2005 MERCEDES-BENZ SPRINTER Service Repair Manual

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)

(2) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(3) If the vehicle is so equipped, unsnap and
remove the plastic cover from the screw that secures
the front seat belt lower anchor to the outboard side
of the seat frame (Fig. 22).
(4) Remove the screw that secures the front seat
belt lower anchor to the outboard side of the seat
frame.
(5) Remove the front seat belt lower anchor from
the outboard side of the seat frame.
(6) Remove the trim panel from the inside of the
B-pillar. (Refer to 23 - BODY/INTERIOR/B-PILLAR
TRIM - REMOVAL).
(7) Pull the height adjuster trim away from the
upper B-pillar to disengage the driver from the lug of
the height adjuster (Fig. 23).
(8) Pull the front seat belt and lower anchor
through the back of the height adjuster trim.
(9) Remove the nut that secures the front seat belt
turning loop to the height adjuster (Fig. 24).
(10) Remove the front seat belt turning loop from
the height adjuster.
CAUTION: Do not pull on the wires to disengage
the connector from the seat belt tensioner initiator
connector receptacle. Improper removal of the con-
nector insulator can result in damage to the seat
belt tensioner circuits or the connector insulator.
Fig. 22 Front Seat Belt Lower Anchor
1 - FRONT SEAT BELT
2 - COVER AND/OR SCREW
Fig. 23 Turning Loop Height Adjuster
1 - HEIGHT ADJUSTER TRIM
2 - LUG
3 - HEIGHT ADJUSTER
4 - DRIVER
Fig. 24 Front Seat Belt Turning Loop
1 - HEIGHT ADJUSTER
2 - NUT
3 - FRONT SEAT BELT
8O - 20 RESTRAINTSVA
FRONT SEAT BELT & RETRACTOR (Continued)

(11) If so equipped, disconnect the vehicle wire
harness connector for the seat belt tensioner from the
initiator receptacle of the retractor located on the
lower inner B-pillar (Fig. 25). The connector is a
tight snap-fit into the initiator receptacle. Firmly
grasp and pull or gently pry on the connector insula-
tor and pull the connector straight out from the ini-
tiator to disconnect it from the receptacle.
(12) Remove the screw that secures the front seat
belt retractor to the lower inner B-pillar.
(13) Remove the front seat belt and retractor unit
from the B-pillar.
INSTALLATION
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 with
an 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 theseat 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) Position the front seat belt and retractor to the
lower inner (Fig. 25). Be certain to engage the guide
on the retractor into the locating notch on the B-pil-
lar.
(2) Install and tighten the screw that secures the
front seat belt retractor to the lower inner B-pillar.
Tighten the screw to 35 N´m (26 ft. lbs.).
(3) If so equipped, reconnect the vehicle wire har-
ness connector for the seat belt tensioner to the ini-
tiator receptacle of the retractor located on the lower
inner B-pillar. The connector is a tight snap-fit into
the initiator receptacle. Reconnect the connector by
pressing the connector insulator straight into the ini-
Fig. 25 Front Seat Belt Retractor
1 - RETRACTOR
2 - CONNECTOR
3 - SCREW
4 - GUIDE
VARESTRAINTS 8O - 21
FRONT SEAT BELT & RETRACTOR (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)

INSTALLATION
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 front seat belt buckle to the
inboard side of the front seat frame (Fig. 26).
(2) Install and tighten the screw that secures the
front seat belt buckle lower anchor to the inboard
side of the front seat frame. Tighten the screw to 35
N´m (26 ft. lbs.).
(3) If the vehicle is so equipped, snap the plastic
cover over the screw that secures the front seat belt
buckle lower anchor to the inboard side of the seat
frame.
(4) On the driver side only, reconnect the seat belt
switch pigtail wire to the vehicle wire harness and
push the joined connectors through the clearance
hole in the seat riser cover.
(5) On the driver side only, route and secure the
seat belt switch pigtail wire to the seat frame with
wire ties.
PASSENGER AIRBAG
DESCRIPTION
The rearward facing surface of the injection
molded, thermoplastic passenger airbag door is the
most visible part of the optional passenger airbag
(Fig. 27). The passenger airbag door is located above
the glove box opening in front of the front seat pas-
senger seating position on the instrument panel. The
upper and lower edges of the airbag door are secured
by a snap-fit to molded plastic clips. The two clips at
the top are each secured by a screw to the instru-
ment panel base trim, while the clips at the bottom
are integral to the panel that surrounds the passen-
ger airbag door opening in the instrument panel base
trim. The airbag door is also secured to the airbaghousing by two wide woven straps that serve as
hinges for the door upon an airbag deployment.
Located behind the passenger airbag door is the
passenger airbag unit (Fig. 28). The airbag housing
is constructed of a long U-shaped aluminum extru-
sion with two stamped steel end plates. A stepped
flange that extends from the back of the extrusion
serves as the airbag mounting flange. This mounting
flange is secured with screws to a stamped steel air-
bag mounting bracket that is secured with screws to
the tubular steel instrument panel structural support
above the glove box opening. The end plates are
secured to each side of the passenger airbag housing
with screws.
Fig. 27 Passenger Airbag Door
1 - INSTRUMENT PANEL TRAY
2 - PASSENGER AIRBAG DOOR
3 - GLOVE BOX DOOR
Fig. 28 Passenger Airbag Unit
1 - DOOR
2 - CLIP (2)
3 - HOUSING
4 - CONNECTOR RECEPTACLE
5 - END PLATE (2)
VARESTRAINTS 8O - 23
FRONT SEAT BELT BUCKLE (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)

(4) Remove the three screws that secure the flange
of the passenger airbag housing to the bracket on the
instrument panel structural support.
(5) Pull the passenger airbag unit rearward to dis-
engage the airbag door from the lower clips and far
enough to access the electrical connection on the
right end of the unit.
CAUTION: Do not pull on the wires to disengage
the connector from the passenger airbag inflator
connector receptacle. Improper removal of the con-
nector insulator can result in damage to the airbag
circuits or the connector insulator.(6) The vehicle wire harness connector is a tight
snap-fit into the airbag inflator connector receptacle,
which is located on the right end of the passenger
airbag housing. Firmly grasp and pull or gently pry
on the connector insulator and pull the connector
straight out from the inflator to disconnect it from
the receptacle.
(7) Remove the passenger airbag and airbag door
from the instrument panel as a unit.
Fig. 29 Passenger Airbag Remove/Install
1 - TRAY
2 - SCREW (2)
3 - UPPER CLIP (2)
4 - LOWER CLIP (2)5 - CONNECTOR
6 - PASSENGER AIRBAG
7 - SCREW (3)
VARESTRAINTS 8O - 25
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)