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Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual - part 226

RESTRAINT SYSTEMS

CONTENTS

page

AIR BAG MODULE

. . . . . . . . . . . . . . . . . . . . . . . 3

AIR BAG SERVICE AND TEST PROCEDURES

. . 1

AIR BAG SYSTEM CHECK

. . . . . . . . . . . . . . . . . 3

AIR BAG SYSTEM DIAGNOSTIC

MODULE (ASDM)

. . . . . . . . . . . . . . . . . . . . . . 5

CLOCKSPRING

. . . . . . . . . . . . . . . . . . . . . . . . . . 5

CLOCKSPRING CENTERING PROCEDURE

. . . . . 6

GENERAL INFORMATION

. . . . . . . . . . . . . . . . . . 1

LEFT FRONT IMPACT SENSOR

. . . . . . . . . . . . . 4

RIGHT FRONT IMPACT SENSOR

. . . . . . . . . . . . 4

STEERING COLUMN SWITCHES

. . . . . . . . . . . . 7

STEERING WHEEL

. . . . . . . . . . . . . . . . . . . . . . . 7

AIR BAG SERVICE AND TEST PROCEDURES

WARNING: THIS SYSTEM IS A SENSITIVE, COMPLEX
ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPT-
ING TO DIAGNOSE, REMOVE OR INSTALL THE AIR
BAG SYSTEM COMPONENTS, YOU MUST FIRST DIS-
CONNECT AND ISOLATE THE NEGATIVE (GROUND)
BATTERY CABLE. FAILURE TO DO SO COULD RE-
SULT IN ACCIDENTAL DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.

WHEN AN UNDEPLOYED AIR BAG ASSEMBLY IS

TO BE REMOVED FROM THE STEERING WHEEL,
DISCONNECT BATTERY GROUND CABLE AND
ISOLATE. ALLOW SYSTEM CAPACITOR TO DIS-
CHARGE FOR TWO MINUTES THEN BEGIN AIR
BAG SYSTEM COMPONENT REMOVAL.

Vehicles equipped with a Minivan Driver Air Bag

System must be inspected every 3 years or 30,000
miles / 48,000 Km. To inspect system use Passive
Restraint System Diagnostic Procedures Manual.

If the Air Bag Module Assembly is defective and

non-deployed, refer to Chrysler Motors current return
list for proper handling procedures.

WARNING: REPLACE AIR BAG SYSTEM COMPO-
NENTS WITH CHRYSLER MOPAR

SPECIFIED RE-

PLACEMENT PARTS. SUBSTITUTE PARTS MAY VI-
SUALLY

APPEAR

INTERCHANGEABLE,

BUT

INTERNAL DIFFERENCES MAY RESULT IN INFERIOR
OCCUPANT PROTECTION.

THE FASTENERS, SCREWS, AND BOLTS, ORIGI-

NALLY USED FOR THE AIR BAG COMPONENTS,
HAVE SPECIAL COATINGS AND ARE SPECIFI-
CALLY DESIGNED FOR THE AIR BAG SYSTEM.
THEY MUST NEVER BE REPLACED WITH ANY
SUBSTITUTES. ANYTIME A NEW FASTENER IS
NEEDED, REPLACE WITH THE CORRECT FAS-
TENERS PROVIDED IN THE SERVICE PACKAGE
OR FASTENERS LISTED IN THE PARTS BOOKS.

GENERAL INFORMATION

AIR BAG MODULE

The air bag module is the most visible part of the

system (Fig 1). It contains the air bag cushion and its
supporting components. The air bag module contains a
housing to which the cushion and inflator are attached
and sealed.

The inflator assembly is mounted to the back of the

module housing. When supplied with the proper elec-
trical signal the inflator assembly will produce a gas
and discharges it directly into the cushion. A protective
cover is fitted to the front of the air bag module and
forms a decorative cover in the center of the steering
wheel. The air bag module is mounted directly to the
steering wheel.

FRONT IMPACT SENSORS

The driver air bag system is a safety device designed

to deduce the risk of fatality or serious injury, caused
by a frontal impact of the vehicle.

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 diagnostic module which is

Fig. 1 Minivan Driver Air Bag System

RESTRAINT SYSTEMS

8M - 1

mounted on the floor pan, just forward of the center
console. The other two sensors are mounted on the
upper crossmember of the radiator closure panel on the
left and right side of the vehicle under the hood.

The impact sensors are threshold sensitive switches

that complete an electrical circuit when an impact
provides a sufficient G force to close the switch. The
sensors are calibrated for the specific vehicle and react
to the severity and direction of the impact.

CLOCKSPRING

The clockspring is mounted on the steering column

behind the steering wheel, and is used to maintain a
continuous electrical circuit between the wiring har-
ness and the driver’s air bag module. This assembly
consists of a flat ribbon-like electrically conductive
tape which winds and unwinds with the steering wheel
rotation.

DIAGNOSTIC MODULE

The Air Bag System Diagnostic Module (ASDM)

contains the safing sensor and energy reserve capaci-
tor. The ASDM monitors the system to determine the
system readiness. The ASDM will stored sufficient
energy to deploy the air bag for only two minutes after
the battery is disconnected. Unless both front impact
sensors are open the air bag could be deployed up to 9.5
minutes after the battery is disconnected. The ASDM
contains on-board diagnostics, and will illuminate the
AIR BAG warning lamp in the cluster when a fault
occurs.

STORAGE

The air bag 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 sources of 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.

HANDLING LIVE MODULE

At no time should any source of electricity be permit-

ted near the inflator on the back of the module. When
carrying a live module, the trim cover should be
pointed away from the body to minimize injury in the
event of accidental deployment. In addition, if the
module is placed on a bench or other surface, the
plastic trim cover should be face up to minimize move-
ment in case of accidental deployment.

When handling a steering column with an air bag

module attached, never place the column on the floor or
other surface with the steering wheel or module face
down.

DEPLOYED MODULE

The vehicle interior may contain a very small

amount of sodium hydroxide powder, a byproduct of air

bag deployment. Since this powder can irritate the
skin, eyes, nose or throat, be sure to wear safety
glasses, rubber gloves and long sleeves during cleanup
(Fig. 2).

If you find that the cleanup is irritating your skin,

run cool water over the affected area. Also, if you
experience nasal or throat irritation, exit the vehicle
for fresh air until the irritation ceases. If irritation
continues, see a physician.

CLEANUP PROCEDURE

Begin the cleanup by putting tape over the two air

bag exhaust vents (Fig. 3) so that no additional powder
will find its way into the vehicle interior. Then remove
the air bag and air bag module from the vehicle.

Use a vacuum cleaner to remove any residual powder

from the vehicle interior. Work from the outside in so
that you avoid kneeling or sitting in a uncleaned area.

Be sure to vacuum the heater and A/C outlets as well

(Fig. 4). In fact it’s a good idea to run the blower

Fig. 2 Wear Safety Glasses and Rubber Gloves

Fig. 3 Seal the Air Bag Exhaust Vents

8M - 2

RESTRAINT SYSTEMS

on low and to vacuum up 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.

Place the deployed bag and module in your automo-

tive scrap.

SERVICE OF DEPLOYED AIR BAG MODULE

After an air bag has been deployed, the air bag

module and clockspring must be replaced because they
cannot be reused. Other air bag system components are
replaced if damaged.

AIR BAG SYSTEM CHECK

WARNING: BEFORE BEGINNING ANY AIR BAG SYS-
TEM CHECK PROCEDURES, REMOVE AND ISOLATE
THE BATTERY NEGATIVE (-) CABLE (GROUND)
FROM THE VEHICLE BATTERY. THIS IS THE ONLY
SURE WAY TO DISABLE THE AIR BAG SYSTEM.
FAILURE TO DO THIS COULD RESULT IN ACCIDEN-
TAL AIR BAG DEPLOYMENT AND POSSIBLE PER-
SONAL INJURY.

WHEN AN UNDEPLOYED AIR BAG ASSEMBLY IS

TO BE REMOVED FROM THE STEERING WHEEL,
DISCONNECT BATTERY GROUND CABLE AND
ISOLATE. ALLOW SYSTEM CAPACITOR TO DIS-
CHARGE FOR TWO MINUTES, THEN BEGIN AIR
BAG REMOVAL.

(1) Disconnect the battery negative cable and iso-

late.

(2) Remove forward console or cover as necessary.
(3) Connect DRB II to ASDM diagnostic 6-way con-

nector, located at right side of module.

(4) Turn the ignition key to ON position. Exit vehicle

with DRB II. Use the latest version of the proper
cartridge.

(5) After checking that no one is inside the vehicle,

connect the negative battery cable.

(6) Using the DRB II, read and record active fault

data.

(7) Read and record any stored faults.
(8) Refer to the Passive Restraint Diagnostic Test

Manual if any faults are found in steps 6 and 7.

(9) Erase stored faults if there are no active fault

codes. If problems remain, fault codes will not erase.

(10) With the ignition key in the ON position, make

sure no one is in the vehicle.

(11) From the passenger side of vehicle, turn the

ignition key to OFF then ON and observe the instru-
ment cluster air bag lamp. It should go on for six to
eight seconds, then go out; indicating system is func-
tioning normally.

If air bag warning lamp either fails to light, or

goes on and stays on, there is a system malfunc-
tion. Refer to the Passive Restraint Diagnostic
Test Manual to diagnose the problem.

AIR BAG MODULE

WARNING: BEFORE BEGINNING ANY AIR BAG SYS-
TEM REMOVAL OR INSTALLATION PROCEDURES,
REMOVE AND ISOLATE THE BATTERY NEGATIVE (-)
CABLE (GROUND) FROM THE VEHICLE BATTERY.
THIS IS THE ONLY SURE WAY TO DISABLE THE AIR
BAG SYSTEM. FAILURE TO DO THIS COULD RESULT
IN ACCIDENTAL AIR BAG DEPLOYMENT AND POS-
SIBLE PERSONAL INJURY.

UNDEPLOYED AIR BAG REMOVAL FROM THE

STEERING

WHEEL:

DISCONNECT

BATTERY

GROUND CABLE AND ISOLATE. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES.
BEGIN AIR BAG REMOVAL.

REMOVAL

When removing a deployed module, rubber gloves,

eye protection and long sleeve shirt should be worn, as
there may be deposits on the surface which could
irritate the skin and eyes.

(1) Disconnect battery negative cable and isolate.
(2) Wait two minutes for the reserve capacitor to

discharge before removing undeployed module.

(3) Remove four nuts attaching air bag module to

steering wheel (Fig. 5).

(4) Lift module, and disconnect electrical connector

from rear of module.

(5) Remove module.
(6) When replacing a deployed module, the clock-

spring must also be replaced. Refer to Clockspring
Removal and Installation for proper procedure.

INSTALLATION

(1) Connect clockspring squib connector to the mod-

ule, by pressing straight in on the connector.

(2) Install four nuts and tighten to 9 to 11 N

Im (80

to 100 in. lbs.) torque.

Fig. 4 Vacuum Heater and A/C Outlets

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8M - 3

(3) Do not connect battery negative cable. Refer to

Air Bag System Check for proper procedure.

LEFT FRONT IMPACT SENSOR

REMOVAL

(1) Disconnect battery negative cable and isolate.
(2) Remove three nuts holding sensor to upper cross-

member of radiator closure panel and remove sensor
(Fig. 6).

(3) Disconnect impact sensor electrical connector.

INSTALLATION

(1) Connect sensor wiring lead from harness to con-

nector on body of sensor.

(2) Install left sensor with arrow pointing forward

(Fig. 6) and tighten nuts to 4.5 to 7 N

Im ( 40 to 60 in.

lbs.) torque using nuts provided with the new sensor.

(3) Do not connect battery negative cable. Refer to

Air Bag Systems Check for proper procedure.

RIGHT FRONT IMPACT SENSOR

REMOVAL

(1) Disconnect battery negative cable and isolate.

(2) Remove three nuts holding sensor to upper cross-

member of radiator closure panel. Remove right sensor.

(3) Disconnect impact sensor electrical connector

(Fig. 7).

INSTALLATION

(1) Connect sensor wiring lead from harness to con-

nector on body of sensor.

Fig. 5 Air Bag Module

Fig. 6 Left Impact Sensor

Fig. 7 Right Impact Sensor

8M - 4

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