PASSENGER AIRBAG
DESCRIPTION
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 airbag door also includes a depressed area and clearance holes to accommodate the instrument panel grab handle (3). The edges of the airbag door are secured with integral snap features to the instrument panel base trim.
Located below the passenger airbag door within the instrument panel is the passenger airbag unit. The passenger airbag unit is secured through two lower studs (5) and a stamped upper mounting bracket (6) to the die cast instrument panel structural support armature.
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 and welded metal housing, the airbag cushion (3), and dual airbag inflators. The airbag housing contains the airbag inflators and the folded airbag cushion. An approximately 80 centimeter (31.5 inch) wide by 90 centimeter (35.5 inch) high rectangular fabric cushion is used.
The airbag inflator is a non-azide, pyrotechnic-type unit that is secured to and sealed within the airbag housing. Two inflator initiators (4) are connected to the vehicle electrical system through dedicated take outs and connectors of the instrument panel wire harness.
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.
OPERATION
The multistage passenger airbag is deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the passenger airbag squib 1 and squib 2 circuits to the two initiators for the dual airbag inflators. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by providing one of several delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy.
When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the airbag cushion and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the passenger airbag door will split at predetermined tear seam lines concealed on the inside surface of the door, then the door will pivot up over the top of the instrument panel and out of the way. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas through a vent hole in each fabric side panel of the airbag cushion.
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. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT).
Proper diagnosis of the passenger airbag inflator and the passenger airbag squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.
REMOVAL
WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes.
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. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS). 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. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT).
1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service.
2. Remove the trim plug (2) from the access hole in the top of the instrument panel (1) between the windshield and the forward edge of the passenger airbag door (3).
3. Working through the access hole, loosen the nut that secures the passenger airbag upper bracket and the instrument panel armature to the stud near the windshield fence line.
4. Remove the grab handle above the glove box door from the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/GRAB HANDLE - REMOVAL).
5. Remove the glove box from the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/GLOVE BOX - REMOVAL).
6. Reach up into the instrument panel glove box opening to access and remove the two nuts (3) that secure the passenger airbag lower studs to the instrument panel armature (2) on each side of the glove box latch striker (1).
7. Using a trim stick or another suitable wide flat-bladed tool, gently pry the edges of the passenger airbag door rearward far enough to disengage the snap features on the door from the receptacles in the instrument panel base trim.
8. Grasp the lower edge of the passenger airbag door and pull the door and airbag rearward far enough 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 the connector insulators.
9. Disconnect the instrument panel wire harness connectors from the airbag inflators. 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 passenger airbag and airbag door from the instrument panel as a unit.
DISASSEMBLY
WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
WARNING: To avoid serious or fatal injury, service of this unit should be performed only by DaimlerChrysler-trained and authorized dealer service technicians. Failure to take the proper precautions or to follow the proper procedures could result in accidental, incomplete, or improper airbag deployment and possible occupant injuries.
WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the passenger airbag, or becoming entrapped between the passenger airbag cushion and the passenger airbag door. Failure to observe this warning could result in occupant injuries upon airbag deployment.
WARNING: To avoid serious or fatal injury, the passenger airbag door must never be painted. Replacement airbag doors are serviced in the original colors. Paint may change the way in which the material of the airbag door responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment.
NOTE: The following procedures can be used to replace the passenger airbag door. If the passenger airbag is deployed, the passenger airbag unit and the airbag door must both be replaced.
1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service.
2. Remove the passenger airbag from the instrument panel. (Refer to 8 - ELECTRICAL/RESTRAINTS/PASSENGER AIRBAG - REMOVAL).
3. Place the passenger airbag on a suitable work surface with the passenger airbag door (2) facing down. If the airbag door will be reused, be certain to take the proper precautions to prevent the airbag door from receiving cosmetic damage during the following procedures.
4. Disengage each of the 12 hooks (3) of the airbag housing (1) from the 12 windows in the vertical walls of the receptacle on the back of the airbag door, one wall at a time. To disengage the hooks, use hand pressure to push the adjacent edge of the airbag housing firmly and evenly downward into the airbag door receptacle, while at the same time pulling outward on the upper edge of the receptacle wall.
5. With all of the hooks disengaged, lift the housing, inflator and cushion from the receptacle on the back of the passenger airbag door.
ASSEMBLY
WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
WARNING: To avoid serious or fatal injury, service of this unit should be performed only by DaimlerChrysler-trained and authorized dealer service technicians. Failure to take the proper precautions or to follow the proper procedures could result in accidental, incomplete, or improper airbag deployment and possible occupant injuries.
WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the passenger airbag, or becoming entrapped between the passenger airbag cushion and the passenger airbag door. Failure to observe this warning could result in occupant injuries upon airbag deployment.
WARNING: To avoid serious or fatal injury, the passenger airbag door must never be painted. Replacement airbag doors are serviced in the original colors. Paint may change the way in which the material of the airbag door responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment.
NOTE: The following procedures can be used to replace the passenger airbag door. If the passenger airbag is deployed, the passenger airbag unit and the airbag door must both be replaced.
1. Place the passenger airbag door (2) on a suitable work surface with the airbag receptacle facing up. Be certain to take the proper precautions to prevent the airbag door from receiving cosmetic damage during the following procedures.
2. Carefully position the passenger airbag housing (1) into the airbag door receptacle.
3. Work around the perimeter of the unit engaging each of the 12 hooks (3) on the passenger airbag housing through the 12 windows in the walls of the airbag door receptacle.
4. After the passenger airbag has been assembled, try pulling the airbag door and the airbag housing away from each other. This action will fully seat the edges of the windows into the cradles of the hooks.
5. Reinstall the passenger airbag onto the instrument panel. (Refer to 8 - ELECTRICAL/RESTRAINTS/PASSENGER AIRBAG - INSTALLATION).
INSTALLATION
WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the passenger airbag, or becoming entrapped between the passenger airbag cushion and the passenger airbag door. Failure to observe this warning could result in occupant injuries upon airbag deployment.
WARNING: To avoid serious or fatal injury, the passenger airbag door must never be painted. Replacement passenger airbag units are serviced with doors in the original colors. Paint may change the way in which the material of the airbag door responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment.
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. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS). 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. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT).
1. Position the passenger airbag and airbag door 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, then pushing the locks straight into the connectors. Be certain to engage each keyed and color-coded connector to the matching connector receptacle.
3. Slide the passenger airbag forward being certain that the upper passenger airbag bracket is engaged with the stud and under the nut on the windshield fence line and that the two lower studs of the airbag are engaged in the holes of the instrument panel armature (2).
4. Install and tighten the two nuts (3) that secure the passenger airbag lower studs to the instrument panel armature. Tighten the nuts to 6 N·m (55 in. lbs.).
5. Using hand pressure, press the passenger airbag door forward and downward until each snap feature on the edges of the airbag door is fully engaged into its receptacle in the instrument panel base trim.
6. Reinstall the grab handle onto the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/GRAB HANDLE - INSTALLATION).
7. Reinstall the glove box into the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/GLOVE BOX - INSTALLATION).
8. Working through the access hole in the top of the instrument panel (1) between the windshield and the forward edge of the passenger airbag door (3), tighten the nut that secures the passenger airbag upper bracket and the instrument panel armature to the stud near the windshield fence line. Tighten the nut to 6 N·m (55 in. lbs.).
9. Reinstall the trim plug (2) into the access hole in the top of the instrument panel.
10. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - VERIFICATION TEST).