Passenger side airbag module

The following procedure is for replacement of a faulty or damaged passenger side airbag module. If the passenger side airbag module has been deployed, the instrument panel assembly must be replaced.

The instrument panel assembly includes the passenger side airbag module and the passenger side airbag door. Refer to Instrument Panel Assembly in the Removal and Installation section of Group 8E - Instrument Panel Systems for the instrument panel assembly service procedures.

WARNING:

• THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE 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.
• WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG MODULE AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES.

REMOVAL

(1) Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service.

(2) Remove the instrument panel top cover and the passenger side airbag module from the instrument panel as a unit. Refer to Instrument Panel Top Cover in the Removal and Installation section of Group 8E - Instrument Panel Systems for the procedures.

(3) Place the instrument panel top cover assembly on a suitable work surface. Be certain to take the proper precautions to protect the top cover from any possible cosmetic damage.

(4) Apply masking tape over the passenger side airbag module vents on each end of the module (Fig.

9). The tape will help to prevent foreign material from entering the airbag module through the vents during removal and installation of the module from the upper airbag door flange and bracket.

WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE INSTRUMENT PANEL TOP COVER AND THE PASSENGER SIDE AIRBAG MODULE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.

Fig. 9 Passenger Side Airbag Module Vents

1 - LOWER BRACKET

2 - PASSENGER SIDE AIRBAG MODULE

3 - UPPER BRACKET

4 - VENTS

5 - CONNECTOR

(5) Using a suitable center punch, carefully drive out the mandrels from the four rivets that secure the passenger side airbag module upper mounting bracket to the upper airbag door flange and bracket on the instrument panel top cover (Fig. 10).

Fig. 10 Passenger Side Airbag Module Rivets

1 - RIVETS

2 - PASSENGER SIDE AIRBAG MODULE

(6) Use a suitable pair of rivet cutters or a large pair of side cutters to cut the rims or heads off of the four rivets that secure the passenger side airbag module upper mounting bracket to the upper airbag door flange and bracket on the underside of the instrument panel top cover.

WARNING: DO NOT USE A DRILL TO REMOVE THE RIVETS. SPARKS CREATED WHEN DRILLING COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALSO, METAL SHAVINGS CREATED WHEN DRILLING COULD ENTER THE PASSENGER SIDE AIRBAG MODULE AND RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.

(7) Remove the passenger side airbag module from the upper airbag door flange and bracket on the underside of the instrument panel top cover (Fig. 11).

Fig. 11 Passenger Side Airbag Module Remove/ Install

1 - PASSENGER SIDE AIRBAG MODULE

2 - LOWER BRACKET

3 - AIRBAG DOOR FLANGE AND BRACKET

4 - UPPER BRACKET

INSTALLATION

WARNING:

• USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE AIRBAG CUSHION AND THE PASSENGER SIDE AIRBAG DOOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.
• THE PASSENGER SIDE AIRBAG DOOR MUST NEVER BE PAINTED. REPLACEMENT INSTRUMENT PANEL ASSEMBLIES AND TOP COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE PASSENGER SIDE AIRBAG DOOR RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.

(1) Carefully position the passenger side airbag module upper mounting bracket to the upper airbag door flange and bracket on the underside of the instrument panel top cover.

NOTE: Use only the correct rivets that are specified in the Chrysler Mopar Parts Catalog, or that are supplied in the service package with the new airbag module and/or the new instrument panel top cover when installing the passenger side airbag module.

(2) Secure the passenger side airbag module upper mounting bracket to the upper airbag door flange and bracket with four rivets.

(3) Remove the masking tape applied to the passenger side airbag module vents during the removal procedures.

(4) Install the instrument panel top cover and the passenger side airbag module onto the instrument panel as a unit. Refer to Instrument Panel Top Cover in the Removal and Installation section of Group 8E - Instrument Panel Systems for the procedures.

(5) Be certain that the passenger side airbag module wire harness connector is fully engaged with and latched to the instrument panel wire harness connector.

(6) Do not reconnect the battery negative cable at this time. Refer to Airbag System in the Diagnosis and Testing section of this group for the proper procedures.