Downloaded from www.Manualslib.com manuals search engine 8B-91 Air Bag System:
CAUTION!
After detecting one time of such collision as
to meet deployment conditions, the SDM
must not be used.
Refer to “Air Bag Diagnostic System Check”
when checking the SDM.
Accident with Deployment / Activation – Component
Replacement
When driver and passenger air bags are deployed, the
following components must be replaced.
• Driver and passenger air bag (inflator) modules
• Driver and passenger seat belt pretensioners
• SDM after detecting such collision as to meet
deployment conditions
• Forward impact-sensor
• Instrument panel
When side-air bag and side curtain-air bag are deployed,
the following components must be replaced.
• Deployed side-air bag (inflator) module
• Deployed side curtain-air bag (inflator) module
• Side impact-sensor
•SDM
Accident with or without Deployment / Activation –
Component Inspections
Certain air bag and restraint system components must
be inspected after any crash, whether the air bag system
activated or not. If any faulty condition is found in the
following checks, replace faulty part.
Those components are:
• Steering column (1) and shaft joints
– Check for length, damage and bend according to
“Checking Steering Column for Accident Damage in
Section 6B”.
• Steering column bracket (2) and capsules
– Check for damage and bent.
• Steering wheel and driver air bag (inflator) module
– Check for damage or air bag (inflator) module
fitness.
– Check trim cover (pad surface) for cracks.
– Check wire harness and connector for damage or
tightness.• Contact coil assembly
– Check wire harness and connectors for damage or
tightness.
– Check contact coil case for damage.
– Check contact coil circuit referring to “Contact Coil
Cable and Its Circuit Check”.
• Instrument panel member and reinforcement
– Check for any distortion, bending, cracking or other
damage.
– Check instrument panel for cracks or deformities.
• Passenger air bag (inflator) module
– Check for dents, cracks, damage or fitness.
– Check harness and connector for damage or
tightness.
•SDM
– Check for external damage such as deformation,
scratch, crack, peeled paint, etc.
– Check SDM for a cause in itself preventing its
proper installation. (There is a gap between SDM
and SDM plate, or it cannot be fixed securely.)
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Downloaded from www.Manualslib.com manuals search engine 8B-113 Air Bag System:
12) Notify all people in immediate area that you intend to
deploy / activate air bag (inflator) module or seat belt
pretensioner.
NOTE
• When air bag (inflator) module deploys and
seat belt pretensioner activates, rapid gas
expansion will create substantial report.
Wear suitable ear protection. Notify all
people in immediate area that you intend
to deploy air bag (inflator) module or
activate seat belt pretensioner and suitable
ear protection should be worn.
• When driver air bag (inflator) module
deploys, driver air bag (inflator) module
may jump about 30 cm (1 ft) vertically. This
is normal reaction to force of rapid gas
expansion inside of drive air bag (inflator)
module.
• After air bag (inflator) module has been
deployed, surface of air bag (inflator) may
contain powdery residue. This powder
consists primarily of cornstarch (used to
lubricate bag (inflator) as it inflates) and by
products of chemical reaction.
WARNING!
• Do not place deployed air bag (inflator)
module and activated seat belt
pretensioner near any flammable objects.
• Do not apply water, oil, etc. to deployed air
bag (inflator) module and activated seat
belt pretensioner.
• Wait for about 30 minutes before touching
any metal surface of air bag (inflater)
module or seat belt pretensioner module.
Disregarding these precautions may cause
fire or personal injury.
Failure to follow procedures may result in fire
or personal injury.
13) Separate two banana plugs (1) on deployment
harness.
14) Connect deployment harness to 12 volts vehicle
battery (2). This will immediately deploy or activate
air bag (inflator) module or seat belt pretensioner.
15) Disconnect deployment harness from 12 volts
vehicle battery (2) and short two deployment
harness leads together by fully seating one banana
plug into the other.16) In the unlikely event that air bag (inflator) module or
seat belt pretensioner did not deploy / activate after
following these procedures, proceed immediately
with Step 22) through 25). If air bag (inflator) module
or seat belt pretensioner did deploy or activate,
proceed with Steps 18) through 21).
17) Put on pair of shop gloves to protect your hands from
possible irritation and heat when handling deployed
air bag (inflator) module or activated seat belt
pretensioner.
18) Disconnect adapter cable (special tool) from air bag
(inflator) module or seat belt pretensioner as soon as
possible. This will prevent adapter cable (special
tool) from damage due to possible contact with hot
air bag (inflator) module or hot seat belt
pretensioner.
19) Check adapter cable as follows.
• For air bag (inflator) module
Be sure to check air bag (inflator) module adapter
cable (special tool) for damage after deployment
and replace it with new adapter cable (special
tool), if it is damaged.
• For seat belt pretensioner
Be sure to check seat belt pretensioner adapter
cable (special tool) for damage after seat belt
pretensioner is activated. Replace it with spare
connector (special tool) or new adapter, if
necessary.
20) Dispose of deployed air bag (inflator) module (1) or
activated seat belt pretensioner (2) through normal
refuse channels after it has cooled for at least 30
minutes and tightly seal air bag (inflator) module (1)
or seat belt pretensioner (2) in strong vinyl bag.
Refer to “Deployed Air Bag (Inflator) Module and
Activated Seat Belt Pretensioner Disposal” for
details.
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Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-116
8) Route deployment harness (1) out of vehicle.
9) Check that inside of vehicle and area surrounding
vehicle are clear of all people and loose or
flammable objects.
10) Stretch deployment harness (1) to its full length 10 m
(33 ft).
11) Place 12 volts vehicle battery (2) near shorted end of
deployment harness (1).
12) Completely cover windshield area and front door
window openings with drop cloth, a blanket or any
similar item. This reduces possibility of injury due to
possible fragmentation of vehicle’s glass or interior.
13) Notify all people in immediate area that you intend to
deploy air bag (inflator) module or activate seat belt
pretensioners.
NOTE
• When air bag (inflator) module deploys or
seat belt pretensioners activate, rapid gas
expansion will create substantial report.
Wear suitable ear protection. Notify all
people in immediate area that you intend
to deploy air bag (inflator) module or to
activate seat belt pretensioner and suitable
ear protection should be worn.
• After air bag (inflator) module has been
deployed, surface of air bag may contain
powdery residue. This powder consists
primarily of cornstarch (used to lubricate
air bag (inflator) module as it inflates) and
by-products of chemical reaction.
WARNING!
• Do not place deployed air bag (inflator)
module and activated seat belt
pretensioners near any flammable objects.
• Do not apply water, oil, etc. to deployed air
bag (inflator) module and activated seat
belt pretensioners.
• Wait for about 30 minutes before touching
any metal surface of air bag (inflater)
module or seat belt pretensioner modules.
Disregarding these precautions may cause
fire or personal injury.
Failure to follow procedures may result in fire
or personal injury.
14) Separate two banana plugs (1) on deployment
harness (2).
15) Connect deployment harness (2) to 12 volts vehicle
battery (3). This will immediately deploy or activate
air bag (inflator) module or seat belt pretensioners.
16) Disconnect deployment harness (2) from 12 volts
vehicle battery (3) and short two deployment
harness leads together by fully seating one banana
plug into the other.
17) Repeat Steps 3) through 16) to deploy / activate air
bag (inflator) modules and seat belt pretensioners
which has not been deployed / activated, if any.
18) In the unlikely event that air bag (inflator) module
and seat belt pretensioners after following these
procedures, proceed immediately with Step 24)
through 26). If air bag (inflator) module and seat belt
pretensioners did deploy / activate, proceed with
Steps 19) through 23).
19) Carefully remove drop cloth from vehicle and clean
off any fragments or discard it entirely.
20) Put on pair of shop gloves to protect your hands from
possible irritation and heat when handling deployed
air bag (inflator) module and activated seat belt
pretensioners.
10 m (33 ft)
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Downloaded from www.Manualslib.com manuals search engine 8B-117 Air Bag System:
21) Disconnect adapter cable (special tool) from air bag
(inflator) module or seat belt pretensioner as soon as
possible. This will prevent adapter cable (special
tool) from damage due to possible contact with hot
air bag (inflator) module or hot seat belt
pretensioner.
22) Check adapter cable connector as follows.
Adapter cable connector (special tool) is designed to
be reused. However it should be inspected for
damage after deployment and replaced if necessary.
23) With air bag (inflator) modules deployed and seat
belt pretensioners activated, vehicle may be
scrapped in the same manner as non-air bag system
/ seat belt pretensioner equipped vehicle.
NOTE
Remaining steps are to be followed in the
unlikely event that air bag (inflator) module
did not deploy or seat belt pretensioner did
not activate.
24) Remove undeployed air bag (inflator) module(s) and/
or inactivated seat belt pretensioner(s) from vehicle.
For driver air bag (inflator) module, refer to “Driver
Air Bag (Inflator) Module Removal and Installation”.
For passenger air bag (inflator) module, refer to
“Passenger Air Bag (Inflator) Module Removal and
Installation”. For side air bag (inflator) module, refer
to “Side-Air Bag (Inflator) Module Removal and
Installation”. For side curtain-air bag (inflator)
module, refer to “Side Curtain-Air Bag (Inflator)
Module Removal and Installation”. For seat belt
pretensioner, refer to “Front Seat Belt Removal and
Installation in Section 8A”.
25) Temporarily store undeployed air bag (inflator)
module referring to “Precautions on Service and
Diagnosis of Air Bag System” for details.
26) Contact your local distributor for further assistance.
Deployed Air Bag (Inflator) Module and
Activated Seat Belt Pretensioner Disposal
S6RW0D8206019
WARNING!
Failure to follow proper air bag (inflator)
module and seat belt pretensioner disposal
procedures can result in air bag deployment
and pretensioner activation which may cause
personal injury. The undeployed air bag
(inflator) module and the inactivated seat belt
pretensioner must not be disposed of
through normal refuse channels.
The undeployed air bag (inflator) module and
the inactivated seat belt pretensioner
contains substances that can cause severe
illness or personal injury if the sealed
container is damaged during disposal.
Deployed air bag (inflator) module and the activated seat
belt pretensioner can be disposed of through normal
refuse channels just like any other parts. For their
disposal, however, the following points should be noted.
• The air bag (inflator) module and the seat belt
pretensioner immediately after deployment / activation
is very hot. Wait for 30 minutes to cool it off before
handling it.
• Never apply water, oil, etc. to deployed air bag
(inflator) module and the activated seat belt
pretensioner to cool it off and be careful so that water,
oil etc. does not get on the deployed air bag (inflator)
module and the activated seat belt pretensioner.
• After the air bag (inflator) module has been deployed,
the surface of the air bag may contain a powdery
residue. This powder consists primarily of cornstarch
(used to lubricate the bag as it inflates) and by-
products of the chemical reaction. As with many
service procedures, you should wear gloves and
safety glasses.
• When disposing of the deployed air bag (inflator)
module and the activated seat belt pretensioner, be
sure to seal it in a vinyl bag.
• When air bag (inflator) module and seat belt
pretensioner have been deployed / activated inside
the vehicle which is going to be scrapped, leave them
as installed to the vehicle.
• Be sure to wash your hands with mild soap and water
after handling them.
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Downloaded from www.Manualslib.com manuals search engine 9A-1 Wiring Systems:
Body, Cab and Accessories
Wiring Systems
Precautions
Cautions in Body Electrical System ServicingS6RW0D9100001
When servicing the electric systems, observe the cautions described in “Air Bag Warning in Section 00” to protect
electrical parts and to prevent a fire.
General Description
AbbreviationsS6RW0D9101001
Refer to the “Abbreviations in Section 0A” for the general abbreviations.
ESP
® is a registered trademark of Daimler Chrysler AG.
Wire / Connector Color SymbolsS6RW0D9101002
Refer to “Wire Color Symbols in Section 0A”. Abbreviation Full term Abbreviation Full term
2WD 2 wheel drive vehicles J/B Junction block
4WD 4 wheel drive vehicles J/C Joint connector
A/B Air bag KLS Keyless start system
ACC Accessory L Left
CAN Controller area network LED Light emitting diode
COMB Combination LHD Left hand drive vehicle
DSL Diesel engine LO Low
ELCM EVAP leak check module OCV Oil control valve
ESP
®Electronic stability program P/N Power normal
FWD Forward R Right
HI High RHD Right hand drive vehicle
IF EQPD If equipped ST Starter
IG COIL Ignition coil TPMS Tire pressure monitoring system
ILL Illumination VIM Valiable intake manifold
IND Indicator VSV Vacuum switching valve
INT Intermittent 5 dr 5 door
Downloaded from www.Manualslib.com manuals search engine 9A-107 Wiring Systems:
GEAR
ABS
BELT
DOOR
CHARGE
CHECK ENGINEAIRBAG
OILDRLD/F LOCK4WD AUTO
SETCRUISEIMMOBI
BRAKE
FUEL
DOME
15A37
32 5
WHT/RED
WHT/RED
J/B
G271
G241
1
2
J/C
G308B
B
IF EQPD
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Downloaded from www.Manualslib.com manuals search engine 9A-131 Wiring Systems:
F-1 Air-Bag System Circuit Diagram (4ch)S6RW0D910E032
2
ORN
Y
A/B
SDM
L04
J/B
15AA/B
27
RED
L313
BCM
15
BLK
1
15ADOME
37
WHT/RED
G2715
E388
L3721G349
L3992
PNK/BLK
E40
Forward sensor
1 2
Contact
coil
G347
S172
L377
G3442L399
G34911
L28312S121
YEL/RED
GRN
12
21
YEL/RED
L285 G25912
4
38
75
69
10 2832 27
37
5051
2
"A-8"
L378
G345
ORN
PNK/BLKYEL
YEL
GRN/RED
GRN/REDGRNGRN/ORNGRN/YEL
BLU/RED
BLU/REDBLU/ORNBLU/YEL
L3134
G27213
J/B J/B
"C-3"YB
YEL/BLK
YEL/BLK
J/B side connector (BCM)
Except M16A engine M/T
M16A engine M/T
Except Taiwan
Taiwan A
B
E
D
2 12 1
BCDE
Check terminal
J/C
G308B
B
5
4
C
51114
E382
G33419
C343
E3718
BLK/ORN
BLK/ORNBLK/ORN
7
BLU
PPL/WHT
PPL/WHT
BLU
PPL/WHT
J/C IF EQPD
G308A
A
L313
G043
5
J/CJ/B
G309B
B
DLC
16
WHT
WHT/RED
RED
RW
PW
PW
"A-8"
14 6
BCM
BCM
(CAN)
G2114
BLKBLK
BLK
E
Y"A-8"
D
8A
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Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-10
DRL System Symptom Diagnosis (If Equipped)S6RW0D9204002
Headlight Auto Leveling System Symptom Diagnosis (If Equipped)S6RW0D9204019
Headlight Manual Leveling System Symptom Diagnosis (If Equipped)S6RW0D9204003
Condition Possible cause Correction / Reference Item
Headlight does not light
when lighting switch is in
OFF position and engine
is runningLighting switch faultyCheck lighting switch referring to “Headlight
Switch (in Lighting Switch) Inspection”.
Oil pressure switch faultyCheck oil pressure switch referring to “Oil
Pressure Switch Inspection in Section 9C”.
DRL controller faultyCheck lighting switch referring to “Inspection of
DRL Controller and Its Circuits (If Equipped)”.
Wiring or grounding faultyRepair circuit.
Headlight lights even if
engine stop and lighting
switch is OFF positionLighting switch faultyCheck system referring to “Headlight Switch (in
Lighting Switch) Inspection”.
Oil pressure switch faultyCheck oil pressure switch referring to “Oil
Pressure Switch Inspection in Section 9C”.
DRL controller faultyCheck system referring to “Inspection of DRL
Controller and Its Circuits (If Equipped)”.
Wiring or grounding faultyRepair circuit.
Condition Possible cause Correction / Reference Item
Headlight leveling
warning light comes on
steadyHeight sensor faultyCheck height sensor referring to “Height
Sensor and Its Circuit Inspection (If
Equipped)”.
Wiring or ground faultyRepair circuit.
Headlight leveling control module faultyCheck headlight leveling control module for
function referring to “Inspection of Headlight
Leveling Control Module and Its Circuit
(Headlight Auto Leveling System)”.
Optical axes of both
headlights do not changeCircuit fuse blownReplace fuse and check for short circuit.
Supply voltage too low or too highCheck charging system referring to “Generator
Test (Undercharged Battery Check) in Section
1J” or “Generator Test (Overcharged Battery
Check) in Section 1J”.
Wiring or ground faultyRepair circuit.
Headlight leveling control module faultyCheck headlight leveling control module for
function referring to “Inspection of Headlight
Leveling Control Module and Its Circuit
(Headlight Auto Leveling System)”.
Optical axis of only one
headlight does not
changeHeadlight levering actuator faultyCheck actuator referring to “Headlight Leveling
Actuator Inspection (If Equipped)”.
Headlight housing deformedReplace headlight housing.
Wiring or ground faultyRepair circuit.
Condition Possible cause Correction / Reference Item
Optical axes of both
headlights do not changeCircuit fuse blownReplace fuse and check for short circuit.
Headlight leveling switch faultyCheck headlight leveling switch referring to
“Headlight Manual Levering Switch Inspection
(If Equipped)”.
Supply voltage too lowCheck charging system referring to “Generator
Test (Undercharged Battery Check) in Section
1J”.
Wiring or grounding faultyRepair circuit.
Optical axis of only one
headlight does not
changeCircuit fuse blownReplace fuse and check for short circuit.
Headlight leveling actuator faultyCheck actuator referring to “Headlight Leveling
Actuator Inspection (If Equipped)”.
Headlight housing deformedReplace headlight housing.
Wiring or grounding faultyRepair circuit.