Restraints - Service Information: Other Chrysler Crossfire I

ACTIVE RESTRAINTS

The Active restraints include

Front Driver and Passenger Seat Belts - Both seating positions are equipped with a three-point restraint. Seat Belt Tensioners (SBT) that actuate to remove slack in the seat belts and to snug the occupant into the seat at the onset of an impact event. This controls the occupant's forward movement to reduce the likelihood of injury as a result of contacting any interior components. Especially during the primary impact event phase, the tensioning power of the SBTs guarantees optimum transmission of the passenger compartment deceleration to the passenger. The vehicle's SBTs employ load-limiting retractors that "give" with higher seat belt loads. If a given seat belt force is exceeded, the seat belt force limiter permits a controlled forward inclination of the occupant's upper body. This protective function reduces the risk of chest and shoulder injuries and permits the passenger to plunge deeper into the airbag for a smooth dissipation of the occupant's kinetic energy. The drivers SBT is mounted in the B pillar below the belt line which locks only as a result of a sudden vehicle stop or a rapid extension of the webbing. This is called "Emergency Locking", it will allow free movement under normal driving conditions. To allow the retention of a child seat, a dual-mode passenger SBT is mounted in the B pillar below the belt line and can be switched between "Emergency Locking" and "Automatic Locking". Seat-mounted, inboard buckles allow seat adjustment while maintaining a consistent relationship between the buckle and the seat belt. For easy and consistent access and adjustment, a free-running latch plate on each belt slides along the webbing and stops against a button near the occupant's shoulder when unfastened. A seat belt warning lamp in the Instrument Cluster (IC) comes on and a warning chime sounds for a short time if the driver's seat belt is not fastened when the ignition switch is turned to the "RUN" position. After starting the engine, the seat belt warning indicator flashes briefly as an added precaution.

Child Restraint Anchors - The front passenger seat includes a LATCH (Lower Anchors and Tether for Children) child seat anchorage system. LATCH-compatible child seats are those engineered for retention by direct attachment to the vehicle's seat structure rather than with the vehicle's seat belts. The child seat's lower anchors attach to the seat structure via heavy-gauge wire loops at the intersection of the seat cushion and seat back. The child seat's upper tether strap attaches to a child seat tether anchor. Child seats can also be securely fastened in the passenger seat using the seat belts. For this purpose, the passenger seat belt includes a dual-mode SBT. After the child seat is positioned and the belt routed according to instructions for the child seat, the seat belt is pulled all the way out of the SBT to the end of its travel. This switches the SBT to the "Automatic Locking" mode. As the seat belt retracts, the SBT locks to prevent the belt from being pulled out again. Pulling the belt snugly over the child seat secures the seat in place. When the belt retracts fully after child seat removal, normal "Emergency Locking" action is restored to the SBT.

PASSIVE RESTRAINTS

The passive restraints include

Scheme 40

Driver and Passenger Front Airbags - This airbag system is a passive, inflatable, Supplemental Restraint System (SRS). Vehicles with this equipment can be readily identified by the "SRS AIRBAG" logo molded into the driver airbag trim cover in the steering wheel (1) and also into the passenger airbag area (2) of the instrument panel top pad above the glove box.

Scheme 41

Vehicles with the SRS can also be identified by the Airbag Warning Indicator, which will illuminate in the Instrument Cluster (IC) for about six seconds as a bulb test each time the ignition switch is turned to the "RUN" position.

The Supplemental Restraint System (SRS) also includes the following major components.

Scheme 42

Occupant Restraint Controller (ORC) - The Occupant Restraint Controller (ORC) is located on a mount on the top of the transmission tunnel (2) in front of the shifter, under the front center console.

ORC System Logic - The Supplemental Restraint System (SRS) uses an impact severity level (threshold) to determine the appropriate response from the ORC. Impacts that exceed the initial threshold in frontal, front-angled, and rear impacts trigger only the SBT that have the seat belt fastened. If the seat belt is not fastened, the system will not recognize the belt and not trigger the SBT. But, if the impact is severe enough, the airbags will be triggered even if the seat belts are not fastened. Impacts that exceed the higher threshold always trigger the airbags. The driver and passenger SRS systems operate independently of one another based on seat belt use. SBT actuation occurs only if the seat belts are buckled. After an impact that activates an SBT, the SBT assembly must be replaced. The ORC monitors operational readiness of the SRS and illuminates the airbag warning indicator lamp in the Instrument Cluster (IC) if a malfunction should occur. The following system components are monitored or undergo a self-check at startup. The side-impact sensor, airbag ignition circuits (squibs), seat belt buckle switches and the SBT. The airbag warning indicator lamp also illuminates briefly each time the engine is started, allowing the driver to verify its operation.

Airbag Warning Indicator Lamp - The airbag warning indicator lamp is integral to the Instrument Cluster (IC), which is located on the Instrument Panel (IP) in front of the driver.

Scheme 43

Clockspring - The clockspring is located at the top of the steering column, directly beneath the steering wheel where it is attached to the column by two screws (1).

Driver Front Airbag - The driver front airbag (1) is located in the center of the steering wheel, as part of the steering wheel trim cover.

Scheme 44

Passenger Front Airbag - The passenger front airbag (1) is located on the instrument panel structural duct, beneath the instrument panel top pad and above the glove box.

Scheme 45

The passenger front air bag can be deactivated when a child seat or small child occupies that seat by using the ignition key to turn the switch (1) to the OFF position. This will illuminate the passenger airbag OFF warning lamp on the center console. This indicates that the passenger front airbag is deactivated. The passenger front airbag will not be activated until the switch is turned to the ON position and the passenger airbag OFF warning lamp goes out.

Scheme 46

The passenger airbag off warning lamp (1) in the center console illuminates when the air bag is deactivated.

Scheme 47

Side Impact Sensor - Two side impact sensors (2) are installed, one left side and one right side. The sensors are mounted on the body cross brace in the center of the door sill plates directly under the carpet.

Scheme 48

Side Impact Airbag - The side impact airbags are concealed behind the door trim panels above the armrest. The side impact airbag is riveted (1) to the door's interior structure and activated by a squib (2). SRS logos on the trim panels denote the presence of the airbags. If the airbag is triggered during a lateral collision, the airbag tears open a seam on the inner door trim and inflates within 0.007 seconds to form a protective cushion between the passenger and the door. Thus the impact on the passenger's thorax and the ejecting motion of the head, which might otherwise cause serious injuries, are reduced.

The ORC and the Instrument Cluster (IC) each contain a central processing unit and programming that allow them to communicate with each other using the Controller Area Network (CAN). This method of communication is used by the ORC for control of the airbag indicator lamp.

Hard wired circuitry connects the SRS components to each other through the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system, and to the SRS components through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds.

The primary passenger restraints in this or any other vehicle are the standard equipment factory-installed seat belts and child restraint anchors. Seat belts and child restraint anchors are referred to as an active restraint because the occupants are required to physically fasten and properly adjust these restraints in order to benefit from them. See the Owner's Manual for more information on the features, use, and operation of all of the factory-installed active restraints.

Scheme 49

The driver/passenger airbags and the driver/passenger Seat Belt Tensioners (SBT) were designed to reduce the risk of an injury to the chest and head in the event of a head-on collision.

The side airbags were designed to protect primarily the upper body and also to help protect the head in the event of a side collision.

Malfunctions in the SRS system are indicated on the Instrument Cluster (IC) by the airbag warning indicator lamp.

SRS - AIRBAG WARNING INDICATOR

The SRS airbag warning indicator lamp indicates that the SRS is ready for operation. When no faults are present in the system, the airbag warning indicator illuminates when the ignition switch is turned to the ON or RUN position and then goes out after approximately six seconds.

An error or malfunction is indicated in the SRS by the airbag warning indicator not illuminating when the ignition switch is turned to the ON or RUN position or not going out after six seconds.

Errors and malfunctions not endangering occupant protection are indicated by the airbag warning indicator illuminating for approximately two minutes when the ignition switch is turned to the ON or RUN position.

Errors and malfunctions which may endanger the occupant are indicated by the airbag warning indicator illuminating continuously.

In the case of an error or a malfunction the entire system should be checked according to the diagnosis instructions. The active restraints ARE NOT affected by an error or a malfunction in the SRS and remain operational.

PASSENGER AIRBAG OFF INDICATOR LAMP

The passenger Airbag Off Indicator Lamp operates in conjunction with the Passenger Airbag On/Off Switch. When the switch is turned to either the On or the Off position, the switch position is communicated to the Passenger Seat Occupant Simulator. The Passenger Seat Occupant Simulator then translates the switch position into a signal that the Occupant Restraint Controller is capable of reading in order to switch the Passenger Airbag on or off depending upon the Switch position. The Passenger Airbag Off Indicator Lamp will stay illuminated as long as the Passenger Airbag On/Off Switch is in the Off position.

Scheme 50

Only the seat belt tensioners (SBT) are triggered.

The ORC registers medium-deceleration (stage-one threshold) due to a collision.

The triggering pulse is transferred only to the SBT squibs, because the restraint function of the seat belts in combination with the SBT is sufficient enough to effectively protect the vehicles passengers for this type of collision.

A check is made whether the seat belts are fastened. If a seat belt is not fastened and the stage one threshold is exceeded the driver and passenger airbags are triggered to provide protection for the front passengers.

Scheme 51

"Stage two threshold" The ORC recognizes the vehicles rapid deceleration due to a collision. The ORC routes the triggering pulse to the driver and passenger airbag squibs. At the same time the driver and passenger SBTs are also triggered.

Scheme 52

When the ORC registers sudden acceleration which exceeds the forward threshold value a check is made to determine which front seat belts are fastened. The ORC then activates only the SBTs which have fastened seat belts. The driver/passenger airbags are not activated unless a frontal collision which exceeds the stage two threshold is detected.

Scheme 53

When either the driver or passenger side impact side airbag sensor detects a sudden lateral acceleration which exceeds the lateral threshold value a signal is sent to the ORC. The ORC then deploys the appropriate side airbag.

The SRS electrical circuits are continuously monitored and controlled by a microprocessor and software contained within the Occupant Restraint Controller (ORC) (1). An airbag warning indicator lamp in the Instrument Cluster (IC) illuminates for about six seconds as a bulb test each time the ignition switch is turned to the On or Start positions. Following the bulb test, the airbag warning indicator lamp is turned On or Off by the ORC to indicate the status of the SRS. If the airbag warning indicator lamp comes on at any time other than during the bulb test, it indicates that there is a concern in the SRS electrical circuits. Such a problem may cause airbags to not deploy when required, or to deploy when not required.

Deployment of the driver and passenger airbags depends upon the angle and severity of an impact. Deployment is not based upon vehicle speed; rather, deployment is based upon the rate of deceleration as measured by the forces of gravity (G force). When an impact is severe enough, the microprocessor in the ORC signals the inflator of the appropriate airbag units to deploy their airbag cushions. The SBT is provided with a deployment signal by the ORC in conjunction with the driver and passenger airbags. During a frontal vehicle impact, the seat belts are used to restrain both the driver and the passenger in the proper position for an airbag deployment. The SBT removes the slack from the seat belts to provide further assurance that the driver and passenger are properly positioned and restrained for an airbag deployment.

Typically, the vehicle occupants recall more about the events preceding and following a collision than they do of an airbag deployment itself. This is because the airbag deployment and deflation occur so rapidly. In a typical 30 mile-per-hour (48 kilometer-per-hour) barrier impact, from the moment of impact until the airbags are fully inflated takes about 40 milliseconds. Within one to two seconds from the moment of impact, the airbags are almost entirely deflated. The times cited for these events are approximations, which apply only to a barrier impact at the given speed. Actual times will vary somewhat, depending upon the vehicle speed, impact angle, severity of the impact, and the type of collision.

When the ORC monitors a concern in any of the SRS circuits or components, including the SBT, it stores a fault code or Diagnostic Trouble Code (DTC) in its memory circuit and sends an electronic message to the IC via the CAN to illuminate the airbag warning indicator. Proper testing of the SRS components, CAN data bus, ORC signals, and DTC information requires the use of a DRBIII(R) scan tool. Refer to the appropriate diagnostic information.

See the Owners Manual for more information regarding features, use, and operation of all of the factory-installed active restraints.

WARNING

STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS

STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT

Any vehicle which is to be returned to use following a supplemental restraint deployment, must have the deployed restraint replaced. In addition, if the driver airbag has been deployed, the clockspring must also be replaced. If the passenger airbag is deployed, the instrument panel top pad must be replaced. If a side airbag has been deployed, the complete airbag unit and the door trim panel must be replaced. These components are not intended for reuse and will be damaged or weakened as a result of a supplemental restraint deployment, which may or may not be obvious during a visual inspection.

The passenger airbag mounting points on the instrument panel structural duct must be closely inspected for damage, and the instrument panel assembly must be replaced if structural duct damage is evident. It is also critical that the mounting surfaces and/or mounting brackets for the Occupant Restraint Controller (ORC) and the side impact sensors must be closely inspected and restored to their original conditions following any vehicle impact damage. Because the ORC and each impact sensor are used by the SRS to monitor or confirm the direction and severity of a vehicle impact, improper orientation or insecure fastening of these components may cause airbags not to deploy when required, or to deploy when not required.

All other vehicle components should be closely inspected following any SRS deployment, but are to be replaced only as required by the extent of the visible damage incurred.

AIRBAG SQUIB STATUS

Multistage airbags with multiple initiators (squibs) must be checked to determine that all squibs were used during the deployment event. The driver and passenger airbags in this model are deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the driver or passenger squib 1 and squib 2 circuits to the two initiators in the airbag inflators. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used due to an airbag system fault; therefore, it is always necessary to confirm that both initiators have been used in order to avoid the improper handling or disposal of potentially live pyrotechnic or hazardous materials. The following procedure should be performed using a DRBIII(R) scan tool to verify the status of both airbag squibs before either deployed airbag is removed from the vehicle for disposal.

1. Be certain that the DRBIII(R) scan tool contains the latest version of the proper DRBIII(R) software. Connect the DRBIII(R) to the Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel, outboard of the steering column.
2. Turn the ignition switch to the On position.
3. Using the DRBIII(R), read and record the active (current) Diagnostic Trouble Code (DTC) data.

Using the active DTC information, refer to the AIRBAG SQUIB STATUS table to determine the status of both driver and/or passenger airbag squibs.

AIRBAG SQUIB STATUS

If no squib open codes are active the status of the airbag squibs is unknown. In this case the airbag should be handled and disposed of assuming that both squibs were live.

Scheme 54

Following a supplemental restraint deployment, the vehicle interior will contain a powdery residue. This residue consists primarily of harmless by-products used to deploy a supplemental restraint. However, this residue may also contain traces of sodium hydroxide powder, a chemical by-product of the propellant material that is used to generate the inert gas which inflates the airbag. Since sodium hydroxide powder can irritate the skin, eyes, nose, or throat, be sure to wear safety glasses (1), rubber gloves (2), and a long-sleeved shirt during cleanup.

Scheme 55

1. Begin the cleanup by using 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 a non-cleaned area.
2. Be certain to vacuum the heater and air conditioning outlets as well. Run the heater and air conditioner blower on the lowest speed setting and vacuum any powder expelled from the outlets.
3. Next, remove the deployed supplemental restraints from the vehicle. Driver side airbag. «(Refer to ELECTRICAL/RESTRAINTS/DRIVER AIRBAG - REMOVAL)»(ref-250618-S31903776472007031500000) . Passenger side airbag. «(Refer to ELECTRICAL/RESTRAINTS/PASSENGER AIRBAG - REMOVAL)»(ref-250618-S25585236312007031500000) . Side impact airbag. «(Refer to ELECTRICAL/RESTRAINTS/SIDE IMPACT AIRBAG CONTROL MOD - REMOVAL)»(ref-250618-S11510454162007031500000) . Seat belt tensioners. «(Refer to ELECTRICAL/RESTRAINTS/SEAT BELT & RETRACTOR - REMOVAL)»(ref-250618-S35820939472007031500000) .
4. You may need to vacuum the interior of the vehicle a second time to recover all of the powder.

STANDARD PROCEDURE - ORC PROGRAMMING

This procedure requires the use of the DRBIII(R) scan tool.

After the Occupant Restraint Controller (ORC) has been replaced, the Airbag Warning Indicator Light in the Instrument Cluster flashes. This indicates that the ORC has not yet been programmed. Follow this procedure using the DRBIII(R) scan tool

1. The side airbag equipment is programmed to YES on the parts control modules.
2. The seatbelt buckle equipment is programmed to YES.
3. The passenger seat occupant simulator is programmed to YES.
4. The front passenger airbag is programmed to YES.
5. Turn the ignition to off and then on.
6. Read out and erase any DTCs.

At this time the Airbag Warning Indicator Light will flash on and off to conclude the programming. When a front passenger airbag is retrofitted, the ORC only needs to be reprogrammed, not replaced. After finishing this procedure, any programming failure is due to a defective ORC.

STANDARD PROCEDURE - CLOCKSPRING CENTERING

The clockspring is designed to wind and unwind when the steering wheel is rotated, but is only designed to rotate the same number of turns (about five complete rotations) as the steering wheel can be turned from stop to stop. Centering the clockspring indexes the clockspring tape to other steering components so that it can operate within its designed travel limits. The rotor of a centered clockspring can be rotated two and one-half turns in either direction from the centered position, without damaging the clockspring tape.

However, if the clockspring is removed for service or if the steering column is disconnected from the steering gear, the clockspring tape can change position relative to the other steering components. The clockspring must then be re-centered following completion of such service or the clockspring tape may be damaged.

Note. Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position.

1. Place the front wheels in the straight-ahead position.
2. Remove the clockspring from the steering column. «(Refer to ELECTRICAL/RESTRAINTS/CLOCKSPRING - REMOVAL)»(ref-250618-S20069317112007031500000) .
3. Hold the clockspring case in one hand so that it is oriented as it would be when it is installed on the steering column.
4. Use your other hand to rotate the clockspring rotor clockwise to the end of its travel. Do not apply excessive torque.
5. From the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise, until the arrows on the clockspring rotor label and the clockspring case are aligned. The uppermost pin on the lower surface of the clockspring rotor should now be aligned with the oblong pin.
6. The clockspring is now centered. Secure the clockspring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column.
7. The front wheels should still be in the straight-ahead position. Reinstall the clockspring onto the steering column. «(Refer to ELECTRICAL/RESTRAINTS/CLOCKSPRING - INSTALLATION)»(ref-250618-S01153462892007031500000) .

AIRBAG DEPLOYMENT SEQUENCE

1. When the impact threshold for the passenger airbag is exceeded an electric pulse (firing pulse) is sent from the ORC to the squib in the initiator.
2. The squib ignites the solid propellant in the initiator. The solid propellant burns, developing a gas which flows explosively under high pressure into the airbag.
3. Under the pressure of the gas, the airbag rips open the airbag housing, blows the airbag flap out of the instrument panel and inflates in the passenger compartment.
4. After approximately 50 ms. the airbag reaches its maximum volume.
5. After reaching the maximum volume, the pressure in the airbag starts decreasing. The gas escapes from the airbag through a filter and the airbag deflates.

Note. Typically, both initiators are used during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic materials.

Scheme 56

Scheme 57

Scheme 58

1. Before attempting any service to the airbag system, refer to the warnings in this service information. «(Refer to ELECTRICAL/RESTRAINTS - WARNING)»(ref-250618-S04426623642007031500000) .
2. Disconnect the negative battery cable (2). Wait two minutes for the system capacitor to discharge before further service.
3. Remove the upper section (1) of instrument panel «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL)»(ref-250612-S03897787692007031500000) .
4. Disconnect the passenger airbag squib harness connector (1) from the passenger side airbag. CAUTION: Do not pull on the squib connector wires or pry on the connector insulator to disengage the connector from the passenger airbag inflator connector receptacle. Improper removal of the squib wires and their connector insulators can result in damage to the airbag circuits or connector insulators.
5. Remove the four bolts (1) that secure the airbag to the instrument panel.
6. Remove the passenger airbag as a unit.

Note. If the passenger airbag has been deployed, carefully inspect the airbag mounting points on the instrument panel. If the airbag mounting points have been damaged or deformed, the instrument panel structural duct must be replaced.