Restraints - Service Information: Removal & Installation Dodge Nitro I

REMOVAL

Note. A service replacement clockspring is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed, the clockspring centering procedure must be performed.

Note. When a clockspring is installed into a vehicle without properly centering and locking the entire steering system, the Steering Angle Sensor (SAS) data does not agree with the true position of the steering system and causes the Electronic Stability Program (ESP) system to shut down. This may also damage the clockspring without any immediate malfunction. Unlike some other DaimlerChrysler vehicles, this SAS never requires calibration. See STANDARD PROCEDURE .

Note. Determining if the clockspring/SAS is centered is also possible electrically using the diagnostic scan tool. Steering wheel position is displayed as ANGLE with a range of up to 900 degrees. Refer to the appropriate menu item on the diagnostic scan tool.

Note. Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position and that the entire steering system is locked or inhibited from rotation.

Scheme 18

Scheme 19

1. Place the front wheels in the straight ahead position and inhibit the steering column shaft from rotation.
2. Disconnect and isolate the battery negative cable.
3. Remove the steering wheel from the steering shaft. Refer to «REMOVAL»(ref-306136-S01792899582008120900000) .
4. If the removed clockspring is to be reused, be certain to secure the clockspring rotor to the clockspring case to maintain clockspring centering until the steering wheel is reinstalled on the steering column. If clockspring centering is not maintained, the clockspring must be centered again before the steering wheel is reinstalled. See «STANDARD PROCEDURE»(ref-306149-S20119168472008120900000) .
5. Move the steering column to the fully lowered position and leave the tilt release lever in the released (down) position.
6. Remove the upper and lower shrouds from the steering column. Refer to «REMOVAL»(ref-306136-S42198261482008120900000) .
7. Remove the right multi-function switch (3) from the clockspring (4). Refer to «REMOVAL»(ref-306164-S07982957822008120900000) .
8. Remove the left multi-function switch (5) from the clockspring. Refer to «REMOVAL»(ref-306148-S18328931252008120900000) .
9. Remove the three screws (1) that secure the clockspring to the steering column lock housing (2).
10. Pull the clockspring (1) away from the steering column lock housing far enough to access and disconnect the three instrument panel wire harness connectors (2) from the receptacles on the back of the clockspring case.
11. Remove the clockspring from the steering column.

INSTALLATION

Note. A service replacement clockspring is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed, the clockspring centering procedure must be performed.

Note. When a clockspring is installed into a vehicle without properly centering and locking the entire steering system, the Steering Angle Sensor (SAS) data does not agree with the true position of the steering system and causes the Electronic Stability Program (ESP) system to shut down. This may also damage the clockspring without any immediate malfunction. Unlike some other DaimlerChrysler vehicles, this SAS never requires calibration. See STANDARD PROCEDURE .

Note. Determining if the clockspring/SAS is centered is also possible electrically using the diagnostic scan tool. Steering wheel position is displayed as ANGLE with a range of up to 900 degrees. Refer to the appropriate menu item on the diagnostic scan tool.

Note. Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position and that the entire steering system is locked or inhibited from rotation.

1. If a new clockspring (1) is being installed, transfer the multifunction switch jumper harness from the old clockspring or position a new jumper harness onto the new clockspring.
2. Carefully slide the clockspring down over the steering column upper shaft far enough to reconnect the three instrument panel wire harness connectors (2) to the receptacles on the back of the clockspring case.
3. Position the clockspring (4) onto the steering column lock housing (2).
4. Install and tighten the three screws (1) that secure the clockspring to the lock housing in the following sequence: lower right, upper left, upper right. Tighten the screws to 3 N.m (27 in. lbs.). NOTE: Use of an improper sequence when tightening the clockspring mounting screws may result in an audible ticking noise as the steering wheel is rotated.
5. Reinstall the left multi-function switch (5) onto the clockspring. Refer to «INSTALLATION»(ref-306148-S02704736242008120900000) .
6. Reinstall the right multi-function switch (3) onto the clockspring. Refer to «INSTALLATION»(ref-306164-S06416159352008120900000) .
7. Reinstall the upper and lower shrouds onto the steering column. Refer to «INSTALLATION»(ref-306136-S18959592572008120900000) .
8. Move the steering column back to the fully raised position and move the tilt release lever back to the locked (up) position.
9. Reinstall the steering wheel onto the steering column. Refer to «INSTALLATION»(ref-306136-S30788770522008120900000) .
10. Remove the plastic locking pin that secures the clockspring rotor to the clockspring case to maintain clockspring centering.
11. Reconnect the battery negative cable.

Scheme 20

Side curtain airbags are standard equipment for this vehicle when it is also equipped with dual front airbags. These airbags are passive, inflatable, Supplemental Restraint System (SRS) components, and vehicles with this equipment can be readily identified by a molded identification trim plug with the SRS - AIRBAG logo located near the tops of the B and C-pillar trim. This system is designed to reduce injuries to the vehicle occupants in the event of a side impact collision or a vehicle rollover incident.

Scheme 21

Each vehicle has two individually controlled curtain airbag units (2). These airbag units are concealed and mounted above the headliner where they are each secured to one of the roof side rails by two plastic push-in fasteners and to five studs on the inner roof side rail by five nuts. Each folded airbag cushion is contained within a fabric wrap and has molded plastic ramps that extend along the roof rail from the A-pillar at the front of the vehicle to just behind the C-pillar at the rear of the vehicle.

A long tether (1) extends down the A-pillar from the front of the airbag cushion. The tether is secured to mounting holes in the inner A-pillar sheet metal with plastic push-in routing clips and is secured to the base of the A-pillar near the belt line with a metal key engaged into a slot in the A-pillar. A plastic push-in fastener fills the A-pillar slot after the metal key is installed to prevent the key from becoming disengaged.

The hybrid-type inflator (3) for each airbag is secured to the roof rail at the rear of the airbag unit between the C-pillar and the D-pillar, and is connected to the airbag cushion by a long tubular manifold. The bracket holding the inflator is secured by nuts to two studs on the inner roof side rail.

One end of a two-wire jumper harness connects to the initiator at the forward end of the curtain airbag inflator. The other end is routed down the D-pillar with plastic push-in routing clips and connects to the body wire harness near the belt line, which connects the airbag unit to the Occupant Restraint Controller (ORC).

The side curtain airbag unit cannot be adjusted or repaired and must be replaced if deployed, ineffective, or in any way damaged. Once a side curtain airbag has been deployed, the complete airbag unit, the headliner, the upper A, B, C and D-pillar trim, and all other visibly damaged components must be replaced.

Note. The following procedure is for replacement of an ineffective or damaged side curtain airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See STANDARD PROCEDURE . If the side curtain airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle.

Scheme 22

1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service.
2. Remove the headliner from the vehicle. Refer to «REMOVAL»(ref-306147-S24093444742008120900000) .
3. Disengage the plastic push-in routing clips that secure the jumper wire harness (9) to the inner D-pillar.
4. Disconnect the jumper wire harness from the body wire harness connector (8) for the side curtain airbag located on the inner D-pillar near the belt line.
5. Remove the push-in fastener that secures the side curtain airbag tether metal key (6) in the slot near the base of the inner A-pillar.
6. Disengage the tether metal key from the A-pillar slot.
7. Disengage the two plastic push-in routing clips (5) that secure the tether to the inner A-pillar.
8. Remove the seven nuts (3) that secure the side curtain airbag (4) and the inflator (1) bracket to the studs on the inner roof side rail.
9. Disengage the two plastic push-in fasteners (2) that secure the airbag unit to the inner roof side rail.
10. Disengage the side curtain airbag from under the grab handle bracket (7) on the inner roof side rail above the rear door opening.
11. Remove the side curtain airbag from the vehicle as a unit.

Note. The following procedure is for replacement of an ineffective or damaged side curtain airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See STANDARD PROCEDURE . If the side curtain airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle.

1. Position the side curtain airbag (4) into the vehicle as a unit.
2. Engage the rear plastic push-in fastener (2) that secures the airbag unit to the inner roof side rail.
3. Tuck the side curtain airbag under the grab handle bracket (7) on the inner roof side rail above the rear door opening.
4. Engage the front plastic push-in fastener (2) that secures the airbag unit to the inner roof side rail.
5. Engage the two plastic push-in routing clips (5) that secure the tether to the inner A-pillar.
6. Engage the side curtain airbag tether metal key (6) into the slot near the base of the inner A-pillar.
7. Install a plastic push-in fastener to secure the tether metal key within the inner A-pillar slot.
8. Position the side curtain airbag mounting tabs and the inflator (1) bracket onto the seven studs on the inner roof side rail.
9. Working from the rear of the vehicle to the front, install and tighten the seven nuts (3) that secure the side curtain airbag and inflator bracket to the studs. Tighten the nuts to 8 N.m (71 in. lbs.).
10. Reconnect the jumper wire harness (9) to the body wire harness connector (8) for the side curtain airbag located on the inner D-pillar near the belt line.
11. Engage the plastic push-in routing clips that secure the jumper wire harness to the inner D-pillar.
12. Reinstall the headliner into the vehicle. Refer to «INSTALLATION»(ref-306147-S32285375162008120900000) .
13. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See «STANDARD PROCEDURE»(ref-306149-S11237404792008120900000) .

Scheme 23

The injection molded, thermoplastic driver airbag protective trim cover (2) is the most visible part of the driver airbag. The driver airbag is located in the center of the steering wheel (1), where it is secured to the armature within the hub cavity of the four-spoke steering wheel. An injection molded, bright emblem with the Dodge Ram logo is applied to the center of the trim cover.

Scheme 24

Concealed beneath the driver air bag trim cover are the folded airbag cushion, the airbag housing, the airbag inflator and the retainers that secure the inflator to the housing. The airbag cushion, housing (3), and inflator (2) are secured within an integral receptacle molded into the back of the trim cover (1). The vertical walls of this receptacle have numerous integral latch features that are inserted through numerous openings around the perimeter of the airbag housing. After the trim cover latches are fully seated in the housing a blocking tab integral to the housing is bent down to block the latch feature of the trim cover, locking the trim cover securely into place on the airbag housing. Three wire loop snap retainers (5) extend from the housing to secure the airbag to the steering wheel armature. The snap retainer at the 6 o'clock position has a distinctive V-shape to ensure proper orientation of the airbag when it is installed onto the steering wheel.

The airbag used in this vehicle is a multistage-type that complies with revised federal airbag standards to deploy with less force than those used in some prior vehicles. A radial deploying 67.3 centimeter (26.5 inch) diameter fabric airbag cushion with internal tethers is used. The airbag inflator is a dual-initiator, non-azide, pyrotechnic-type unit and is secured to the stamped metal airbag housing using four flanged hex nuts. Two keyed and color-coded connector receptacles (4) on the driver airbag inflator connect the two inflator initiators to the vehicle electrical system through two yellow-jacketed, two-wire pigtail harnesses of the clockspring.

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

Note. The following procedure is for replacement of an ineffective or damaged driver airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See STANDARD PROCEDURE . If the driver airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle.

Scheme 25

Scheme 26

Scheme 27

Scheme 28

1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service.
2. Release the steering column tilt lever and lower the column to its most downward position for easiest driver airbag removal access. NOTE: It may be helpful to use a small mirror to aid visibility during the initial attempt to remove the driver airbag from the steering wheel.
3. There are three airbag retainer access holes (1) on the instrument panel side of the hub of the steering wheel (2), located at the two o'clock, six o'clock and ten o'clock positions. The steering wheel must be rotated to bring each of these access holes up to the twelve o'clock position of the steering column one at a time for removal access.
4. Insert the tip of a short handled, flat-bladed screwdriver (1) into either of the upper (two o'clock or ten o'clock) access holes of the steering wheel hub trim cover (3) being certain to place the screwdriver blade (2) on the inboard side of the airbag snap retainer wire loop.
5. Twist the screwdriver handle in either direction far enough to disengage the snap retainer wire loop (4) from the hook (2) of the steering wheel armature. At the same time, gently pull the driver airbag (3) away from the steering wheel (5) to prevent the retainer from snapping back into place over the hook once it is disengaged.
6. Repeat step 4 and step 5 at the other upper (two o'clock or ten o'clock) access hole to disengage the other upper snap retainer wire loop.
7. Repeat step 4 and step 5 at the lower (six o'clock) access hole to disengage the lower snap retainer wire loop. The lower snap retainer wire loop has a distinctive V-shape and must always be installed onto the six o'clock hook of the steering wheel armature.
8. Pull the driver airbag away from the steering wheel far enough to access the electrical connections (1) at the back of the airbag housing. 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 the connector insulators.
9. The clockspring driver airbag pigtail wire connectors (4) are secured by an integral lock to the airbag inflator (5) connector receptacles, which are located on the back of the driver airbag (1) housing. Firmly grasp and pull the lock straight out from the connector insulator, then pull the insulators straight out from the airbag inflator to disconnect them from the connector receptacles.
10. Remove the driver airbag from the steering wheel.
11. If the driver airbag has been deployed, the clockspring must be replaced. See «REMOVAL»(ref-306149-S34304333582008120900000) .

Note. The following procedure is for replacement of an ineffective or damaged driver airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See STANDARD PROCEDURE . If the driver airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle.

1. Position the driver airbag (1) close enough to the steering wheel to reconnect the electrical connections (4) to the back of the airbag housing.
2. When installing the driver airbag, reconnect the two clockspring driver airbag pigtail wire connectors to the airbag inflator (5) connector receptacles by pressing straight in on the connectors, then push the locks straight into the connectors. Be certain to engage each keyed and color-coded connector to the matching connector receptacle.
3. Carefully position the driver airbag into the steering wheel hub. Be certain that the clockspring pigtail wires are not pinched between the driver airbag and the horn switch or the steering wheel armature.
4. Engage the lower airbag snap retainer wire loop (3) onto the lower hook of the steering wheel armature. The lower snap retainer wire loop has a distinctive V-shape and must always be installed onto the six o'clock hook of the steering wheel armature.
5. Roll the driver airbag (3) upwards and press firmly and evenly over the two upper snap retainer wire loop (4) locations simultaneously until they snap into place over the two upper hooks (2) of the steering wheel armature.
6. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See «STANDARD PROCEDURE»(ref-306149-S11237404792008120900000) .

Scheme 29

Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front sensor is secured with a nut to a stud on the back of the front end module carrier on either side of the cooling module, below and inboard of the front park/turn signal lamp socket within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection.

The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. A nylon cover is laser-welded over the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a short jumper wire harness to a dedicated take out and connector of the body wire harness.

The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced.

Note. A non-calibrated Occupant Classification Module (OCM) is available for separate service replacement. The OCM and all of the other components of the Occupant Classification System (OCS) including the passenger side front seat, the seat weight sensors, and the passenger seat adjusters, cushion, back, frame, foam, springs, and wiring harness are a factory-calibrated and assembled unit. Any time any one of these components is removed or replaced for any reason, the OCM must be re-calibrated using a diagnostic scan tool, the Occupant Classification Seat Weight special tool, and the Occupant Classification System Verification Test. Refer to the appropriate diagnostic procedures.

Scheme 30

1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service.
2. Reach under the front edge of the passenger side front seat cushion to access and disconnect the two seat wire harness connectors from the Occupant Classification Module (OCM) (1) connector receptacles located on the forward-facing end of the module.
3. Remove the two screws (3) that secure the OCM to the top of the mounting bracket (4) on the inboard passenger side front seat riser (2).
4. Remove the OCM from under the passenger side front seat cushion.

Note. A non-calibrated Occupant Classification Module (OCM) is available for separate service replacement. The OCM and all of the other components of the Occupant Classification System (OCS) including the passenger side front seat, the seat weight sensors, and the passenger seat adjusters, cushion, back, frame, foam, springs, and wiring harness are a factory-calibrated and assembled unit. Any time any one of these components is removed or replaced for any reason, the OCM must be re-calibrated using a diagnostic scan tool, the Occupant Classification Seat Weight special tool, and the Occupant Classification System Verification Test. Refer to the appropriate diagnostic procedures.

1. Reach under the front edge of the passenger side front seat cushion to carefully position the Occupant Classification Module (OCM) (1) to the top of the mounting bracket (4) on the inboard passenger side front seat riser (2). When the OCM is correctly positioned, the connector receptacles on the module will be pointed forward.
2. Install and tighten the two screws (3) that secure the OCM to the mounting bracket. Tighten the screws to 2 N.m (20 in. lbs.).
3. Reconnect the two seat wire harness connectors to the OCM connector receptacles located on the forward-facing end of the module. Be certain that the latches on each connector are fully engaged.
4. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See «STANDARD PROCEDURE»(ref-306149-S11237404792008120900000) .
5. Following successful completion of the SRS verification test procedure, perform the Occupant Classification System Verification Test using a diagnostic scan tool. Refer to the appropriate diagnostic procedures.

Scheme 31

The Occupant Restraint Controller (ORC) (1) is secured with four screws to a molded plastic mounting bracket (5). The mounting bracket and ORC unit is then secured with two nuts and two screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel between the two front seats beneath the floor console and rearward of the transmission gearshift mechanism in the passenger compartment of the vehicle. Concealed within a hollow in the center of the molded plastic ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A molded plastic end cover plate with a rubber O-ring seal is secured to the open end of the ORC housing with two integral latch features to enclose and protect the internal electronic circuitry and components.

An arrow (4) printed on the label (3) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has four integral mounting flanges with metal sleeves to provide crush protection. Two molded plastic electrical connector receptacles (2) are integral to the end cover plate. These receptacles connect the ORC to the vehicle electrical system through dedicated take outs and connectors from the instrument panel and the body wire harnesses.

The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced as a unit with the molded plastic mounting bracket.

Note. The Occupant Restraint Controller (ORC) should only be removed as a complete unit with the molded plastic mounting bracket. The service replacement ORC is supplied already installed on a new bracket.

Scheme 32

1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service.
2. Remove the center console from the top of the floor panel transmission tunnel. Refer to «REMOVAL»(ref-306147-S32216171222008120900000) .
3. Unlatch and disconnect the body wire harness connector (5) and the instrument panel wire harness connector (6) from the Occupant Restraint Controller (ORC) (3) connector receptacles located on the forward-facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector.
4. Remove the two nuts (2) that secure the left side of the ORC mounting bracket to the two studs on the ORC mount (4) welded onto the top of the floor panel transmission tunnel.
5. Remove the two screws (1) that secure the right side of the ORC mounting bracket to the ORC mount.
6. Remove the ORC and mounting bracket unit from the ORC mount.

Note. The Occupant Restraint Controller (ORC) should only be removed as a complete unit with the molded plastic mounting bracket. The service replacement ORC is supplied already installed on a new bracket.

1. Carefully position the Occupant Restraint Controller (ORC) and mounting bracket unit (3) onto the two studs on the left side of the ORC mount (4) on the floor panel transmission tunnel. When the ORC is correctly positioned, the bracket will fit flush with the mount and the orientation arrow on the label on top of the housing will be pointed forward in the vehicle.
2. Install and tighten the two screws (1) that secure the right side of the ORC mounting bracket to the ORC mount. Tighten the screws to 10.5 N.m (95 in. lbs.).
3. Install and tighten the two nuts (2) that secure the left side of the ORC mounting bracket to the two studs on the ORC mount. Tighten the nuts to 10.5 N.m (95 in. lbs.).
4. Reconnect the instrument panel wire harness connector (6) and the body wire harness connector (5) to the ORC connector receptacles located on the forward-facing side of the module. Be certain that the latches on the connectors are each fully engaged.
5. Reinstall the center console onto the top of the floor panel transmission tunnel. Refer to «INSTALLATION»(ref-306147-S30866878842008120900000) .
6. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See «STANDARD PROCEDURE»(ref-306149-S11237404792008120900000) .

Scheme 33

The rearward facing surface of the injection molded, thermoplastic passenger airbag door (1) is the most visible part of the passenger airbag. The passenger airbag door is located above the glove box (2) opening on the top and face of the instrument panel in front of the front seat passenger seating position. The upper and lower edges of the airbag door are secured with integral snap features to the instrument panel base trim.

Scheme 34

Located behind the passenger airbag door within the instrument panel is the passenger airbag unit. The passenger airbag unit is secured through two lower studs (5) to the instrument panel structural support armature above the glove box opening. While the two upper studs (6) are secured to a heavy stamped steel instrument panel bracket secured to the dash panel near the lower windshield fence line and to the instrument panel structural duct.

The passenger airbag housing (1) fits into a molded receptacle on the back of the airbag door, where several stamped hook formations (2) on the upper and lower edges of the airbag housing are engaged in mating small window openings on the upper and lower flanges of the receptacle to secure the airbag door to the airbag housing. These airbag door fasteners and mounting provisions are all concealed beneath the instrument panel base trim.

The passenger airbag unit used in this vehicle is a multistage, Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior vehicles. The passenger airbag unit consists of a stamped metal housing, the airbag cushion (3), and a dual initiator airbag inflator. The airbag housing contains the airbag inflator and the folded airbag cushion. An approximately 80 centimeter (31.5 inch) wide by 90 centimeter (35.5 inch) high rectangular fabric cushion with internal tethers is used.

The airbag inflator is a non-azide, hybrid-type unit that is secured to and sealed within the airbag housing. The two inflator initiators (4) are connected to the vehicle electrical system through dedicated take outs and connectors of the instrument panel wire harness with connector insulators that connect directly to the two inflator initiators. The connector insulators are uniquely keyed and color-coded to ensure they can only be connected to the correct initiator.

A service replacement passenger airbag does not include the airbag door. The passenger airbag door may be disassembled from the passenger airbag and is available for individual service replacement. The passenger airbag unit cannot be repaired and must be replaced if deployed, ineffective, or in any way damaged.

Note. The following procedure is for replacement of an ineffective or damaged passenger airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See STANDARD PROCEDURE . If the passenger airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle.

Scheme 35

Scheme 36

1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service.
2. Remove the top cover from the instrument panel. Refer to «REMOVAL»(ref-306147-S13406240552008120900000) .
3. Remove the two screws (4) from the screw guide (3) on the top of the instrument panel (2) near the windshield (1) that secure the instrument panel bracket for the passenger airbag to the dash panel.
4. Using a trim stick or another suitable wide flat-bladed tool, pry the screw guide away from the top of the instrument panel far enough to disengage the two integral latch features that secure it and remove the screw guide to allow access to the trim screw that secures the passenger airbag instrument panel bracket to the instrument panel structural duct.
5. Work through the rectangular hole in the top of the instrument panel beneath the removed screw guide to access and remove the one screw that secures the center tab of the passenger airbag instrument panel bracket to the structural duct.
6. Remove the glove box from the instrument panel. Refer to «REMOVAL»(ref-306147-S34322015752008120900000) .
7. Reach up into the instrument panel above the upper glove box opening (2) to access and remove the two nuts (3) that secure the passenger airbag lower studs to the instrument panel base trim on each side of the glove box latch striker (1).
8. Using a trim stick or another suitable wide flat-bladed tool, gently pry the lower edge of the passenger airbag door rearward away from the upper glove box opening reinforcement far enough to disengage the snap features on the door from the receptacles in the instrument panel base trim.
9. Grasp the lower edge of the passenger airbag door and gently pull the door and airbag rearward far enough to disengage the upper snap features from the receptacles in the instrument panel base trim and to access the two instrument panel wire harness connections to the airbag inflators at each side of the airbag housing. CAUTION: Do not pull on the instrument panel wire harness take outs or pry on the connector insulators to disengage the connectors from the passenger airbag inflator connector receptacles. Improper removal of these take outs and their connector insulators can result in damage to the airbag circuits or connector insulators.
10. The instrument panel passenger airbag wire harness connectors are secured by integral latches to the airbag inflator connector receptacles, which are located on the sides of the passenger airbag housing. Depress the latches on each side of each connector insulator and pull the insulators straight out from the airbag inflator to disconnect them from the connector receptacles.
11. Remove the passenger airbag, airbag door and instrument panel bracket from the instrument panel as a unit.

Note. The following procedure is for replacement of an ineffective or damaged passenger airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See STANDARD PROCEDURE . If the passenger airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle.

1. Position the passenger airbag, airbag door and instrument panel bracket to the opening in the face of the instrument panel base trim as a unit.
2. Reconnect the two connector insulators of the instrument panel wire harness take outs to the airbag inflator connector receptacles on each side of the airbag housing by pressing straight in on the connectors. Be certain to engage each keyed and color-coded connector to the matching connector receptacle. You can be certain that each connector is fully engaged in its receptacle by listening carefully for a distinct, audible click as the connector latches snap into place.
3. Slide the passenger airbag forward being certain that the instrument panel bracket is engaged between the dash panel and the instrument panel structural support at the lower windshield fence line and that the two lower studs of the airbag are engaged in the holes of the instrument panel base trim. It may be necessary to angle the forward end of the unit slightly downward and then roll it upward to engage the instrument panel bracket properly between the fence line and the structural support.
4. Reach up into the instrument panel above the upper glove box opening (2) to install and tighten the two nuts (3) that secure the passenger airbag lower studs to the instrument panel base trim on each side of the glove box latch striker (1). Tighten the nuts to 7 N.m (62 in. lbs.).
5. Reinstall the glove box into the instrument panel. Refer to «INSTALLATION»(ref-306147-S35230032082008120900000) .
6. Work through the rectangular hole in the top of the instrument panel to install and tighten the one screw that secures the center tab of the passenger airbag instrument panel bracket to the instrument panel structural duct. Tighten the screw to 2.9 N.m (25 in. lbs.).
7. Position the screw guide (3) onto the top of the instrument panel (2) near the windshield (1) and, using hand pressure, press the screw guide downward until both integral latch features snap into place.
8. Install and tighten the two screws (4) through the screw guide that secure the instrument panel bracket for the passenger airbag to the dash panel. Tighten the screws to 29.5 N.m (21.5 ft. lbs.).
9. Using hand pressure, press the top of the passenger airbag door forward and downward until each snap feature on the upper edge of the airbag door is fully engaged into its receptacle in the instrument panel base trim.
10. Using hand pressure, wrap the passenger airbag door downward tightly against the instrument panel, then push forward until each snap feature on the lower edge of the airbag door is fully engaged into its receptacle in the instrument panel base trim.
11. Visually verify that each of the snap features of the airbag door is fully engaged in the instrument panel. There will be a distinct bulge in the door over any snap that is not fully engaged.
12. Reinstall the top cover onto the instrument panel. Refer to «INSTALLATION»(ref-306147-S05098774272008120900000) .
13. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See «STANDARD PROCEDURE»(ref-306149-S11237404792008120900000) .

WEB STOP BUTTON REPLACEMENT

The webbing of each of the tip half seat belts in this vehicle is equipped with a molded plastic web stop button, which holds the latch plate of the seat belt tip half in a readily accessible stored position and prevents it from falling to the lower belt anchor while the belt is not in use. If this button becomes damaged or separated from the belt webbing, it may be successfully replaced using the following procedure without the need for removing or replacing the entire seat belt assembly.

The web stop button replacement kit includes two molded plastic replacement button halves: a male button half with a pointed spike in its center, and a female button half with a hole in its center. The button halves are not available separately. In addition to the button replacement kit, a pair of wheel weight pliers (such as KD Tools® #3358, Snap-on® #WWPR13A or equivalent) and a gel-type super adhesive glue (such as Mopar® Bond-All Gel #04467709 or equivalent) are required.

Note. Avoid using heavy-duty, truck-style wheel weight pliers as the jaws may not close far enough to successfully complete web stop button replacement.

Scheme 37

Scheme 38

Scheme 39

Scheme 40

1. Carefully inspect the seat belt webbing to identify the hole or a witness mark where the original web stop button halves (2 and 5) were installed. If no distinct evidence of the prior button location is found, go to Step 2. If the original button location is clearly evident, go to Step 3.
2. Find the appropriate dimension in the Web Stop Button Location table. Measure and mark that distance (4) in the center of the belt webbing from the point where the webbing is secured to the seat belt lower anchor plate (3). WEB STOP BUTTON LOCATION SEATING POSITION DIMENSION FRONT 350 plus or minus 10 millimeters (13.78 plus or minus 0.39 inches) SECOND ROW 280 plus or minus 15 millimeters (11.02 plus or minus 0.59 inches) CAUTION: Be certain that the seat belt latch plate (1) is located and secured above the web stop button location mark before installing the replacement button.
3. Working from the side of the seat belt webbing that faces the interior of the vehicle, pierce the webbing with the spike in the center of the male button half. The male button head should face the interior of the vehicle.
4. Apply a small dot of gel-type super adhesive glue (2) around the center hole on the back side of the female button half (1).
5. Press the female button half over the spike of the male button half that protrudes through the side of the belt webbing that faces away from the interior of the vehicle.
6. Use the flat anvil-like jaw (3) of the wheel weight pliers to flatten the sharp spike (2) of the male button half that protrudes through the female button half (1) on the back side of the belt webbing (4).
7. Carefully use the curved jaw (3) of the wheel weight pliers to compress and form the flattened spike of the male button half (2) on the back side of the seat belt webbing (1) until it is concave and entirely below the outer convex surface of the female button half.
8. Check to be certain that the web stop button is secure.

Scheme 41

1. Remove the upper trim (4) from the inside of the B-pillar (1). Refer to «REMOVAL»(ref-306147-S34318920982008120900000) .
2. Remove the screw that secures the seat belt turning loop (3) to the height adjuster (2) on the upper B-pillar.
3. Remove the seat belt turning loop from the height adjuster.
4. Remove the screw that secures the upper end of the seat belt turning loop adjuster to the upper B-pillar.
5. Pull the turning loop adjuster upward and away from the B-pillar far enough to disengage the tabs on the lower end of the adjuster from the keyed holes in the B-pillar.
6. Remove the seat belt turning loop adjuster from the B-pillar.

1. Position the seat belt turning loop adjuster (2) to the inner B-pillar (1).
2. Engage the tabs on the lower end of the adjuster into the keyed holes in the B-pillar.
3. Position the upper end of the turning loop adjuster against the B-pillar.
4. Install and tighten the screw that secures the seat belt turning loop adjuster to the upper B-pillar. Tighten the screw to 44.5 N.m (33 ft. lbs.).
5. Position the seat belt turning loop (3) onto the height adjuster on the upper B-pillar. Be certain that the seat belt webbing (5) between the retractor and the turning loop, and between the turning loop and the lower anchor is not twisted.
6. Install and tighten the screw that secures the seat belt turning loop to the height adjuster. Tighten the screw to 44.5 N.m (33 ft. lbs.).
7. Reinstall the upper trim (4) onto the inside of the B-pillar. Refer to «INSTALLATION»(ref-306147-S33035132222008120900000) .

Scheme 42

The seat weight sensors are strain gauge-type units. The electronic elements of the sensor are encased within the sensor body (5) and the sensor body is located within a stamped metal cage (3). Four sensors are used in the Occupant Classification System (OCS). The sensors are located below the seat cushion between the seat adjuster track and the seat track riser at each corner of the passenger side front seat.

A threaded mounting stud (2) on each sensor body is secured by a nut to the seat track riser, and two nuts secure each sensor mounting flange (1) to two studs integral to the front and rear of the inboard and outboard passenger side lower seat adjuster tracks. A molded connector receptacle (4) integral to each sensor body is oriented towards the center of the seat and is connected to the vehicle electrical system through a dedicated connector and take out of the passenger seat wire harness beneath the seat cushion.

The seat weight sensors cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced.

Scheme 43

Scheme 44

Scheme 45

1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service.
2. Remove the passenger side front seat from the vehicle. Refer to «REMOVAL»(ref-306147-S34977607592008120900000) .
3. From the underside of the seat, disconnect the seat wire harness from the connector receptacles of each of the four weight sensors.
4. Disconnect the seat wire harness from the connector receptacle of the seat track position sensor located on the inboard side of the inboard seat adjuster upper track near the rear of the seat track. CAUTION: A strain gauge alignment tool (Special Tool No. 9689) (2) must be used to secure the body of the seat weight sensor (1) from any rotation during removal or installation of the nut that secures the sensor stud to the seat track riser. In addition, the sensor fasteners should always be serviced using hand tools ONLY, and not electric or pneumatic power tools. Failure to observe these cautions may result in irreversible sensor damage requiring sensor replacement.
5. Install the strain gauge alignment tool (Special Tool 9689) on the sensors by inserting the center fork (1) of the tool between the flats on each side of the sensor body and inside of the cage, then seating the tool support yoke (2) firmly against the outside of the sensor cage.
6. With the alignment tool securing the body of the seat weight sensor (2), remove the nut (4) that secures the sensor stud to the seat track riser (5).
7. Transfer the special tool to each weight sensor, one at a time, and remove the nuts that secure the sensor studs to the seat track risers until all four nuts have been removed.
8. Carefully separate the seat track risers from the seat weight sensor studs.
9. Remove the two nuts (3) that secure the sensor to the studs on the lower track of the seat adjuster (1).
10. Remove the seat weight sensor from the seat adjuster.

1. Position the seat weight sensor (2) over the studs on the lower track of the passenger side front seat adjuster (1).
2. Install and tighten the two nuts (3) that secure the sensor to the studs. Tighten the nuts to 28 N.m (21 ft. lbs.).
3. Carefully position the seat track risers (5) over all four seat weight sensor studs. CAUTION: A strain gauge alignment tool (Special Tool No. 9689) (2) must be used to secure the body of the seat weight sensor (1) from any rotation during removal or installation of the nut that secures the sensor stud to the seat track riser. In addition, the sensor fasteners should always be serviced using hand tools ONLY, and not electric or pneumatic power tools. Failure to observe these cautions may result in irreversible sensor damage requiring sensor replacement.
4. Install the strain gauge alignment tool (Special Tool 9689) on the sensors by inserting the center fork (1) of the tool between the flats on each side of the sensor body and inside of the cage, then seating the tool support yoke (2) firmly against the outside of the sensor cage.
5. With the alignment tool securing the body of the seat weight sensor, install and tighten the nut that secures the sensor stud to the seat track riser. Tighten the nut to 44.5 N.m (33 ft. lbs.).
6. Transfer the special tool to each weight sensor, one at a time, then install and tighten the nuts that secure each of the four sensor studs to the seat track risers until all four nuts have been installed and tightened.
7. From the underside of the seat, reconnect the seat wire harness to the connector receptacle of the seat track position sensor located on the inboard side of the inboard seat adjuster upper track near the rear of the seat track.
8. Reconnect the seat wire harness to the connector receptacles of each of the four weight sensors.
9. Reinstall the passenger side front seat into the vehicle. Refer to «INSTALLATION»(ref-306147-S28598523962008120900000) .
10. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See «STANDARD PROCEDURE»(ref-306149-S11237404792008120900000) .
11. Following successful completion of the SRS verification test procedure, perform the Occupant Classification System (OCS) Verification Test using a diagnostic scan tool and the Occupant Classification Seat Weight special tool. Refer to the appropriate diagnostic procedures.