity of
the steering wheel (Fig. 21).
(3) Pull the driver airbag away from the steering
wheel far enough to access the electrical connection
at the back of the airbag housing.
CAUTION: Do not pull on the clockspring pigtail
wires to disengage the connector from the driver
airbag inflator connector receptacle. Improper
removal of these pigtail wires and their connector
insulator can result in damage to the airbag circuits
or the connector insulator.
(4) The clockspring driver airbag pigtail wire con-
nector is a tight snap-fit into the airbag inflator con-
nector receptacle, which is located on the back of the
driver airbag housing. Firmly grasp and pull or gen-
tly pry on the connector insulator and pull the con-
nector straight out from the airbag inflator to
disconnect it from the connector receptacle.
(5) Remove the driver airbag from the steering
wheel.
(6) If the driver airbag has been deployed, the
clockspring and the steering wheel must also be
replaced. (Refer to 8 - ELECTRICAL/RESTRAINTS/
CLOCKSPRING - REMOVAL) and (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
REMOVAL).INSTALLATION
The following procedure is for replacement of a
faulty or damaged driver airbag. If the airbag is
faulty or damaged, but not deployed, review the rec-
ommended procedures for handling non-deployed
supplemental restraints. (Refer to 8 - ELECTRICAL/
RESTRAINTS - STANDARD PROCEDURE - HAN-
DLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the driver airbag has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the airbag from the vehicle. (Refer to
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
CEDURE - SERVICE AFTER A SUPPLEMENTAL
RESTRAINT DEPLOYMENT).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, 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.
Fig. 21 Driver Airbag Remove/Install
1 - AIRBAG CONNECTOR
2 - DRIVER AIRBAG3 - SCREW (2)
4 - STEERING WHEEL
8O - 18 RESTRAINTSVA
DRIVER AIRBAG (Continued)

WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
WARNING: THE DRIVER AIRBAG TRIM COVER
MUST NEVER BE PAINTED. REPLACEMENT AIR-
BAGS ARE SERVICED WITH TRIM COVERS IN THE
ORIGINAL COLORS. PAINT MAY CHANGE THE WAY
IN WHICH THE MATERIAL OF THE TRIM COVER
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Position the driver airbag close enough to the
steering wheel to reconnect the clockspring driver
airbag pigtail wire connector at the back of the air-
bag housing.
(2) When installing the driver airbag, reconnect
the clockspring driver airbag pigtail wire connector
to the airbag inflator connector receptacle by press-
ing straight in on the connector (Fig. 21). You can be
certain that the connector is fully engaged by listen-
ing carefully for a distinct, audible click as the con-
nector snaps into place.
(3) Carefully position the driver airbag in the
steering wheel. Be certain that the clockspring pig-
tail wire and horn switch wires in the steering wheel
hub area are not pinched between the driver airbag
and the horn switch armature.
(4) From the underside of the steering wheel,
install and tighten the two screws that secure the
driver airbag to the horn switch armature within the
hub cavity of the steering wheel. Tighten the screws
to 6 N´m (53 in. lbs.).
(5) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).
FRONT SEAT BELT &
RETRACTOR
REMOVAL
The following procedure is for replacement of a
faulty or damaged front seat belt and retractor unit,
which includes a seat belt tensioner for the driver
side as standard equipment. Vehicles equipped withan optional passenger airbag also have a seat belt
tensioner for the passenger side. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/SEAT BELT TENSIONER -
DESCRIPTION). If the seat belt or retractor is faulty
or damaged, but the seat belt tensioner is not
deployed, review the recommended procedures for
handling non-deployed supplemental restraints.
(Refer to 8 - ELECTRICAL/RESTRAINTS - STAN-
DARD PROCEDURE - HANDLING NON-DE-
PLOYED SUPPLEMENTAL RESTRAINTS). If the
seat belt tensioner has been deployed, review the rec-
ommended procedures for service after a supplemen-
tal restraint deployment before removing the front
seat belt and retractor from the vehicle. (Refer to 8 -
ELECTRICAL/RESTRAINTS - STANDARD PROCE-
DURE - SERVICE AFTER A SUPPLEMENTAL
RESTRAINT DEPLOYMENT).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, 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.
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE,
RETRACTORS, AND ANCHORS FOR PROPER
INSTALLATION, OPERATION, OR DAMAGE.
REPLACE ANY BELT THAT IS CUT, FRAYED, OR
TORN. STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR
A SEAT BELT COMPONENT. ALWAYS REPLACE
DAMAGED OR FAULTY SEAT BELT COMPONENTS
WITH THE CORRECT, NEW AND UNUSED
REPLACEMENT PARTS LISTED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
(1) Move the front seat to its most forward position
for easiest access to the B-pillar trim.
VARESTRAINTS 8O - 19
DRIVER AIRBAG (Continued)

tiator receptacle. You can be certain that the connec-
tor is fully engaged by listening carefully for a
distinct, audible click as the connector snaps into
place.
(4) Position the front seat belt turning loop onto
the height adjuster on the upper B-pillar (Fig. 24).
(5) Install and tighten the nut that secures the
front seat belt turning loop to the height adjuster.
Tighten the nut to 35 N´m (26 ft. lbs.).
(6) Route the front seat belt and lower anchor
through the back of the height adjuster trim (Fig.
23).
(7) Position the height adjuster trim to the upper
B-pillar so that the driver on the back of the trim
engages the lug of the height adjuster.
(8) Reinstall the trim panel onto the inside of the
B-pillar. (Refer to 23 - BODY/INTERIOR/B-PILLAR
TRIM - INSTALLATION).
(9) Position the front seat belt lower anchor to the
outboard side of the seat frame (Fig. 22).
(10) Install and tighten the screw that secures the
front seat belt lower anchor to the outboard side of
the seat frame. Tighten the screw to 35 N´m (26 ft.
lbs.).
(11) If the vehicle is so equipped, snap the plastic
cover over the screw that secures the front seat belt
lower anchor to the outboard side of the seat frame.
(12) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).
FRONT SEAT BELT BUCKLE
REMOVAL
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE,
RETRACTORS, AND ANCHORS FOR PROPER
INSTALLATION, OPERATION, OR DAMAGE.
REPLACE ANY BELT THAT IS CUT, FRAYED, OR
TORN. STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR
A SEAT BELT COMPONENT. ALWAYS REPLACE
DAMAGED OR FAULTY SEAT BELT COMPONENTS
WITH THE CORRECT, NEW AND UNUSED
REPLACEMENT PARTS LISTED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.(1) On the driver side only, move the seat to its
most forward position for easiest access to the seat
belt switch pigtail wire and connector.
(2) On the driver side only, remove the wire ties
that secure the seat belt switch pigtail wire to the
seat frame (Fig. 26).
(3) On the driver side only, pull the seat belt
switch pigtail wire out through the clearance hole in
the seat riser cover far enough to access and discon-
nect the pigtail wire from the vehicle wire harness.
(4) If the vehicle is so equipped, unsnap and
remove the plastic cover from the screw that secures
the front seat belt buckle lower anchor to the inboard
side of the seat frame.
(5) Remove the screw that secures the front seat
belt buckle lower anchor to the inboard side of the
seat frame.
(6) Remove the front seat belt buckle from the
inboard side of the front seat frame.
Fig. 26 Front Seat Belt Buckle Remove/Install
1 - SEAT RISER COVER PANEL
2 - SEAT BELT SWITCH PIGTAIL WIRE (DRIVER SIDE ONLY)
3 - BUCKLE
4 - SCREW AND/OR COVER
8O - 22 RESTRAINTSVA
FRONT SEAT BELT & RETRACTOR (Continued)

The passenger airbag unit used in this model is a
Next Generation-type that complies with revised fed-
eral airbag standards to deploy with less force than
those used in some prior models. The airbag housing
contains the folded airbag cushion, the airbag
retainer, and the airbag inflator. The airbag is a rect-
angular fabric cushion. The airbag inflator is a solid
fuel, pyrotechnic-type unit that is secured to and
sealed within the airbag housing along with the
folded airbag cushion. The inflator initiator connector
receptacle is connected to the vehicle electrical sys-
tem through a dedicated take out of the vehicle wire
harness with a yellow connector insulator.
The passenger airbag and airbag door unit cannot
be repaired, and must be replaced if deployed, faulty
or in any way damaged.
OPERATION
The passenger airbag is deployed by an electrical
signal generated by the Airbag Control Module
(ACM) through the passenger airbag squib circuits to
the initiator in the airbag inflator. When the ACM
sends the proper electrical signal to the initiator the
electrical energy generates enough heat to initiate a
small pyrotechnic charge which, in turn, ignites
chemical pellets within the inflator. Once ignited,
these chemical pellets burn rapidly and produce a
large quantity of inert gas. The inflator is sealed to
the back of the airbag housing and a diffuser in the
inflator directs all of the inert gas into the airbag
cushion, causing the cushion to inflate.
As the airbag cushion inflates, the passenger air-
bag door will unsnap from the clips that retain it to
the instrument panel at the top and bottom, then
pivot towards the top of the instrument panel and
out of the way on the woven straps. Following a pas-
senger airbag deployment, the airbag cushion quickly
deflates by venting the inert gas through the loose
weave of the fabric used to construct the back
(instrument panel side) of the airbag cushion.
Some of the chemicals used to create the inert gas
may be considered hazardous while in their solid
state before they are burned, but they are securely
sealed within the airbag inflator. However, the gas
that is produced when the chemicals are burned is
harmless. A small amount of residue from the burned
chemicals may cause some temporary discomfort if it
contacts the skin, eyes, or breathing passages. If skin
or eye irritation is noticed, rinse the affected area
with plenty of cool, clean water. If breathing pas-
sages are irritated, move to another area where there
is plenty of clean, fresh air to breath. If the irritation
is not alleviated by these actions, contact a physician
immediately.
REMOVAL
The following procedure is for replacement of a
faulty or damaged passenger airbag. If the airbag is
faulty or damaged, but not deployed, review the rec-
ommended procedures for handling non-deployed
supplemental restraints. (Refer to 8 - ELECTRICAL/
RESTRAINTS - STANDARD PROCEDURE - HAN-
DLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the passenger airbag has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the airbag from the vehicle. (Refer to
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
CEDURE - SERVICE AFTER A SUPPLEMENTAL
RESTRAINT DEPLOYMENT).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, 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.
WARNING: WHEN REMOVING A DEPLOYED AIR-
BAG, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(2) Remove the instrument panel top cover tray
from over the passenger airbag (Fig. 29). (Refer to 23
- BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - TRAY - REMOVAL).
(3) Remove the two screws that secure the passen-
ger airbag door upper clips to the instrument panel
base trim.
8O - 24 RESTRAINTSVA
PASSENGER AIRBAG (Continued)

INSTALLATION
The following procedure is for replacement of a
faulty or damaged passenger airbag. If the airbag is
faulty or damaged, but not deployed, review the rec-
ommended procedures for handling non-deployed
supplemental restraints. (Refer to 8 - ELECTRICAL/
RESTRAINTS - STANDARD PROCEDURE - HAN-
DLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the passenger airbag has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the airbag from the vehicle. (Refer to
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
CEDURE - SERVICE AFTER A SUPPLEMENTAL
RESTRAINT DEPLOYMENT).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, 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.
WARNING: WHEN REMOVING A DEPLOYED AIR-
BAG, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE PAS-
SENGER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE PASSENGER AIRBAG DOOR. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.WARNING: THE PASSENGER AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT PASSENGER
AIRBAGS ARE SERVICED WITH DOORS IN THE
ORIGINAL COLORS. PAINT MAY CHANGE THE WAY
IN WHICH THE MATERIAL OF THE AIRBAG DOOR
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Carefully position the passenger airbag and
airbag door unit to the instrument panel (Fig. 29).
(2) When installing the passenger airbag, recon-
nect the vehicle wire harness connector to the airbag
inflator connector receptacle by pressing straight in
on the connector. You can be certain that the connec-
tor is fully engaged by listening carefully for a dis-
tinct, audible click as the connector snaps into place.
(3) Push the passenger airbag unit forward far
enough to engage the lower edge of the airbag door
with the two lower clips in the instrument panel.
(4) Install and tighten the two screws that secure
the flange of the passenger airbag housing to the
bracket on the instrument panel structural support.
Tighten the screws to 10 N´m (89 in. lbs.).
(5) Install and tighten the two screws that secure
the passenger airbag door upper clips to the instru-
ment panel base trim. Tighten the screws to 2 N´m
(18 in. lbs.).
(6) Reinstall the instrument panel top cover tray
onto the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL TOP
COVER - TRAY - INSTALLATION).
(7) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).
8O - 26 RESTRAINTSVA
PASSENGER AIRBAG (Continued)

SEAT BELT TURNING LOOP
ADJUSTER
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.
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE,
RETRACTORS, AND ANCHORS FOR PROPER
INSTALLATION, OPERATION, OR DAMAGE.
REPLACE ANY BELT THAT IS CUT, FRAYED, OR
TORN. STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR
A SEAT BELT COMPONENT. ALWAYS REPLACE
DAMAGED OR FAULTY SEAT BELT COMPONENTS
WITH THE CORRECT, NEW AND UNUSED
REPLACEMENT PARTS LISTED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
(1) Move the front seat to its most forward position
for easiest access to the B-pillar trim.
(2) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(3) Remove the trim panel from the inside of the
B-pillar. (Refer to 23 - BODY/INTERIOR/B-PILLAR
TRIM - REMOVAL).
(4) Pull the height adjuster trim away from the
upper B-pillar to disengage the driver from the lug of
the height adjuster (Fig. 40).
(5) Remove the nut that secures the front seat belt
turning loop to the height adjuster (Fig. 41).
(6) Remove the front seat belt turning loop from
the height adjuster.(7) Remove the two screws that secure the seat
belt turning loop height adjuster to the upper inner
B-pillar (Fig. 42).
Fig. 40 Turning Loop Height Adjuster
1 - HEIGHT ADJUSTER TRIM
2 - LUG
3 - HEIGHT ADJUSTER
4 - DRIVER
Fig. 41 Front Seat Belt Turning Loop
1 - HEIGHT ADJUSTER
2 - NUT
3 - FRONT SEAT BELT
VARESTRAINTS 8O - 33

(8) Remove the seat belt turning loop height
adjuster from the inner B-pillar.
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 SUREWAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE,
RETRACTORS, AND ANCHORS FOR PROPER
INSTALLATION, OPERATION, OR DAMAGE.
REPLACE ANY BELT THAT IS CUT, FRAYED, OR
TORN. STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR
A SEAT BELT COMPONENT. ALWAYS REPLACE
DAMAGED OR FAULTY SEAT BELT COMPONENTS
WITH THE CORRECT, NEW AND UNUSED
REPLACEMENT PARTS LISTED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
(1) Position the seat belt turning loop height
adjuster onto the inner B-pillar (Fig. 42).
(2) Install and tighten the two screws that secure
the seat belt turning loop height adjuster to the
upper inner B-pillar. Tighten the screws to 35 N´m
(26 ft. lbs.).
(3) Position the front seat belt turning loop onto
the height adjuster on the upper B-pillar (Fig. 41).
(4) Install and tighten the nut that secures the
front seat belt turning loop to the height adjuster.
Tighten the nut to 35 N´m (26 ft. lbs.).
(5) Position the height adjuster trim to the upper
B-pillar so that the driver on the back of the trim
engages the lug of the height adjuster (Fig. 40).
(6) Reinstall the trim panel onto the inside of the
B-pillar. (Refer to 23 - BODY/INTERIOR/B-PILLAR
TRIM - INSTALLATION).
(7) Reconnect the battery negative cable.
Fig. 42 Seat Belt Turning Loop Adjuster Remove/
Install
1 - SCREW (2)
2 - ADJUSTER
3 - B-PILLAR
8O - 34 RESTRAINTSVA
SEAT BELT TURNING LOOP ADJUSTER (Continued)