RESTRAINT SYSTEMS

8M - 1

RESTRAINT SYSTEMS
CONTENTS
page page

AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . 3

AIRBAG SYSTEM
WARNING: THIS SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIRBAG SYSTEM OR RELATED STEERING WHEEL AND STEERING COLUMN COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. WARNING: THE AIRBAG MODULE INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. DO NOT ATTEMPT TO DISMANTLE THE MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURES EXCEEDING 200F. WARNING: REPLACE AIRBAG SYSTEM COMPONENTS WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG ONLY. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. WARNING: WHEN A STEERING COLUMN HAS AN AIRBAG MODULE ATTACHED, NEVER PLACE THE COLUMN ON THE FLOOR OR OTHER SURFACE WITH THE STEERING WHEEL OR AIRBAG MODULE FACE DOWN.

GENERAL INFORMATION
The airbag system is a standard equipment safety device on Dakota models. It is designed to protect the driver from serious injury, caused by a frontal impact of the vehicle. To inspect this system use Airbag System - Body Diagnostic Procedures manual. If the airbag module assembly is defective and non-deployed, refer to Chrysler Corporation current return list for proper handling procedures. Following are general descriptions of the major components in the Dakota airbag system. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.

AIRBAG MODULE
The airbag module protective cover is the most visible part of the system. The module is mounted directly to the steering wheel. Under the airbag module cover, the airbag cushion and its supporting components are contained. The airbag module contains a housing to which the cushion and inflator are attached and sealed. The airbag module is non-serviceable, and must be replaced if deployed or damaged in any way. The inflator assembly is mounted to the back of the module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the

8M - 2

RESTRAINT SYSTEMS CLOCKSPRING

The clockspring is mounted on the steering column behind the steering wheel. It is used to maintain a continuous electrical circuit between the wiring harness and the drivers side airbag module. This assembly consists of a flat, ribbon-like electrically conductive tape which winds and unwinds with the steering wheel rotation.

proper electrical signal. The protective cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this cover will split horizontally.

STORAGE The airbag module must be stored in its original, special container until used for service. Also, it must be stored in a clean, dry environment; away from sources of extreme heat, sparks, and high electrical energy. Always place or store the module on a surface with the trim cover facing up to minimize movement in case of accidental deployment.

AIRBAG CONTROL MODULE

The airbag control module (ACM) contains the safing sensor, and monitors the system to determine its readiness. The ACM contains on-board diagnostics (OBD), and will light the airbag warning lamp in the instrument cluster when a monitored airbag system fault occurs. The ACM also contains an energy storage capacitor. This capacitor stores enough electrical energy to deploy the airbag for up to 2 minutes following a battery disconnect or failure. The purpose of this unit is to provide airbag protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbag.

IMPACT SENSOR
The impact sensors provide verification of the direction and severity of the impact. Three impact sensors are used. One is called a safing sensor. It is located inside the airbag control module (ACM), which is mounted to a bracket under the instrument panel above the heater and A/C housing. The other two sensors are mounted on the radiator closure panel on the left and right side of the vehicle. The impact sensors are threshold sensitive switches that complete an electrical circuit when an impact provides a sufficient deceleration force to close the switch. The sensors are calibrated for the specific vehicle, and react to the severity and direction of the impact.

DIAGNOSIS
A DRB scan tool is required for diagnosis of the airbag system. Refer to Airbag System - Body Diagnostic Procedures manual for more information. (6) Read and record any stored DTC. (7) Refer to the Airbag System - Body Diagnostic Test Procedures manual, if any DTC is found in steps 5 or 6. (8) Erase stored DTC, if there are no active fault codes. If problems remain, DTC will not erase. (9) With the ignition switch in the ON position, make sure nobody is in the vehicle. (10) From right side of vehicle, turn the ignition switch to OFF then ON. Observe airbag warning lamp on the instrument cluster. It should light for 6 to 8 seconds, then go out; indicating system is functioning normally. If the airbag warning lamp fails to light, or lights and stays on, there is a system malfunction. Refer to the Airbag System - Body Diagnostic Test Procedures manual to diagnose the problem.

AIRBAG SYSTEM CHECK

(1) Disconnect battery negative cable and isolate. (2) Connect DRB scan tool to ACM diagnostic 6-way connector. The connector is located under the instrument panel on the reinforcement behind the steering column cover/knee blocker. (3) From right side of vehicle (away from airbag in case of accidental deployment), turn the ignition switch to the ON position. Exit vehicle with DRB. Use the latest version of the proper DRB cartridge. (4) After checking that nobody is inside the vehicle, reconnect the negative battery terminal. (5) Using the DRB, read and record active diagnostic trouble code (DTC) data.

RESTRAINT SYSTEMS SERVICE PROCEDURES AIRBAG SYSTEM SERVICE (DEPLOYED)

Any vehicle which is to be returned to use after an airbag deployment, must have the airbag module and clockspring replaced. These are one-time components and cannot be reused. Other airbag system components are replaced as required by the extent of damage.

8M - 3

CLEANUP PROCEDURE
Begin cleanup by putting tape over the airbag exhaust vent (Fig. 2) so that no more powder will find its way into the vehicle interior. Then remove the airbag and airbag module from the vehicle.

AIRBAG MODULE HANDLING

UNDEPLOYED At no time should any source of electricity be permitted near the inflator on the back of the module. When carrying an undeployed module, the trim cover should be pointed away from the body to minimize injury in the event of accidental deployment. If the module is placed on a bench or other surface, the plastic trim cover should be face up to minimize movement in case of accidental deployment. DEPLOYED Following an airbag deployment, the vehicle interior will contain a powdery residue. This residue is primarily sodium bicarbonate (baking soda), used as an airbag cushion lubricant. However, there will also be traces of sodium hydroxide powder, a chemical byproduct of the generant used for airbag deployment. Since this powder can irritate the skin, eyes, nose or throat, be sure to wear safety glasses, rubber gloves and a long-sleeved shirt during cleanup (Fig. 1).

Fig. 2 Airbag Exhaust Vent Sealing

Use a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or sitting on an uncleaned area. Be sure to vacuum the heater and A/C outlets as well (Fig. 3). Run the blower on low and vacuum any powder expelled from the plenum. You may need to vacuum the interior of the car a second time to recover all of the powder.

Fig. 1 Wear Safety Glasses And Rubber Gloves

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 physician.

Fig. 3 Vacuum Heater And A/C Outlets

Place the deployed airbag and module in your vehicular scrap pile.

8M - 4

RESTRAINT SYSTEMS

AIRBAG MODULE REMOVE/INSTALL

WARNING: THIS SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIRBAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. When removing a deployed airbag module, rubber gloves, eye protection and long-sleeved shirt should be worn. There may be deposits on the airbag module and other interior surfaces, which can cause irritation to the skin and eyes in large doses. (1) Disconnect battery negative cable and isolate. If airbag module is undeployed, wait 2 minutes for system capacitor to discharge before further service. (2) From underside of steering wheel, remove speed control switch mounting screws (Fig. 4), if equipped.

Fig. 5 Speed Control Switch Connector Remove/Install

Fig. 6 Right Rear Steering Wheel Cover Remove/Install

Fig. 4 Speed Control Switch Remove/Install

(3) Pull switches from wheel and unplug connector (Fig. 5). (4) Using a small screwdriver, remove right rear steering wheel cover (Fig. 6). (5) Remove 4 nuts attaching airbag module to steering wheel (Fig. 7). (6) Remove airbag module from steering wheel. (7) Unplug electrical connector from airbag module. (8) When installing, connect clockspring wiring connector to the module by pressing straight in on the connector. The connector should latch securely beneath the module connector locking clip to assure positive connection. (9) Install 4 nuts and torque to 9 to 11 Nm (80 to 100 in. lbs.).

(10) Do not connect negative battery cable at this time. See Airbag System Check for proper procedure.

IMPACT SENSOR REMOVE/INSTALL

The impact sensors are located on the radiator support behind the grille opening reinforcement.

LEFT SIDE (1) Disconnect battery negative cable and isolate. If airbag module is undeployed, wait 2 minutes for system capacitor to discharge before further service. (2) Remove battery holddown (Fig. 8) and move battery rearward. (3) Unplug connector from sensor. (4) Remove 3 nuts holding left sensor to closure panel support (Fig. 9) and remove sensor.

RESTRAINT SYSTEMS

8M - 5

Fig. 9 Airbag Impact Sensor (Typical)

(5) When installing, mount sensor (arrow pointed forward) using 3 nuts provided with new sensor. Torque nuts to 3 to 4 Nm (24 - 36 in. lbs.). (6) Connect left sensor wiring lead from harness to connector on body of sensor. (7) Install battery making sure that it is properly positioned in battery tray (Fig. 8). (8) Install battery holddown strap, making sure that it is properly positioned on battery. Tighten bolts to 2.2 Nm (20 in. lbs.) (9) Do not connect negative battery cable at this time. See Airbag System Check for proper procedure.

Fig. 7 Airbag Module Remove/Install

Fig. 8 Battery Holddown Remove/Install

If stud plate needs to be replaced, remove push nut from stud and discard. Always use new push nut (Fig. 9) when installing stud plate.

RIGHT SIDE (1) Disconnect battery negative cable and isolate. If airbag module is undeployed, wait 2 minutes for system capacitor to discharge before further service. (2) Pull air cleaner inlet tube off radiator support. (3) Unplug connector from right sensor. (4) Remove 3 nuts holding right sensor to radiator support (Fig. 9) and remove sensor. If stud plate needs to be replaced, remove push nut from stud and discard. Always use new push nut (Fig. 9) when installing stud plate. (5) When installing, mount sensor (arrow pointed forward) using 3 nuts provided with new sensor. Torque nuts to 3 to 4 Nm (24 - 36 in. lbs.). (6) Connect sensor wiring lead from harness to connector on body of sensor. (7) Install air cleaner inlet tube to radiator support. (8) Do not connect negative battery cable at this time. See Airbag System Check for proper procedure.

8M - 6

RESTRAINT SYSTEMS

AIRBAG CONTROL MODULE REMOVE/INSTALL

WARNING: THE ACM CONTAINS ONE OF THE IMPACT SENSORS WHICH ENABLE THE SYSTEM TO DEPLOY THE AIRBAG. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM UNLESS IT IS BOLTED TO VEHICLE. BEFORE BEGINNING ANY AIRBAG SYSTEM REMOVAL OR INSTALLATION PROCEDURES, REMOVE AND ISOLATE THE BATTERY NEGATIVE (-) CABLE FROM THE VEHICLE BATTERY. THEN WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, AND POSSIBLE PERSONAL INJURY. (1) Disconnect battery negative cable and isolate. If airbag is undeployed, wait 2 minutes for system capacitor to discharge before further service. (2) Remove screws along bottom edge of knee blocker (Fig. 10).

Fig. 11 Indicator Cable Remove/Install

Fig. 10 Knee Blocker Remove/Install

(3) Pull knee blocker down to disengage slide tabs and remove. (4) Column shift vehicles, place gear shift lever in 1 position and remove indicator cable (Fig. 11). (5) Remove 2 nuts holding steering column support bracket to instrument panel. (6) Remove both cowl kick trim panels. (7) Remove both door hinge pillar trim panels. (8) Remove 5 upper instrument panel retaining screws. (9) Loosen lower instrument panel retaining screws. Roll instrument panel rearward. (10) Unplug 2 electrical connectors from ACM (Fig. 12). (11) Remove 4 screws holding ACM. (12) Remove ACM. (13) When installing, position the ACM with the arrow pointing forward. (14) Attach the ACM to the bracket with the 4 screws. Torque to 3 to 5 Nm (25-45 in. lbs.). (15) Connect wiring at ACM, making sure both connectors are seated and locking tabs are engaged. (16) Raise and install instrument panel.

Fig. 12 Airbag Control Module Remove/Install

(17) Tighten lower instrument panel screws. (18) Install both door hinge pillar trim pieces. (19) Install both cowl kick trim panels. (20) Install the steering column. Tighten nuts to 12 Nm (105 in. lbs.) torque. (21) Do not connect battery negative cable at this time. See Airbag System Check for proper procedure.

CLOCKSPRING REMOVE/INSTALL
(1) Place the front wheels in the straight-ahead position before starting the repair. (2) Disconnect battery negative cable and isolate. If airbag is undeployed, wait 2 minutes for system capacitor to discharge before further service. (3) Remove the airbag module. See Airbag Module Remove/Install. (4) Remove speed control switch and connector, if equipped.

RESTRAINT SYSTEMS
(5) Remove the steering wheel with steering wheel puller tool (C-3428B). (6) Unplug wiring connectors from horn switches. (7) Remove upper and lower steering column shrouds to gain access to clockspring wiring (Fig. 13). (8) Disconnect the 2-way connector between the

8M - 7

(15) Install the airbag module, and torque nuts to 9 to 11 Nm (80 to 100 in. lb.). (16) Do not connect negative battery cable at this time. See Airbag System Check for proper procedure.

CLOCKSPRING CENTERING
If the rotating tape within the clockspring is not positioned properly in relation to the steering wheel and the front wheels, the clockspring may fail during use. The clockspring MUST BE CENTERED, if it is not known to be properly positioned, or if the front wheels were moved from the straight-ahead position. (1) Place front wheels in the straight-ahead position. (2) Disconnect battery negative cable and isolate. If airbag is undeployed, wait 2 minutes for system capacitor to discharge before further service. (3) Remove airbag module. Remove steering wheel with steering wheel puller tool (C-3428B). (4) Depress the two plastic auto-locking tabs (Fig. 14).

Fig. 13 Steering Column Shrouds Remove/Install

clockspring and the instrument panel wiring harness at the base of the steering column. (9) To remove, pull clockspring assembly from steering column by lifting locating fingers as necessary. The clockspring cannot be repaired. It must be replaced if faulty, or if airbag has been deployed. (10) When installing, snap clockspring onto the steering column. If the clockspring is not properly positioned, see Clockspring Centering before installing steering wheel. (11) Connect the clockspring assembly to the instrument panel wiring harness. Make sure wiring locator clips are properly seated on the outside of the wiring trough and locking tabs are engaged. (12) Reinstall steering column shrouds. Be sure airbag wire is inside the shrouds. (13) Front wheels should still be in the straight-ahead position. Install steering wheel making sure to fit the flats on the hub of the steering wheel with the formations on the inside of clockspring. Pull the horn wiring through the upper, smaller hole in steering wheel hub. Pull the airbag and speed control wiring through the bottom, larger hole in the steering wheel hub. Make sure not to pinch wiring between the steering wheel and nut. (14) Connect the horn switch wire, then the airbag wire to the airbag module. To assure complete connection, latching arms must be visibly on top of connector housing.

Fig. 14 Clockspring Auto-Locking Tabs

(5) Keeping locking mechanism disengaged, rotate the clockspring rotor CLOCKWISE to the end of its travel. Do not apply excessive torque. (6) From the end of travel, rotate the rotor two and one-half turns COUNTER CLOCKWISE. The horn wire should end up at the top, and the airbag wire at the bottom. (7) Reinstall steering wheel. (8) Install airbag module. Torque nuts to 9 to 11 Nm (80 to 100 in. lbs.). (9) Do not connect battery negative cable at this time. See Airbag System Check for proper procedure.