Restraints - Service Information: Removal & Installation Chrysler Crossfire I

REMOVAL

Scheme 22

Scheme 23

1. Disconnect the negative battery cable (2). Wait two minutes for the system capacitor to discharge before further service.
2. Remove the center console. «(Refer to BODY/INTERIOR/CENTER CONSOLE - REMOVAL)»(ref-250612-S17954963242007031500000) .
3. Disconnect the occupant restraint controller harness connector (2).
4. Remove the bolts (1) attaching the occupant restraint controller to the transmission tunnel.
5. Remove the occupant restraint controller from the vehicle.

INSTALLATION

1. Carefully position the occupant restraint controller on the mount that is welded onto the top of the floor panel transmission tunnel. The arrow on the housing must point toward the front of the vehicle.
2. Install and tighten the screws (1) that secure the occupant restraint controller to the mount. Observe the ground lead mounting location on the left rear screw. Tighten the screws to 11 N.m (97 in. lbs.).
3. Connect the occupant restraint controller harness connector (2).
4. Install the center console. «(Refer to BODY/INTERIOR/CENTER CONSOLE - INSTALLATION)»(ref-250612-S32158713072007031500000) .
5. Do not reconnect the negative battery cable at this time. The new ORC module must be programmed, perform the Supplemental Restraint System verification test procedure after servicing any Supplemental Restraint System component. «(Refer to ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE)»(ref-250618-S11813776752007031500000) .

Scheme 24

The clockspring assembly is secured to the multifunction switch mounting housing near the top of the steering column behind the steering wheel.

Within the plastic case and wound around the rotor spool is a long ribbon-like tape. The outer end of the tape terminates at the connector receptacles that face the instrument panel, while the inner end of the tape terminates at the pigtail wires and connector receptacles on the hub of the clockspring rotor that face the steering wheel.

Service replacement clocksprings are shipped pre-centered and with a molded plastic locking pin installed. The locking pin secures the centered clockspring rotor to the clockspring case during shipment and handling, but must be removed from the clockspring after it and the multifunction switch mounting housing are installed on the steering column.

The clockspring cannot be repaired. If the clockspring is faulty, damaged, or if the driver airbag has been deployed, the clockspring must be replaced.

The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed.

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

Scheme 25

Scheme 26

1. Place the front wheels in the straight ahead position.
2. Disconnect the negative battery cable (2). Wait two minutes for the system capacitor to discharge before further service.
3. Remove the driver side airbag. «(Refer to ELECTRICAL/RESTRAINTS/DRIVER AIRBAG - REMOVAL)»(ref-250618-S31903776472007031500000) . WARNING: DO NOT PLACE AN INTACT UNDEPLOYED AIRBAG FACE DOWN ON A HARD SURFACE, THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED.
4. Remove the steering wheel tapered bolt (1) from the steering column with a suitable tool (2).
5. Remove the steering wheel. «(Refer to STEERING/COLUMN/STEERING WHEEL - REMOVAL)»(ref-250617-S04361163022007031500000) .
6. Remove the two screws (1) that secure the clockspring to the steering column upper housing.
7. Remove the clockspring.
8. Separate the clockspring from the steering angle sensor. «(Refer to BRAKES/ELECTRICAL/STEERING ANGLE SENSOR - REMOVAL)»(ref-250639-S02333903152007031500000) .

Note. If the clockspring is to be reused, be certain to secure the clockspring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column. If clockspring centering is not maintained, the clockspring must be centered again before it is reinstalled. (Refer to ELECTRICAL/RESTRAINTS/CLOCKSPRING - STANDARD PROCEDURE) .

Scheme 27

Scheme 28

1. Install the steering angle sensor to the clockspring using the alignment points on the housings (1). «(Refer to BRAKES/ELECTRICAL/STEERING ANGLE SENSOR - INSTALLATION)»(ref-250639-S07871098202007031500000) . NOTE: If the clockspring is being reused, be certain to remove anything securing the clockspring rotor to the clockspring case that was used to maintain clockspring centering until reinstallation on the steering column. If clockspring centering was not maintained, the clockspring must be centered again before it is installed. «(Refer to ELECTRICAL/RESTRAINTS/CLOCKSPRING - STANDARD PROCEDURE)»(ref-250618-S05704240482007031500000) .
2. Install the clockspring to the steering column.
3. Install the two screws (1) that secure the clockspring to the steering column housing. Tighten the clockspring screws 1 N.m (9 in. lbs.).
4. Install the steering wheel to the steering column using the tapered bolt (1). «(Refer to STEERING/COLUMN/STEERING WHEEL - INSTALLATION)»(ref-250617-S11806709362007031500000) .
5. Install the driver airbag and screws (1) to the steering wheel. «(Refer to ELECTRICAL/RESTRAINTS/DRIVER AIRBAG - INSTALLATION)»(ref-250618-S01057896462007031500000) .
6. Do not reconnect the negative battery cable at this time. Perform the Supplemental Restraint System verification test procedure after servicing any Supplemental Restraint System component. «(Refer to ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE)»(ref-250618-S11813776752007031500000) .

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. From the underside of the steering wheel, remove the two screws (1) that secure the driver airbag to the steering wheel.
4. Pull the driver airbag away from the steering wheel far enough to access the electrical connections to the steering wheel.
5. Disconnect the steering wheel wire harness connectors for the horn switch.
6. Disconnect the clockspring driver airbag pigtail harness connectors. CAUTION: Do not pull on the clockspring pigtail wires or pry on the connector insulator to disengage the connector from the driver airbag inflator connector receptacle. Improper removal of these pigtail wires and their connector insulators can result in damage to the airbag circuits or connector insulators.
7. Remove the driver airbag from the steering wheel.

Note. If the driver airbag has been deployed, the clockspring must be replaced. (Refer to ELECTRICAL/RESTRAINTS/CLOCKSPRING - REMOVAL) .

1. Verify the negative battery cable (2) is disconnected before proceeding. Wait two minutes for the system capacitor to discharge before further service.
2. Position the driver airbag close enough to the steering wheel to connect the squib and horn harness connections. (ART) CAUTION: Use caution when connecting the clockspring connector to the driver airbag inflator connector receptacle. Improper assembly of these wires or connector insulators can result in damage to the airbag circuits or connector insulators.
3. Carefully position the driver airbag in the steering wheel. NOTE: Be certain that the clockspring wires and horn switch harness in the steering wheel hub area are not pinched between the driver airbag and the steering wheel.
4. From the underside of the steering wheel, install and tighten the two screws (1) that secure the driver airbag to the steering wheel. Tighten to 8 N.m (71 in. lbs.).
5. Do not reconnect the negative battery cable at this time. Perform the Supplemental Restraint System verification test procedure after servicing any Supplemental Restraint System component. «(Refer to ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE)»(ref-250618-S11813776752007031500000) .

1. Verify the negative battery cable (2) is disconnected before proceeding. Wait two minutes for the system capacitor to discharge before further service.
2. Carefully position the passenger airbag unit onto the instrument panel.
3. Install the four bolts (1) that secure the passenger airbag to the instrument panel. Tighten to 35 N.m (26 ft. lbs.).
4. Connect the passenger airbag squib harness connector (1). CAUTION: Use caution when connecting the squib harness connector to the passenger airbag inflator connector receptacle. Improper assembly of these pigtail wires and their connector insulators can result in damage to the airbag circuits or connector insulators.
5. Install the top section of the instrument panel (1) «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION)»(ref-250612-S16964306012007031500000) .
6. Do not reconnect the negative battery cable at this time. Perform the Supplemental Restraint System verification test procedure after servicing any Supplemental Restraint System component. «(Refer to ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE)»(ref-250618-S11813776752007031500000) .

1. Verify the negative battery cable (2) is disconnected before proceeding. Wait two minutes for the system capacitor to discharge before further service.
2. Connect the passenger seat occupant simulator harness connector and attach the passenger seat occupant simulator (1) to the base plate with a plastic wire tie.
3. Rotate the base plate and install it over the mounting studs on the floor panel. NOTE: Be sure not to pinch or cause interference with the wiring harnesses while locating the base plate to the floor mounting studs.
4. Install the plastic retaining nuts (1) and secure the base plate to the vehicle floor.
5. Install the foam insulating panel.
6. Install the carpeting in the passenger footwell.
7. Install the floor mat to the carpet.
8. Do not reconnect the negative battery cable at this time. Perform the Supplemental Restraint System verification test procedure after servicing any Supplemental Restraint System component. «(Refer to ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE)»(ref-250618-S11813776752007031500000) .

INSTALLATION - LEFT SIDE

1. Verify the negative battery cable (2) is disconnected before proceeding. Wait two minutes for the system capacitor to discharge before further service.
2. Position the side impact sensor (1) on the body cross brace.
3. Install the bolts attaching the side impact sensor to the body cross brace. Tighten the side impact sensor bolts to 12 N.m (106 in. lbs.). CAUTION: Use caution when connecting the squib harness connector to the side impact sensor receptacle. Improper assembly of these connectors can result in damage to the airbag circuits or connector insulators.
4. Connect the side impact sensor harness connector.
5. Reposition the carpet to the floor. NOTE: The carpet is firmly molded, and will need to be properly seated to the contours of the vehicle floor.
6. Install the carpet hold down button (3).
7. Install the front seat.
8. Reconnect the power seat harness connectors.
9. Install the seat belt bolt (2). Tighten the seat belt bolt to 35 N.m (26 ft. lbs.).
10. Install the seat track rear bolts (1). Tighten the rear bolts to 50 N.m (37 ft. lbs.).
11. Temporarily reconnect the negative battery cable.
12. Move the seat to the full rearward position.
13. Disconnect the negative battery cable again.
14. Install the seat track front bolts (1). Tighten the front bolts to 50 N.m (37 ft. lbs.).
15. Install the door sill plate (1) by pushing it firmly down onto the retaining clips.
16. Install the ignition key.
17. Do not reconnect the negative battery cable at this time. Perform the Supplemental Restraint System verification test procedure after servicing any Supplemental Restraint System component. «(Refer to ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE)»(ref-250618-S11813776752007031500000) .

INSTALLATION - RIGHT SIDE

1. Verify the negative battery cable (2) is disconnected before proceeding. Wait two minutes for the system capacitor to discharge before further service.
2. Position the side impact sensor (1) on the body cross brace.
3. Install the bolts attaching the side impact sensor to the body cross brace. Tighten the side impact sensor bolts to 12 N.m (106 in. lbs.). CAUTION: Use caution when connecting the squib harness connector to the side impact sensor receptacle. Improper assembly of these connectors can result in damage to the airbag circuits or connector insulators.
4. Connect the side impact sensor harness connector.
5. Reposition the carpet to the floor. NOTE: The carpet is firmly molded, and will need to be properly seated to the contours of the vehicle floor.
6. Install the carpet hold down button (1).
7. Install the front seat.
8. Reconnect the power seat harness connectors.
9. Install the seat belt bolt (2). Tighten the seat belt bolt to 35 N.m (26 ft. lbs.).
10. Install the seat track rear bolts (1). Tighten the rear bolts to 50 N.m (37 ft. lbs.).
11. Temporarily reconnect the negative battery cable.
12. Move the seat to the full rearward position.
13. Disconnect the negative battery cable again.
14. Install the seat track front bolts (1). Tighten the front bolts to 50 N.m (37 ft. lbs.).
15. Install the door sill plate by pushing it firmly down onto the retaining clips.
16. Install the ignition key.
17. Do not reconnect the negative battery cable at this time. Perform the Supplemental Restraint System verification test procedure after servicing any Supplemental Restraint System component. «(Refer to ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE)»(ref-250618-S11813776752007031500000) .

Scheme 29

Side air bags with a volume of about 975 cubic inches (16 liters) each are concealed behind the inner door trim above the armrest. If the air bag is triggered during a lateral collision, the air bag 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 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 warning indicator lamp.

1. Before attempting any service procedure refer to the warnings at the beginning of 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 ignition key.
4. Remove the door trim panel. «(Refer to BODY/DOOR - FRONT/TRIM PANEL - REMOVAL)»(ref-250612-S00376062812007031500000) .
5. Disconnect the side impact airbag squib harness connector (2) from the side impact airbag. CAUTION: Do not pull on the squib connector wires or pry on the connector insulator to disengage the connector from the side 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.
6. Drill out the mounting rivets (1) for the side impact airbag.
7. Remove the side impact airbag from the door.

1. Verify the negative battery cable (2) is disconnected before proceeding. Wait two minutes for the system capacitor to discharge before further service.
2. Position the side impact airbag to the door.
3. Install new mounting rivets (1) for the side impact airbag. NOTE: Use only the proper rivets when reinstalling the side impact airbag.
4. Connect the squib connector (2). CAUTION: Use caution when connecting the squib harness connector to the side impact airbag receptacle. Improper assembly of these connectors can result in damage to the airbag circuits or connector insulators.
5. Install the door trim panel. «(Refer to BODY/DOOR - FRONT/TRIM PANEL - INSTALLATION)»(ref-250612-S10572715752007031500000) .
6. Install the ignition key.
7. Do not reconnect the negative battery cable at this time. Perform the Supplemental Restraint System verification test procedure after servicing any Supplemental Restraint System component. «(Refer to ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE)»(ref-250618-S11813776752007031500000) .

Scheme 30

The left and right front seat belt buckle restraint system switches are located in the respective buckles. The seat belt buckles are bolted to the base frame of the seat. The seat belt buckles are a typical buckle design with a release button on the top to free the seat belt.

The left and right front seat belt buckle restraint system monitors the status of the driver's and passenger's seat belt switch. The airbag unit can be ignited if the seat belt is not fastened during the initial triggering threshold.

Scheme 31

1. Move the seat to the full rearward position.
2. Remove the seat track front bolts (1).
3. Move the seat to the full forward position. NOTE: The seat track rear bolts are easily accessed when the seat back is tilted fully forward.
4. Remove the seat track rear bolts (1).
5. Remove the seat belt bolt (2) holding the seat belt to the seat.
6. Tilt the seat back, to gain access to the bottom of the seat.
7. Disconnect the power seat harness connectors.
8. Carefully remove the seat from the vehicle.
9. Disconnect the seat belt buckle harness connector and remove the bolt (1) attaching the belt buckle to the seat.

1. Route the seat belt buckle harness through the seat.
2. Position the seat belt buckle to the seat.
3. Install the bolt (1) to the seat belt buckle. Tighten to 35 N.m (26 ft. lbs.).
4. Connect the seat belt buckle harness connector.
5. Install the front seat.
6. Reconnect the power seat harness connectors.
7. Install the seat belt bolt (2). Tighten the seat belt bolt to 35 N.m (26 ft. lbs.).
8. Install the seat track rear bolts (1). Tighten the rear bolts to 50 N.m (37 ft. lbs.).
9. Move the seat to the full rearward position.
10. Install the seat track front bolts (1). Tighten the front bolts to 50 N.m (37 ft. lbs.).

Scheme 32

In the event of a collision (head-on or rear-end) the seat belt tensioner eliminates the slack in the belt and prevents the seat belt from unreeling. The tight seat belt causes the vehicle passengers to decelerate at the same rate as the body at an earlier point in time. The Seat Belt Tensioner (SBT) for the driver and passenger are located at the bottom of the B-pillar behind the plastic trim panel.

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Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

1. Before attempting any service procedure refer to the warnings in this service information. «(Refer to ELECTRICAL/RESTRAINTS - WARNING)»(ref-250618-S04426623642007031500000) .
2. Move the seat to the full forward position.
3. Disconnect the negative battery cable (2). Wait two minutes for the system capacitor to discharge before further service.
4. Remove the plastic bolt cover from the seat.
5. Remove the bolt (1) on the belt end attaching it to the seat.
6. Remove the screws (1) attaching the plastic cover (3) to the door opening.
7. Remove the plastic cover (3).
8. Remove the door edge guard (2).
9. Remove the bolt (1) attaching the belt guide to the vehicle.
10. Fold back the carpet (1) in the upper corner area.
11. Disconnect the seat belt tensioner squib harness connector (1). CAUTION: Do not pull on the squib connector wires or pry on the connector insulator to disengage the connector from the inflator connector receptacle. Improper removal of the squib wires and their connector insulators can result in damage to the airbag circuits or connector insulators.
12. Remove the bolt (1) attaching the seat belt tensioner to the vehicle.
13. Remove the seat belt tensioner from the vehicle.

Scheme 39

1. Inspect the Occupant Restraint Controller (ORC) with the DRB III(R).
2. Read and record all DTCs.
3. Inspect the Seat Belt Tensioner squib status: Red Pin (1) is visible: All squibs have been fired. Red Pin (1) is not visible: All squibs have not been fired.

1. Verify the negative battery cable (2) is disconnected before proceeding. Wait two minutes for the system capacitor to discharge before further service.
2. Position the seat belt tensioner in the vehicle.
3. Install the bolt (1) attaching the seat belt tensioner to the vehicle. Tighten to 35 N.m (26 ft. lbs.).
4. Connect the seat belt tensioner squib harness connector (1). CAUTION: Use caution when connecting the squib harness connector to the inflator connector receptacle. Improper assembly of these wires and their connector insulators can result in damage to the airbag circuits or connector insulators.
5. Install the bolt (1) on the upper belt guide. Tighten to 35 N.m (26 ft. lbs.).
6. Reinstall the carpet (1) in the upper corner area.
7. Position the plastic cover (3) over the seat belt.
8. Install the screws (1) attaching the plastic cover (3) to the door opening.
9. Install the door edge guard (2).
10. Install the bolt (1) on the belt end attaching it to the seat. Tighten to 35 N.m (26 ft. lbs.).
11. Install the plastic bolt cover over the seat belt bolt.
12. Do not reconnect the negative battery cable at this time. Perform the Supplemental Restraint System verification test procedure after servicing any Supplemental Restraint System component. «(Refer to ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE)»(ref-250618-S11813776752007031500000) .