Chrysler RG Voyager. Manual - part 757

WARNING:

Never

replace

both

the

Occupant

Restraint Controller (ORC) and the Occupant Clas-
sification Module (OCM) at the same time. If both
require replacement, replace one, then perform the
Airbag System test (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING - AIRBAG
SYSTEM) before replacing the other. Both the ORC
and the OCM store Occupant Classification System
(OCS) calibration data, which they transfer to one
another when one of them is replaced. If both are
replaced at the same time, an irreversible fault will
be set in both modules and the OCS may malfunc-
tion and result in personal injury or death.

(1) Install the ORC into vehicle (Fig. 39).
(2) Connect the wire connector to the ORC (Fig.

39).

(3) Install three bolts holding ORC to floor bracket

(Fig. 39). Torque bolts to 7.3 - 9.6 N·m (65 to 85 in.
lbs.)

(4) Install the storage bin onto the instrument

panel (Refer to 23 - BODY/INSTRUMENT PANEL/
STORAGE BIN - INSTALLATION).

WARNING: Do not connect the battery negative
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.

(5) Verify vehicle and system operation.
(6) Close hood.

PASSENGER AIRBAG

DESCRIPTION

WARNING: Never disassemble the passenger air-
bag. The passenger airbag has no serviceable
parts. If tampered with internally, the airbag could
deploy and result in personal injury or death.

The Passenger Airbag is located beneath the

instrument panel and pad assembly. The airbag is
mounted to the back side of the instrument panel
reinforcement.

The instrument panel top pad is the most visible

part of the passenger airbag system. Located under
the instrument panel top pad are the airbag door, the
passenger airbag cushion and the airbag cushion
supporting components.

The passenger airbag includes a magnesium hous-

ing within which the cushion and inflator are
mounted and sealed.

Following a passenger airbag deployment, the pas-

senger airbag and the instrument panel must be

replaced. The passenger airbag cannot be repaired,
and must be replaced if deployed or damaged in any
way.

OPERATION

The passenger airbag is equipped with two infla-

tors, each with three levels of pressure output. The
inflators seal the hole in the airbag cushion so it can
discharge the gas it produces directly into the cush-
ion when supplied with the proper electrical signal.
Following an airbag deployment, the airbag cushion
quickly deflates by venting this gas through the
cushion material towards the instrument panel.

The passenger airbag is secured with screws to the

instrument panel beneath the instrument panel top
pad and above the glove box opening. The instrument
panel top pad above the glove box opening conceals
the airbag door and a predetermined hinge line
beneath its decorative cover. Upon airbag deploy-
ment, the top pad will bend at the hinge line and the
door will fold back out of the way onto the top of the
instrument panel.

When the front airbag system is deployed, the fol-

lowing MUST be replaced:

• Complete Steering Column Assembly.

• Lower Steering Column Coupler.

• Steering Wheel.

• Clock Spring.

• Driver Airbag.

• Passenger Airbag.

• Upper Instrument Panel with Pad.

CARE OF UNDEPLOYED AIRBAGS

Airbags must be stored in their original special

container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag. When carrying or handling an
undeployed airbag, the trim side of the airbag should
be pointing away from the body to minimize possibil-
ity of injury if accidental deployment occurs. Do not
place undeployed airbag face down on a solid surface,
the airbag will propel into the air if accidental
deployment occurs.

REMOVAL

DEPLOYED AIRBAG

(1) Open hood.
(2) Disconnect and isolate the battery negative

cable.

WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to
do so may result in accidental airbag deployment,
personal injury or death.

RESTRAINTS

8O - 29

OCCUPANT RESTRAINT CONTROLLER (Continued)

(3) Clean powder residue from interior of vehicle

(Refer to 8 - ELECTRICAL/RESTRAINTS - STAN-
DARD PROCEDURE - SERVICE AFTER AN AIR-
BAG DEPLOYMENT).

(4) Remove instrument panel (Refer to 23 - BODY/

INSTRUMENT

PANEL/INSTRUMENT

PANEL

ASSEMBLY - REMOVAL).

(5) Remove all reusable components from the

upper instrument panel and transfer to the new
instrument panel.

UNDEPLOYED AIRBAG

(1) Open hood.
(2) Disconnect and isolate the battery negative

cable.

(3) Remove center console bin between front seats.
(4) Remove left front door sill plate using a trim

stick (special tool #C-4755) or equivalent, and gently
prying up on sill plate.

(5) Remove left cowl panel using a trim stick or

equivalent, and gently prying out on cowl panel.

(6) Remove four screws to lower steering column

cover and remove cover.

(7) Unsnap parking brake lever from knee blocker

reinforcement.

(8) Remove Data Link Connector (DLC) from knee

blocker.

(9) Remove screws to knee blocker.
(10) Unsnap left A-pillar lower extension trim

using a trim stick or equivalent.

(11) Remove three left side instrument panel A-pil-

lar retaining bolts and loosen the instrument panel
roll down bolt.

(12) Remove four nuts at brake pedal support

bracket to instrument panel.

(13) Using a trim stick or equivalent, gently pry

off left side upper A-pillar trim.

(14) Remove six screws and two wiring connectors

to lower instrument panel cubby bin at bottom of
center stack.

(15) Remove two left side nuts at instrument panel

center stack support to floor.

(16) Remove two right side nuts at instrument

panel center stack support to floor.

(17) Remove right front door sill plate using a trim

stick or equivalent, and gently prying up on sill
plate.

(18) Remove right cowl panel using a trim stick or

equivalent, and gently prying out on cowl panel.

(19) Using a trim stick or equivalent, gently pry

out on right instrument panel end cap.

(20) Unsnap right A-pillar lower extension trim

using a trim stick or equivalent.

(21) Remove three right side instrument panel

A-pillar retaining bolts and loosen the instrument
panel roll down bolt.

(22) Using a trim stick or equivalent, gently pry

off right side upper A-pillar trim.

(23) Open glove box, pinch in sides and roll down

towards floor. With a firm pull, snap glove box door
off hinges and remove.

(24) Using a trim stick or equivalent, gently pry

up on rear of instrument panel top cover and then
pull rearward and out.

(25) Using a trim stick or equivalent, gently pry

off the filler bezel just above the cup holder to expose
the lower screws to center bezel.

(26) Remove two screws and then using a trim

stick or equivalent, gently pry off instrument panel
center bezel.

(27) Remove center bezel wiring connectors to

HVAC control and switch assembly (hazard, rear
wiper/washer, heated seats) and remove bezel.

(28) Slide cup holder assembly from instrument

panel.

(29) Remove nineteen screws to right lower instru-

ment panel trim (glove box surround), unplug glove
box lamp wire connector, and remove panel.

(30) Remove four screws and wiring connectors to

radio and remove radio.

(31) Remove one far left instrument panel speaker

retaining screw.

(32) Remove four screws along top front edge of

instrument panel cover/pad.

(33) Remove seven lower instrument panel cover/

pad retaining screws starting from right of vehicle
and only removing these seven, not all of them.

(34) Remove six upper fence line instrument panel

retaining bolts.

(35) Roll back instrument panel just enough to

increase access to the passenger airbag retaining
bolts at the reinforcement. Lift the instrument panel
up slightly so as not to damage the air distribution to
HVAC unit seal.

(36) Disconnect the passenger airbag electrical

connector. Using a trim stick or equivalent, gently
pry electrical connector off of instrument panel rein-
forcement.

(37) Remove the two passenger airbag to instru-

ment panel cover/pad retaining screws.

(38) Remove the three passenger airbag to instru-

ment panel reinforcement retaining bolts.

(39) Pull rearward slightly on the instrument

panel cover/pad to maneuver passenger airbag out
from reinforcement and instrument panel.

8O - 30

RESTRAINTS

PASSENGER AIRBAG (Continued)

INSTALLATION

DEPLOYED AIRBAG

Transfer all reusable components to the new

instrument panel.

(1) Install new Passenger Airbag into instrument

panel.

(2) Install airbag attaching bolts to the instrument

panel.

(a) Torque the two bolts at instrument panel

retainer bosses to 2.7 ± .5 N·m (24 ± 5 in. lbs.).

(b) Torque the three bolts that attach the pas-

senger airbag to cross-car beam to 10 ± 2 N·m (90
± 15 in. lbs.).
(3) Connect yellow wire connector to passenger air-

bag and affix connector to instrument panel rein-
forcement with push pins.

(4) Install Instrument panel (Refer to 23 - BODY/

INSTRUMENT

PANEL/INSTRUMENT

PANEL

ASSEMBLY - INSTALLATION).

UNDEPLOYED AIRBAG

(1) Pull rearward slightly on the instrument panel

cover/pad to maneuver passenger airbag up onto
reinforcement and instrument panel.

(2) Install the three passenger airbag to instru-

ment panel reinforcement retaining bolts but leave
loose. This will help align the passenger airbag for
the cover/pad fit.

(3) Install the two passenger airbag to instrument

panel cover/pad retaining screws. Torque screws to
2.7 ±.5 N·m (24 ± 5 in. lbs.).

NOTE: Insure that the instrument panel cover/pad
locator pins are indexed properly at center stack
area prior to reassembly.

(4) Tighten the three passenger airbag to instru-

ment panel reinforcement retaining bolts. Torque
bolts to 10 ± 2 N·m (90 ± 15 in. lbs.).

(5) Connect the passenger airbag electrical connec-

tor. Install the connector onto the instrument panel
reinforcement with the push-pin fasteners.

(6) Roll

the

instrument

panel

forward

lifting

slightly so as to seat the instrument panel air distri-
bution duct on top of the HVAC unit properly to
avoid any leaks or damage to the seal.

(7) Install six upper fence line instrument panel

retaining bolts.

(8) Install three right side instrument panel A-pil-

lar retaining bolts and tighten the right instrument
panel roll down bolt. Install the smaller 10 mm bolt
first to align the instrument panel properly.

(9) Install three left side instrument panel A-pillar

retaining bolts and tighten the left instrument panel
roll down bolt. Install the smaller 10 mm bolt first to
align the instrument panel properly.

(10) Install seven lower instrument panel cover/

pad retaining screws.

(11) Install four screws along top front edge of

instrument panel cover/pad.

(12) Install one far left instrument panel speaker

retaining screw.

(13) Install wiring connectors to radio. Install

radio and four retaining screws.

(14) Connect glove box lamp wiring connector and

place right lower instrument panel trim (glove box
surround) into position.

(15) Install nineteen right lower instrument panel

trim (glove box surround) and install panel screws.

(16) Slide cup holder assembly into instrument

panel.

(17) Install

center

bezel

wiring

connectors

HVAC control and switch assembly (hazard, rear
wiper/washer, heated seats).

(18) Install instrument panel center bezel by align-

ing slots and firmly snapping into place.

(19) Install two screws to instrument panel center

bezel.

(20) Align filler bezel above cup holder over retain-

ing slots and firmly snap into place.

(21) Place instrument panel top cover into position

and firmly snap down rear edge of top cover.

(22) Install glove box. Align hinges, snap into

place, roll glove box upwards and push in sides to
fully install.

(23) Align right side upper A-pillar trim over

retaining slots and firmly snap into place.

(24) Align right A-pillar lower extension trim over

retaining slots and firmly snap into place.

(25) Align right instrument panel end cap over

retaining slots and firmly snap into place.

(26) Align right cowl panel over retaining slots and

firmly snap into place.

(27) Align right front door sill plate over retaining

slots and firmly snap into place.

(28) Install two right side nuts at instrument

panel center stack support to floor.

(29) Install two left side nuts at instrument panel

center stack support to floor.

(30) Connect the two wiring connectors to lower

instrument panel cubby bin at bottom of center stack
and install six screws.

(31) Align left side upper A-pillar trim over retain-

ing slots and firmly snap into place.

RESTRAINTS

8O - 31

PASSENGER AIRBAG (Continued)

(32) Install four nuts at brake pedal support

bracket to instrument panel.

(33) Align left A-pillar lower extension trim over

retaining slots and firmly snap into place.

(34) Install knee blocker and retaining screws.
(35) Install Data Link Connector (DLC) into bot-

tom of knee blocker.

(36) Align parking brake lever and snap into place

on knee blocker reinforcement.

(37) Install lower steering column cover and four

retaining screws

(38) Align left cowl panel over retaining slots and

firmly snap into place.

(39) Align left front door sill plate over retaining

slots and firmly snap into place.

(40) Install center console bin between front seats.

(41) Close hood.
(42) Verify system and vehicle operation.

PASSENGER AIRBAG
DISABLED INDICATOR

DESCRIPTION

Vehicles equipped with the Occupant Classification

System (OCS) include a Passenger Airbag Disabled
(PAD) indicator (Fig. 40) which is located in the
instrument panel center stack, above the radio. The
PAD indicator is present only in vehicles equipped
with the OCS.

The PAD indicator consists of a molded plastic

housing with an integral connector at the back. An
amber Light Emitting Diode (LED) behind the lens
causes the “PASS AIR BAG OFF” text and icon to
appear silhouetted against an amber field through
the translucent lens when the indicator is illumi-
nated from behind by the LED. The PAD indicator is
available for separate service replacement.

OPERATION

In vehicles equipped with the Occupant Classifica-

tion System (OCS), the Passenger Airbag Disabled
(PAD) indicator gives an indication when the passen-
ger airbag and seat belt tensioner deployment cir-
cuits

are

disabled

the

Occupant

Restraint

Controller (ORC). The PAD indicator is controlled by
a transistor within the ORC through a hard wired
output based upon ORC programming and electronic
occupant classification messages received by the ORC
over the Programmable Communications Interface
(PCI) data bus from the Occupant Classification
Module (OCM). The PAD indicator Light Emitting
Diode (LED) is completely controlled by the ORC.
The LED receives a battery current input on the
fused ignition switch output (RUN/START) circuit.
Therefore, the LED will always be OFF when the
ignition switch is in any position except ON or
START. The LED only illuminates when it is pro-
vided a path to ground by the ORC transistor. The
ORC will turn on the PAD indicator for the following
reasons:

• Bulb Test - Each time the ignition switch is

turned to the ON position the PAD indicator is illu-
minated for about six seconds.

• Child Seat Detected Occupant Classifica-

tion Message - Each time the ORC receives a mes-
sage from the OCM indicating a child seat has been
detected in the passenger front seat, the passenger
airbag and seat belt tensioner deployment circuits
are deactivated and the PAD indicator will be illumi-
nated. The indicator remains illuminated until the
ORC receives an occupant classification message
indicating that:

• The passenger front seat is empty.

• The seat is occupied by a load equal to or

greater than a fifth percentile female.

• OR, Until the ignition switch is turned to the

OFF position, whichever of these three occurs first.
• Load Less Than Fifth Percentile Female

Occupant Classification Message - Each time the
ORC receives a message from the OCM indicating
that a load less than a fifth percentile female has
been detected in the passenger front seat, the pas-
senger airbag and seat belt tensioner deployment cir-
cuits are deactivated and the PAD indicator will be
illuminated. The indicator remains illuminated until:

• The ORC receives an occupant classification

message indicating that the passenger front seat is
empty.

• The seat is occupied by a load equal to or

greater than a fifth percentile female.

• OR, until the ignition switch is turned to the

OFF position, whichever of these three occurs first.
• Load Undetermined Occupant Classifica-

tion Message - Each time the ORC receives a mes-

Fig. 40 PASSENGER AIRBAG DISABLED (PAD)

INDICATOR

8O - 32

RESTRAINTS

PASSENGER AIRBAG (Continued)

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