PASSIVE RESTRAINT SYSTEMS

CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
AIRBAG CONTROL MODULE . . . . . . . . . . . . . . . 3
AIRBAG MODULE . . . . . . . . . . . . . . . . . . . . . . . . 2
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 2
IMPACT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 3
CLEANUP PROCEDURE . . . . . . . . . . . . . . . . . . . 4
REMOVAL AND INSTALLATION
AIRBAG CONTROL MODULE . . . . . . . . . . . . . . . 8
AIRBAG MODULE . . . . . . . . . . . . . . . . . . . . . . . . 4
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DRIVER SIDE AIRBAG TRIM COVER AND
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 6
PASSENGER SIDE AIRBAG REAR MOUNTING
BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ADJUSTMENTS
CLOCKSPRING CENTERING . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . 11
GENERAL INFORMATION
INTRODUCTION
A dual front ai rbag system i s a standard equi p-
ment safety feature on thi s model . The system
i ncl udes an i nfl atabl e ai rbag modul e i n the center of
the steeri ng wheel , and a second i nfl atabl e ai rbag
modul e i n the i nstrument panel above the gl ove box.
Thi s system i s desi gned to reduce seri ous i njuri es to
the dri ver and front seat passenger duri ng a frontal
i mpact of the vehi cl e.
To test thi s passi ve restrai nt system, refer to the
proper Di agnosti c Procedures manual . I f an ai rbag
modul e assembl y i s defecti ve and non-depl oyed, refer
to the Chrysl er Corporati on current parts return l i st
i n the Warranty Pol i ci es and Procedures manual for
the proper handl i ng procedures.
Fol l owi ng are general descri pti ons of the major
components i n the ai rbag system. Refer to 8W-43 -
Ai rbag System i n Group 8W - Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and di agrams.
WARNING:
THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG 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 SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
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. IN
ADDITION, THE PASSENGER AIRBAG MODULE
CONTAINS ARGON GAS PRESSURIZED TO OVER
2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN
AIRBAG MODULE OR TAMPER WITH ITS INFLA-
TOR. DO NOT PUNCTURE, INCINERATE, OR BRING
INTO CONTACT WITH ELECTRICITY. DO NOT
STORE AT TEMPERATURES EXCEEDING 93 C
(200 F).
REPLACE AIRBAG SYSTEM COMPONENTS
ONLY WITH PARTS SPECIFIED IN THE CHRYSLER
MOPAR PARTS CATALOG. SUBSTITUTE PARTS
MAY APPEAR INTERCHANGEABLE, BUT INTERNAL
DIFFERENCES MAY RESULT IN INFERIOR OCCU-
PANT PROTECTION.
THE FASTENERS, SCREWS, AND BOLTS ORIG-
INALLY USED FOR THE AIRBAG SYSTEM COMPO-
NENTS HAVE SPECIAL COATINGS AND ARE
SPECIFICALLY DESIGNED FOR THE AIRBAG SYS-
TEM. THEY MUST NEVER BE REPLACED WITH ANY
SUBSTITUTES. ANY TIME A NEW FASTENER IS
NEEDED, REPLACE IT WITH THE CORRECT FAS-
TENERS PROVIDED IN THE SERVICE PACKAGE OR
ZJ PASSIVE RESTRAINT SYSTEMS 8M - 1
SPECIFIED IN THE CHRYSLER MOPAR PARTS CAT-
ALOG.
WHEN A STEERING COLUMN HAS AN AIRBAG
MODULE ATTACHED, NEVER PLACE THE COLUMN
ON THE FLOOR OR ANY OTHER SURFACE WITH
THE STEERING WHEEL OR AIRBAG MODULE FACE
DOWN.
DESCRIPTION AND OPERATION
AIRBAG MODULE
DRIVER SIDE
The ai rbag modul e protecti ve tri m cover i s the
most vi si bl e part of the dri ver si de ai rbag system.
The modul e i s mounted di rectl y to the steeri ng
wheel . Located under the ai rbag modul e tri m cover
are the horn swi tch, the ai rbag cushi on, and the ai r-
bag cushi on supporti ng components. The ai rbag mod-
ul e i ncl udes a housi ng to whi ch the cushi on and
i nfl ator are attached and seal ed. The ai rbag modul e
cannot be repai red, and must be repl aced i f depl oyed
or i n any way damaged.
The i nfl ator assembl y i s mounted to the back of
the ai rbag modul e. The i nfl ator seal s the hol e i n the
ai rbag cushi on so i t can di scharge the gas i t produces
di rectl y i nto the cushi on when suppl i ed wi th the
proper el ectri cal si gnal . The protecti ve tri m cover i s
fi tted to the front of the ai rbag modul e and forms a
decorati ve cover i n the center of the steeri ng wheel .
Upon ai rbag depl oyment, the cover wi l l spl i t at a pre-
determi ned breakout l i ne.
PASSENGER SIDE
The i nstrument panel top pad i s the most vi si bl e
part of the passenger si de ai rbag system. Located
under the i nstrument panel top pad are the ai rbag
cushi on and i ts supporti ng components. The ai rbag
modul e i ncl udes a housi ng to whi ch the cushi on and
i nfl ator are attached and seal ed. The ai rbag modul e
cannot be repai red, and must be repl aced i f depl oyed
or i n any way damaged.
The i nfl ator assembl y i s mounted to the back of
the ai rbag modul e. The i nfl ator seal s the hol e i n the
ai rbag cushi on so i t can di scharge the gas i t produces
di rectl y i nto the cushi on when suppl i ed wi th the
proper el ectri cal si gnal . The i nstrument panel top
pad above the gl ove box openi ng has a door and pre-
determi ned breakout l i nes conceal ed beneath i ts dec-
orati ve cover. Upon ai rbag depl oyment, the top pad
wi l l spl i t at the breakout l i nes and the door wi l l pi vot
out of the way.
The ai rbag modul e i s secured to two mounti ng
brackets beneath the i nstrument panel top pad and
above the gl ove box openi ng. The ai rbag front mount-
i ng bracket (cl osest to the dash panel ) i s wel ded to
the i nstrument panel armature. The ai rbag rear
mounti ng bracket (cl osest to the passenger) i s bol ted
to the i nstrument panel armature. Fol l owi ng an ai r-
bag depl oyment, the ai rbag rear mounti ng bracket
and the i nstrument panel top pad must be repl aced.
I f the ai rbag front mounti ng bracket i s damaged, the
i nstrument panel armature assembl y must al so be
repl aced.
STORAGE
An ai rbag modul e must be stored i n i ts ori gi nal ,
speci al contai ner unti l used for servi ce. Al so, i t must
be stored i n a cl ean, dry envi ronment; away from
sources of extreme heat, sparks, and hi gh el ectri cal
energy. Al ways pl ace or store an ai rbag modul e on a
surface wi th i ts tri m cover or ai rbag si de faci ng up,
to mi ni mi ze movement i n case of an acci dental
depl oyment.
IMPACT SENSOR
The i mpact sensor provi des veri fi cati on of the
di recti on and severi ty of an i mpact. One i mpact sen-
sor i s used. I t i s l ocated i nsi de the Ai rbag Control
Modul e (ACM), whi ch i s secured to a bracket on the
fl oor panel transmi ssi on tunnel i nsi de the vehi cl e.
The i mpact sensor i s an accel erometer that senses
the rate of decel erati on. The mi croprocessor i n the
ACM moni tors the i mpact sensor si gnal . A pre-pro-
grammed deci si on al gori thm i n the mi croprocessor
determi nes when the decel erati on rate i ndi cates an
i mpact that i s severe enough to requi re ai rbag sys-
tem protecti on. When the programmed condi ti ons are
met, the ACM sends an el ectri cal si gnal to depl oy the
ai rbag system components.
The i mpact sensor i s cal i brated for the speci fi c
vehi cl e. The sensor i s onl y servi ced as a uni t wi th the
ACM. The sensor cannot be repai red or adjusted and,
i f faul ty or damaged, the ACM uni t must be repl aced.
CLOCKSPRING
The cl ockspri ng i s mounted on the steeri ng col umn
behi nd the steeri ng wheel . Thi s assembl y consi sts of
a pl asti c housi ng whi ch contai ns a fl at, ri bbon-l i ke,
el ectri cal l y conducti ve tape that wi nds and unwi nds
wi th the steeri ng wheel rotati on.
The cl ockspri ng i s used to mai ntai n a conti nuous
el ectri cal ci rcui t between the i nstrument panel wi re
harness and the dri ver si de ai rbag modul e, the horn
swi tch, the vehi cl e speed control swi tches, and the
remote radi o swi tches on vehi cl es that are so
equi pped.
The cl ockspri ng must be properl y centered when i t
i s i nstal l ed on the steeri ng col umn fol l owi ng any ser-
vi ce removal , or i t wi l l be damaged. See the Cl ock-
spri ng Centeri ng procedure i n thi s group for more
i nformati on.
8M - 2 PASSIVE RESTRAINT SYSTEMS ZJ
GENERAL INFORMATION (Continued)
The cl ockspri ng cannot be repai red. I f the cl ock-
spri ng i s faul ty, damaged, or i f the ai rbag has been
depl oyed, the cl ockspri ng must be repl aced.
AIRBAG CONTROL MODULE
The Ai rbag Control Modul e (ACM) contai ns the
i mpact sensor, and a mi croprocessor that moni tors
the i mpact sensor and the ai rbag system el ectri cal
ci rcui ts to determi ne the system readi ness. The ACM
contai ns On-Board Di agnosti cs (OBD), and wi l l send
an ai rbag l amp-on message to the i nstrument cl uster
on the Chrysl er Col l i si on Detecti on (CCD) data bus
to l i ght the ai rbag i ndi cator l amp i n the i nstrument
cl uster when a moni tored ai rbag system faul t occurs.
The ACM al so contai ns an energy-storage capaci -
tor. Thi s capaci tor stores enough el ectri cal energy to
depl oy the ai rbags for up to one second fol l owi ng a
battery di sconnect or fai l ure duri ng an i mpact. The
purpose of the capaci tor i s to provi de ai rbag system
protecti on i n a severe secondary i mpact, i f the i ni ti al
i mpact has damaged or di sconnected the battery, but
was not severe enough to depl oy the ai rbags.
The ACM cannot be repai red and, i f damaged or
faul ty, i t must be repl aced.
DIAGNOSIS AND TESTING
AIRBAG SYSTEM
A DRB scan tool i s requi red for di agnosi s of the
ai rbag system. Refer to the proper Di agnosti c Proce-
dures manual for more i nformati on.
(1) Connect the DRB scan tool to the 16-way data
l i nk wi re harness connector. The connector i s l ocated
on the dri ver si de l ower edge of the i nstrument
panel , outboard of the steeri ng col umn (Fi g. 1).
(2) Turn the i gni ti on swi tch to the On posi ti on.
Exi t the vehi cl e wi th the DRB. Use the l atest versi on
of the proper DRB cartri dge.
(3) Usi ng the DRB, read and record the acti ve
Di agnosti c Troubl e Code (DTC) data.
(4) Read and record any stored DTC data.
(5) Refer to the proper Di agnosti c Procedures man-
ual i f any DTC i s found i n Step 3 or Step 4.
(6) Erase the stored DTC data. I f any probl ems
remai n, the stored DTC data wi l l not erase.
(7) Wi th the i gni ti on swi tch sti l l i n the On posi -
ti on, make sure nobody i s i n the vehi cl e.
(8) From outsi de of the vehi cl e (away from the ai r-
bag modul es i n case of an acci dental depl oyment)
turn the i gni ti on swi tch to the Off posi ti on for about
ten seconds, and then back to the On posi ti on.
Observe the ai rbag i ndi cator l amp i n the i nstrument
cl uster. I t shoul d l i ght for si x to ei ght seconds, and
then go out. Thi s i ndi cates that the ai rbag system i s
functi oni ng normal l y.
NOTE: If the airbag indicator lamp fails to light, or
lights and stays on, there is an airbag system mal-
function. Refer to the proper Diagnostic Procedures
manual to diagnose the problem.
SERVICE PROCEDURES
AIRBAG SYSTEM
NON-DEPLOYED
At no ti me shoul d any source of el ectri ci ty be per-
mi tted near the i nfl ator on the back of an ai rbag
modul e. When carryi ng a non-depl oyed ai rbag mod-
ul e, the tri m cover or ai rbag si de of the modul e
shoul d be poi nted away from the body to mi ni mi ze
i njury i n the event of an acci dental depl oyment. I f
the modul e i s pl aced on a bench or any other surface,
the tri m cover or ai rbag si de of the modul e shoul d be
face up to mi ni mi ze movement i n the event of an
acci dental depl oyment.
I n addi ti on, the ai rbag system shoul d be di sarmed
whenever any steeri ng wheel , steeri ng col umn, or
i nstrument panel components requi re di agnosi s or
servi ce. Fai l ure to observe thi s warni ng coul d resul t
i n acci dental ai rbag depl oyment and possi bl e per-
sonal i njury. Refer to Group 8E - I nstrument Panel
Systems for addi ti onal servi ce procedures on the
i nstrument panel . Refer to Group 19 - Steeri ng for
addi ti onal servi ce procedures on the steeri ng wheel
and steeri ng col umn.
Fig. 1 16-Way Data Link Connector - Typical
ZJ PASSIVE RESTRAINT SYSTEMS 8M - 3
DESCRIPTION AND OPERATION (Continued)
DEPLOYED
Any vehi cl e whi ch i s to be returned to use after an
ai rbag depl oyment, must have both ai rbag modul es,
the cl ockspri ng, the i nstrument panel top pad, and
the passenger si de ai rbag rear mounti ng bracket
repl aced. These components wi l l be damaged or
weakened as a resul t of an ai rbag depl oyment, whi ch
may or may not be obvi ous duri ng a vi sual i nspec-
ti on, and are not i ntended for reuse.
Other vehi cl e components shoul d be cl osel y
i nspected, but are to be repl aced onl y as requi red by
the extent of the vi si bl e damage i ncurred.
CLEANUP PROCEDURE
Fol l owi ng an ai rbag system depl oyment, the vehi -
cl e i nteri or wi l l contai n a powdery resi due. Thi s res-
i due consi sts pri mari l y of harml ess parti cul ate
by-products of the smal l pyrotechni c charge used to
i ni ti ate the ai rbag depl oyment propel l ant. However,
thi s resi due wi l l al so contai n traces of sodi um
hydroxi de powder, a chemi cal by-product of the pro-
pel l ant materi al that i s used to generate the ni trogen
gas that i nfl ates the ai rbag. Si nce sodi um hydroxi de
powder can i rri tate the ski n, eyes, nose, or throat, be
sure to wear safety gl asses, rubber gl oves, and a
l ong-sl eeved shi rt duri ng cl eanup (Fi g. 2).
WARNING: 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 PHYSI-
CIAN.
Begi n the cl eanup by removi ng the ai rbag modul es
from the vehi cl e as descri bed i n thi s group.
Use a vacuum cl eaner to remove any resi dual pow-
der from the vehi cl e i nteri or. Cl ean from outsi de the
vehi cl e and work your way i nsi de, so that you avoi d
kneel i ng or si tti ng on a non-cl eaned area.
Be sure to vacuum the heater and ai r condi ti oni ng
outl ets as wel l (Fi g. 3). Run the heater and ai r con-
di ti oni ng bl ower on the l owest speed setti ng and vac-
uum any powder expel l ed from the outl ets. You may
need to vacuum the i nteri or of the vehi cl e a second
ti me to recover al l of the powder.
Pl ace the depl oyed ai rbag modul es i n your vehi cu-
l ar scrap pi l e.
REMOVAL AND INSTALLATION
AIRBAG MODULE
WARNING:
THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG 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 SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WHEN REMOVING A DEPLOYED AIRBAG MOD-
ULE, 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.
Fig. 2 Wear Safety Glasses and Rubber Gloves
Fig. 3 Vacuum Heater and A/C Outlets
8M - 4 PASSIVE RESTRAINT SYSTEMS ZJ
SERVICE PROCEDURES (Continued)
DRIVER SIDE
(1) Di sconnect and i sol ate the battery negati ve
cabl e. I f the ai rbag has not been depl oyed, wai t two
mi nutes for the system capaci tor to di scharge before
further servi ce.
(2) From the undersi de of the steeri ng wheel ,
remove the three screws that secure the dri ver si de
ai rbag modul e to the steeri ng wheel (Fi g. 4).
(3) Pul l the ai rbag modul e away from the steeri ng
wheel far enough to access the wi re harness connec-
tors on the back of the ai rbag modul e.
(4) Unpl ug the ai rbag modul e and horn swi tch
wi re harness connectors from the back of the ai rbag
modul e.
(5) Remove the dri ver si de ai rbag modul e from the
vehi cl e.
(6) I f the ai rbag has been depl oyed, the cl ockspri ng
must be repl aced. See Cl ockspri ng i n thi s group for
the procedures.
(7) When i nstal l i ng the ai rbag modul e, connect the
cl ockspri ng wi re harness connector to the modul e by
pressi ng strai ght i n on the connector. Be certai n that
the connector i s ful l y engaged by observi ng the l atch
arms on each si de of the connector. When these arms
move outward from the connector, the connector i s
l atched.
(8) Connect the horn swi tch wi re harness connec-
tors.
(9) I nstal l the ai rbag modul e i n the steeri ng wheel .
Ti ghten the mounti ng screws to 10.2 Nm (90 i n.
l bs.).
(10) Do not connect the battery negati ve cabl e at
thi s ti me. See Ai rbag System i n the Di agnosi s and
Testi ng secti on of thi s group for the proper proce-
dures.
PASSENGER SIDE
The fol l owi ng procedure i s for repl acement of a
faul ty or damaged passenger si de ai rbag modul e. I f
the passenger si de ai rbag has been depl oyed, the
i nstrument panel top pad and passenger si de ai rbag
rear mounti ng bracket must be repl aced. Refer to
Group 8E - I nstrument Panel Systems for the proce-
dures requi red for i nstrument panel top pad servi ce.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. I f the ai rbag has not been depl oyed, wai t two
mi nutes for the system capaci tor to di scharge before
further servi ce.
(2) Remove the i nstrument panel top pad. Refer to
I nstrument Panel Top Pad i n Group 8E - I nstrument
Panel Systems for the procedures.
(3) Remove the screw that secures the upper ai r-
bag mounti ng bracket tab to the i nstrument panel
base.
(4) Remove the two screws that secure the ai rbag
modul e to the front ai rbag mounti ng bracket (Fi g. 5).
(5) Remove the two screws that secure the ai rbag
modul e to the rear ai rbag mounti ng bracket.
(6) Unpl ug the ai rbag modul e wi re harness con-
nector and remove the ai rbag modul e from the
i nstrument panel .
(7) I f the ai rbag has been depl oyed, the passenger
si de rear ai rbag mounti ng bracket must be repl aced.
See Passenger Si de Rear Ai rbag Mounti ng Bracket i n
thi s group for the procedures.
WARNING: USE EXTREME CARE TO PREVENT
ANY FOREIGN MATERIAL FROM ENTERING THE
PASSENGER SIDE AIRBAG MODULE, OR BECOM-
ING ENTRAPPED BETWEEN THE INSTRUMENT
PANEL TOP PAD AND THE PASSENGER SIDE AIR-
BAG MODULE. FAILURE TO OBSERVE THIS WARN-
ING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
(8) I nstal l the passenger si de ai rbag modul e i n the
i nstrument panel . Ti ghten the l ower ai rbag modul e
mounti ng screws to 11.75 Nm (105 i n. l bs.). Ti ghten
the upper ai rbag modul e mounti ng bracket tab screw
to 2.2 Nm (20 i n. l bs.).
Fig. 4 Driver Side Airbag Module Remove/Install
Fig. 5 Passenger Side Airbag Module Remove/Install
ZJ PASSIVE RESTRAINT SYSTEMS 8M - 5
REMOVAL AND INSTALLATION (Continued)
NOTE: If the lower airbag module mounting screws
cannot be tightened to the specified torque value,
replace the screws with the oversized screws spec-
ified in the Mopar Parts Catalog.
(9) When rei nstal l i ng the passenger si de ai rbag
modul e, be certai n that the ai rbag modul e wi re har-
ness connector l atches are ful l y engaged.
(10) Reverse the remai ni ng removal procedures to
compl ete the i nstal l ati on.
(11) Do not connect the battery negati ve cabl e at
thi s ti me. See Ai rbag System i n the Di agnosi s and
Testi ng secti on of thi s group for the proper proce-
dures.
DRIVER SIDE AIRBAG TRIM COVER AND HORN
SWITCH
WARNING:
THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG 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 SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
THE HORN SWITCH IS INTEGRAL TO THE AIR-
BAG MODULE TRIM COVER. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. I f the ai rbag has not been depl oyed, wai t two
mi nutes for the system capaci tor to di scharge before
further servi ce.
(2) Remove the dri ver si de ai rbag modul e from the
steeri ng wheel . See Ai rbag Modul e i n thi s group for
the procedures.
(3) Remove the pl asti c horn swi tch feed wi re
retai ners from the studs on the ai rbag housi ng (Fi g.
6).
(4) Unpl ug the horn swi tch ground wi re from the
ai rbag modul e l ower tri m cover retai ner.
(5) Remove the four nuts that secure the upper
and l ower tri m cover retai ners to the studs on the
ai rbag housi ng (Fi g. 7).
(6) Remove the upper and l ower tri m cover retai n-
ers from the ai rbag housi ng studs.
(7) Di sengage the fi ve tri m cover l ocki ng bl ocks
from the l i p around the outsi de edge of the ai rbag
housi ng and remove the housi ng from the cover (Fi g.
8).
Fig. 6 Horn Switch Feed Wires Remove/Install
Fig. 7 Airbag Trim Cover Retainers Remove/Install
8M - 6 PASSIVE RESTRAINT SYSTEMS ZJ
REMOVAL AND INSTALLATION (Continued)
WARNING: USE EXTREME CARE TO PREVENT
ANY FOREIGN MATERIAL FROM ENTERING THE
DRIVER SIDE AIRBAG MODULE, OR BECOMING
ENTRAPPED BETWEEN THE DRIVER SIDE AIRBAG
MODULE TRIM COVER AND THE DRIVER SIDE AIR-
BAG MODULE. FAILURE TO OBSERVE THIS WARN-
ING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
(8) When i nstal l i ng the tri m cover and horn
swi tch, be certai n that the l ocki ng bl ocks are ful l y
engaged on the l i p of the ai rbag housi ng and that the
horn swi tch feed wi re i s captured between the l i p of
the ai rbag housi ng and the l ocki ng bl ock (Fi g. 9).
(9) When i nstal l i ng the upper and l ower tri m cover
retai ners, be certai n that the tabs on each retai ner
are engaged i n the retai ner sl ots of the tri m cover
(Fi g. 8).
(10) I nstal l and ti ghten the tri m cover retai ner
nuts to 10 Nm (90 i n. l bs.).
(11) Reverse the remai ni ng removal procedures to
compl ete the i nstal l ati on, but do not connect the bat-
tery negati ve cabl e at thi s ti me. See Ai rbag System
i n the Di agnosi s and Testi ng secti on of thi s group for
the proper procedures.
PASSENGER SIDE AIRBAG REAR MOUNTING
BRACKET
(1) Remove the passenger si de ai rbag modul e from
the i nstrument panel . See Ai rbag Modul e i n thi s
group for the procedures.
(2) Remove the screws that secure the i nstrument
panel wi re harness trough to the ai rbag rear mount-
i ng bracket.
(3) Remove the heater and ai r condi ti oner control
from the i nstrument panel . Refer to Heater-A/C Con-
trol i n Group 24 - Heati ng and Ai r Condi ti oni ng for
the procedures.
(4) Reach through the heater-A/C control openi ng
i n the i nstrument panel to remove the two bol ts that
secure the i nboard end of the ai rbag rear mounti ng
bracket to the i nstrument panel armature (Fi g. 10).
(5) Remove the two bol ts that secure the outboard
end of the ai rbag rear mounti ng bracket from the
passenger si de outboard end of the i nstrument panel
armature (Fi g. 11).
(6) Remove the ai rbag rear mounti ng bracket
through the l ower openi ng of the i nstrument panel
armature, outboard end fi rst.
Fig. 8 Airbag Trim Cover Remove/Install Fig. 9 Airbag Trim Cover Locking Blocks Installed
Fig. 10 Inboard Mounting Bolts Remove/Install
ZJ PASSIVE RESTRAINT SYSTEMS 8M - 7
REMOVAL AND INSTALLATION (Continued)
(7) Reverse the removal procedures to i nstal l .
Ti ghten the bracket mounti ng bol ts to 11.75 Nm
(105 i n. l bs.). Ti ghten the wi re harness trough screws
to 2.2 Nm (20 i n. l bs.).
AIRBAG CONTROL MODULE
WARNING:
THE AIRBAG CONTROL MODULE CONTAINS
THE IMPACT SENSOR, WHICH ENABLES THE SYS-
TEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPT-
ING TO DIAGNOSE OR SERVICE ANY AIRBAG
SYSTEM OR RELATED STEERING WHEEL, STEER-
ING COLUMN, OR INSTRUMENT PANEL COMPO-
NENTS YOU MUST FIRST DISCONNECT AND
ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NEVER STRIKE OR KICK THE AIRBAG CON-
TROL MODULE, AS IT CAN DAMAGE THE IMPACT
SENSOR OR AFFECT ITS CALIBRATION. IF AN AIR-
BAG CONTROL MODULE IS ACCIDENTALLY
DROPPED DURING SERVICE, THE MODULE MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. I f the ai rbag has not been depl oyed, wai t two
mi nutes for the system capaci tor to di scharge before
further servi ce.
(2) Pul l the transmi ssi on shi ft l ever handl e
strai ght up fi rml y and qui ckl y to remove the handl e.
(3) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , pry gentl y between the edge of the
transmi ssi on shi ft i ndi cator bezel and the fl oor con-
sol e to rel ease the snap cl i p retai ners (Fi g. 12).
(4) Rai se the shi ft i ndi cator bezel far enough from
the consol e to remove the l amp sockets from the
bezel , then remove the bezel from the consol e.
(5) Remove the screws that secure the fl oor consol e
to the consol e and parki ng brake l ever mounti ng
brackets.
(6) Remove the fl oor consol e from the fl oor pan
transmi ssi on tunnel .
(7) Unpl ug the Ai rbag Control Modul e (ACM) wi re
harness connector. To unpl ug the wi re harness con-
nector from the ACM (Fi g. 13):
(a) Pul l the two whi te l ocks out about 3 mm
(0.125 i n.) from each si de of the connector.
(b) Squeeze the two connector l atch tabs
between the thumb and forefi nger.
(c) Pul l the connector out of the ACM receptacl e.
NOTE: Always remove and replace the airbag con-
trol module and its mounting bracket as a unit.
Replacement modules include a replacement
mounting bracket. Do not transfer the module to
another mounting bracket.
(8) Remove the four screws that secure the ACM
mounti ng bracket to the fl oor pan transmi ssi on tun-
nel (Fi g. 14).
(9) Remove the ACM and mounti ng bracket from
the vehi cl e as a uni t.
(10) When i nstal l i ng the ACM, posi ti on the uni t
wi th the arrow on the ACM housi ng poi nti ng for-
ward.
Fig. 11 Outboard Mounting Bolts Remove/Install
Fig. 12 Floor Console Components
8M - 8 PASSIVE RESTRAINT SYSTEMS ZJ
REMOVAL AND INSTALLATION (Continued)
(11) Attach the ACM to the fl oor pan transmi ssi on
tunnel wi th the four mounti ng screws. Ti ghten the
mounti ng screws to 10.7 Nm (95 i n. l bs.).
(12) Pl ug i n the wi re harness connector to the
ACM. Be certai n that the connector l atches are ful l y
engaged and that the connector l ocks are pushed i n.
(13) Reverse the remai ni ng removal procedures to
compl ete the i nstal l ati on.
(14) Do not connect the battery negati ve cabl e at
thi s ti me. See Ai rbag System i n the Di agnosi s and
Testi ng secti on of thi s group for the proper proce-
dures.
CLOCKSPRING
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG 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 SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Turn the steeri ng wheel unti l the front wheel s
are i n the strai ght-ahead posi ti on before starti ng the
procedure.
(2) Di sconnect and i sol ate the battery negati ve
cabl e. I f the ai rbag has not been depl oyed, wai t two
mi nutes for the system capaci tor to di scharge before
further servi ce.
(3) Remove the dri ver si de ai rbag modul e from the
steeri ng wheel . See Ai rbag Modul e i n thi s group for
the procedures.
(4) I f the vehi cl e i s so equi pped, unpl ug the vehi cl e
speed control swi tch and the remote radi o swi tch
wi re harness connectors i n the steeri ng wheel .
(5) Remove the nut that secures the steeri ng wheel
to the steeri ng col umn upper shaft.
(6) Remove the steeri ng wheel wi th a steeri ng
wheel pul l er (Speci al Tool C-3428-B).
(7) Remove the upper and l ower steeri ng col umn
shrouds to gai n access to the cl ockspri ng wi re har-
ness connectors (Fi g. 15).
(8) Unpl ug the wi re harness connectors from the
cl ockspri ng.
(9) Remove the l ower fi xed col umn shroud.
(10) Unpl ug the wi re harness connector between
the cl ockspri ng and the i nstrument panel wi re har-
ness, l ocated near the base of the steeri ng col umn.
(11) To remove the cl ockspri ng, careful l y l i ft the
l ocati ng fi ngers of the cl ockspri ng assembl y from the
steeri ng col umn as necessary. The cl ockspri ng cannot
be repai red. I t must be repl aced i f faul ty or damaged,
or i f the ai rbag has been depl oyed.
(12) When i nstal l i ng the cl ockspri ng, snap the
cl ockspri ng onto the steeri ng col umn. I f the cl ock-
spri ng i s not posi ti oned properl y i n rel ati on to the
steeri ng wheel , see Cl ockspri ng Centeri ng i n thi s
group before i nstal l i ng the steeri ng wheel .
Fig. 13 Airbag Control Module Connector Removal
Fig. 14 Airbag Control Module Remove/Install
ZJ PASSIVE RESTRAINT SYSTEMS 8M - 9
REMOVAL AND INSTALLATION (Continued)
(13) Pl ug the cl ockspri ng wi re harness connector
i nto the i nstrument panel wi re harness. Be certai n
that the wi re harness l ocator cl i ps are properl y
seated on the outsi de of the wi ri ng trough and that
the wi re harness connector l atches are ful l y engaged.
(14) Rei nstal l the steeri ng col umn shrouds. Be cer-
tai n that the cl ockspri ng wi re harness i s i nsi de the
shrouds.
(15) The front wheel s shoul d sti l l be i n the
strai ght-ahead posi ti on. I nstal l the steeri ng wheel
bei ng certai n to i ndex the fl ats on the hub of the
steeri ng wheel wi th the formati ons on the i nsi de of
the cl ockspri ng. Pul l the wi re harnesses from the
cl ockspri ng through the upper and l ower hol es i n the
steeri ng wheel hub. Ti ghten the steeri ng wheel nut
to 61 Nm (45 ft. l bs.). Be certai n not to pi nch the
wi ri ng between the steeri ng wheel and the nut.
(16) I f the vehi cl e i s so equi pped, pl ug i n the vehi -
cl e speed control swi tch and remote radi o swi tch wi re
harness connectors.
(17) I nstal l the dri ver si de ai rbag modul e onto the
steeri ng wheel . See Ai rbag Modul e i n thi s group for
the procedures.
ADJ USTMENTS
CLOCKSPRING CENTERING
I f the rotati ng tape wi thi n the cl ockspri ng i s not
posi ti oned properl y i n rel ati on to the steeri ng wheel
and the front wheel s, the cl ockspri ng may fai l duri ng
use. The cl ockspri ng must be centered i f i t i s not
known to be properl y posi ti oned, or i f the front
wheel s were moved from the strai ght-ahead posi ti on
wi th the cl ockspri ng removed duri ng any servi ce pro-
cedure.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG 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 SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Turn the steeri ng wheel unti l the front wheel s
are i n the strai ght-ahead posi ti on before starti ng the
centeri ng procedure.
(2) Di sconnect and i sol ate the battery negati ve
cabl e. I f the ai rbag has not been depl oyed, wai t two
mi nutes for the system capaci tor to di scharge before
further servi ce.
(3) Remove the dri ver si de ai rbag modul e from the
steeri ng wheel . See Ai rbag Modul e i n thi s group for
the procedures.
(4) I f the vehi cl e i s so equi pped, unpl ug the vehi cl e
speed control swi tch and the remote radi o swi tch
wi re harness connectors i n the steeri ng wheel .
(5) Remove the nut that secures the steeri ng wheel
to the steeri ng col umn upper shaft.
(6) Remove the steeri ng wheel wi th a steeri ng
wheel pul l er (Speci al Tool C-3428-B).
(7) Depress the two pl asti c cl ockspri ng auto-l ock-
i ng tabs (Fi g. 16).
(8) Keepi ng the l ocki ng mechani sm di sengaged,
rotate the cl ockspri ng rotor cl ockwi se to the end of
i ts travel . Do not apply excessive torque.
(9) From the end of the cl ockwi se travel , rotate the
rotor about two and one-hal f turns countercl ockwi se.
The horn wi re harness shoul d end up at the top, and
the ai rbag wi re harness at the bottom.
(10) The front wheel s shoul d sti l l be i n the
strai ght-ahead posi ti on. I nstal l the steeri ng wheel
bei ng certai n to i ndex the fl ats on the hub of the
steeri ng wheel wi th the formati ons on the i nsi de of
the cl ockspri ng. Pul l the wi re harnesses from the
cl ockspri ng through the upper and l ower hol es i n the
steeri ng wheel hub. Ti ghten the steeri ng wheel nut
to 61 Nm (45 ft. l bs.). Be certai n not to pi nch any of
the wi ri ng between the steeri ng wheel and the nut.
Fig. 15 Steering Column Shrouds Remove/Install -
Typical
8M - 10 PASSIVE RESTRAINT SYSTEMS ZJ
REMOVAL AND INSTALLATION (Continued)
(11) I f the vehi cl e i s so equi pped, pl ug i n the vehi -
cl e speed control swi tch and remote radi o swi tch wi re
harness connectors.
(12) I nstal l the ai rbag modul e onto the steeri ng
wheel . See Ai rbag Modul e i n thi s group for the pro-
cedures.
SPECIAL TOOLS
STEERING WHEEL
Fig. 16 Clockspring Auto-Locking Tabs
Puller C-3428-B
ZJ PASSIVE RESTRAINT SYSTEMS 8M - 11
ADJ USTMENTS (Continued)