Chrysler Town, Dodge Caravan. Manual — part 133
passenger airbag cushion and the airbag cushion
supporting components.
The passenger airbag includes a magnesium hous-
ing within which the cushion and inflator are
mounted and sealed.
Following a passenger airbag deployment, the pas-
senger airbag and the instrument panel must be
replaced. The passenger airbag cannot be repaired,
and must be replaced if deployed or damaged in any
way.
OPERATION
The passenger airbag is equipped with two infla-
tors, each with three levels of pressure output. The
inflators seal the hole in the airbag cushion so it can
discharge the gas it produces directly into the cush-
ion when supplied with the proper electrical signal.
Following an airbag deployment, the airbag cushion
quickly deflates by venting this gas through the
cushion material towards the instrument panel.
The passenger airbag is secured with screws to the
instrument panel beneath the instrument panel top
pad and above the glove box opening. The instrument
panel top pad above the glove box opening conceals
the airbag door and a predetermined hinge line
beneath its decorative cover. Upon airbag deploy-
ment, the top pad will bend at the hinge line and the
door will fold back out of the way onto the top of the
instrument panel.
When the front airbag system is deployed, the fol-
lowing MUST be replaced:
• Complete Steering Column Assembly.
• Lower Steering Column Coupler.
• Steering Wheel.
• Clock Spring.
• Driver Airbag.
• Passenger Airbag.
• Upper Instrument Panel with Pad.
CARE OF UNDEPLOYED AIRBAGS
Airbags must be stored in their original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag. When carrying or handling an
undeployed airbag, the trim side of the airbag should
be pointing away from the body to minimize possibil-
ity of injury if accidental deployment occurs. Do not
place undeployed airbag face down on a solid surface,
the airbag will propel into the air if accidental
deployment occurs.
REMOVAL
DEPLOYED AIRBAG
(1) Clean powder residue from interior of vehicle
(Refer to 8 - ELECTRICAL/RESTRAINTS - STAN-
DARD PROCEDURE - SERVICE AFTER AN AIR-
BAG DEPLOYMENT).
(2) Remove instrument panel (Refer to 23 - BODY/
INSTRUMENT
PANEL/INSTRUMENT
PANEL
ASSEMBLY - REMOVAL).
(3) Remove all reusable components from the
upper instrument panel and transfer to the new
instrument panel.
UNDEPLOYED AIRBAG
(1) Open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Wait two minutes for the airbag system reserve
capacitor to discharge before attempting any airbag
or instrument panel service.
(4) Remove center console bin between front seats.
(5) Remove left front door sill plate using a trim
stick (special tool #C-4755) or equivalent, and gently
prying up on sill plate.
(6) Remove left cowl panel using a trim stick or
equivalent, and gently prying out on cowl panel.
(7) Remove four screws to lower steering column
cover and remove cover.
(8) Unsnap parking brake lever from knee blocker
reinforcement.
(9) Remove Data Link Connector (DLC) from knee
blocker.
(10) Remove screws to knee blocker.
(11) Unsnap left A-pillar lower extension trim
using a trim stick or equivalent.
(12) Remove three left side instrument panel A-pil-
lar retaining bolts and loosen the instrument panel
roll down bolt.
(13) Remove four nuts at brake pedal support
bracket to instrument panel.
(14) Using a trim stick or equivalent, gently pry
off left side upper A-pillar trim.
(15) Remove six screws and two wiring connectors
to lower instrument panel cubby bin at bottom of
center stack.
(16) Remove two left side nuts at instrument panel
center stack support to floor.
(17) Remove two right side nuts at instrument
panel center stack support to floor.
(18) Remove right front door sill plate using a trim
stick or equivalent, and gently prying up on sill
plate.
(19) Remove right cowl panel using a trim stick or
equivalent, and gently prying out on cowl panel.
(20) Using a trim stick or equivalent, gently pry
out on right instrument panel end cap.
(21) Unsnap right A-pillar lower extension trim
using a trim stick or equivalent.
8O - 8
RESTRAINTS
RS
PASSENGER AIRBAG (Continued)
(22) Remove three right side instrument panel
A-pillar retaining bolts and loosen the instrument
panel roll down bolt.
(23) Using a trim stick or equivalent, gently pry
off right side upper A-pillar trim.
(24) Open glove box, pinch in sides and roll down
towards floor. With a firm pull, snap glove box door
off hinges and remove.
(25) Using a trim stick or equivalent, gently pry
up on rear of instrument panel top cover and then
pull rearward and out.
(26) Using a trim stick or equivalent, gently pry
off the filler bezel just above the cup holder to expose
the lower screws to center bezel.
(27) Remove two screws and then using a trim
stick or equivalent, gently pry off instrument panel
center bezel.
(28) Remove center bezel wiring connectors to
HVAC control and switch assembly (hazard, rear
wiper/washer, heated seats) and remove bezel.
(29) Slide cup holder assembly from instrument
panel.
(30) Remove nineteen screws to right lower instru-
ment panel trim (glove box surround), unplug glove
box lamp wire connector, and remove panel.
(31) Remove four screws and wiring connectors to
radio and remove radio.
(32) Remove one far left instrument panel speaker
retaining screw.
(33) Remove four screws along top front edge of
instrument panel cover/pad.
(34) Remove seven lower instrument panel cover/
pad retaining screws starting from right of vehicle
and only removing these seven, not all of them.
(35) Remove six upper fence line instrument panel
retaining bolts.
(36) Roll back instrument panel just enough to
increase access to the passenger airbag retaining
bolts at the reinforcement. Lift the instrument panel
up slightly so as not to damage the air distribution to
HVAC unit seal.
(37) Disconnect the passenger airbag electrical
connector. Using a trim stick or equivalent, gently
pry electrical connector off of instrument panel rein-
forcement.
(38) Remove the two passenger airbag to instru-
ment panel cover/pad retaining screws.
(39) Remove the three passenger airbag to instru-
ment panel reinforcement retaining bolts.
(40) Pull rearward slightly on the instrument
panel cover/pad to maneuver passenger airbag out
from reinforcement and instrument panel.
INSTALLATION
DEPLOYED AIRBAG
Transfer all reusable components to the new
instrument panel.
(1) Install new Passenger Airbag into instrument
panel.
(2) Install airbag attaching bolts to the instrument
panel.
(a) Torque the two bolts at instrument panel
retainer bosses to 2.7 ± .5 N·m (24 ± 5 in. lbs.).
(b) Torque the three bolts that attach the pas-
senger airbag to cross-car beam to 10 ± 2 N·m (90
± 15 in. lbs.).
(3) Connect yellow wire connector to passenger air-
bag and affix connector to instrument panel rein-
forcement with push pins.
(4) Install Instrument panel (Refer to 23 - BODY/
INSTRUMENT
PANEL/INSTRUMENT
PANEL
ASSEMBLY - INSTALLATION).
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE
CABLE.
REFER
TO
ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
UNDEPLOYED AIRBAG
(1) Pull rearward slightly on the instrument panel
cover/pad to maneuver passenger airbag up onto
reinforcement and instrument panel.
(2) Install the three passenger airbag to instru-
ment panel reinforcement retaining bolts but leave
loose. This will help align the passenger airbag for
the cover/pad fit.
(3) Install the two passenger airbag to instrument
panel cover/pad retaining screws. Torque screws to
2.7 ±.5 N·m (24 ± 5 in. lbs.).
NOTE: Insure that the instrument panel cover/pad
locator pins are indexed properly at center stack
area prior to reassembly.
(4) Tighten the three passenger airbag to instru-
ment panel reinforcement retaining bolts. Torque
bolts to 10 ± 2 N·m (90 ± 15 in. lbs.).
(5) Connect the passenger airbag electrical connec-
tor. Install the connector onto the instrument panel
reinforcement with the push-pin fasteners.
(6) Roll
the
instrument
panel
forward
lifting
slightly so as to seat the instrument panel air distri-
bution duct on top of the HVAC unit properly to
avoid any leaks or damage to the seal.
(7) Install six upper fence line instrument panel
retaining bolts.
(8) Install three right side instrument panel A-pil-
lar retaining bolts and tighten the right instrument
RS
RESTRAINTS
8O - 9
PASSENGER AIRBAG (Continued)
panel roll down bolt. Install the smaller 10 mm bolt
first to align the instrument panel properly.
(9) Install three left side instrument panel A-pillar
retaining bolts and tighten the left instrument panel
roll down bolt. Install the smaller 10 mm bolt first to
align the instrument panel properly.
(10) Install seven lower instrument panel cover/
pad retaining screws.
(11) Install four screws along top front edge of
instrument panel cover/pad.
(12) Install one far left instrument panel speaker
retaining screw.
(13) Install wiring connectors to radio. Install
radio and four retaining screws.
(14) Connect glove box lamp wiring connector and
place right lower instrument panel trim (glove box
surround) into position.
(15) Install nineteen right lower instrument panel
trim (glove box surround) and install panel screws.
(16) Slide cup holder assembly into instrument
panel.
(17) Install
center
bezel
wiring
connectors
to
HVAC control and switch assembly (hazard, rear
wiper/washer, heated seats).
(18) Install instrument panel center bezel by align-
ing slots and firmly snapping into place.
(19) Install two screws to instrument panel center
bezel.
(20) Align filler bezel above cup holder over retain-
ing slots and firmly snap into place.
(21) Place instrument panel top cover into position
and firmly snap down rear edge of top cover.
(22) Install glove box. Align hinges, snap into
place, roll glove box upwards and push in sides to
fully install.
(23) Align right side upper A-pillar trim over
retaining slots and firmly snap into place.
(24) Align right A-pillar lower extension trim over
retaining slots and firmly snap into place.
(25) Align right instrument panel end cap over
retaining slots and firmly snap into place.
(26) Align right cowl panel over retaining slots and
firmly snap into place.
(27) Align right front door sill plate over retaining
slots and firmly snap into place.
(28) Install two right side nuts at instrument
panel center stack support to floor.
(29) Install two left side nuts at instrument panel
center stack support to floor.
(30) Connect the two wiring connectors to lower
instrument panel cubby bin at bottom of center stack
and install six screws.
(31) Align left side upper A-pillar trim over retain-
ing slots and firmly snap into place.
(32) Install four nuts at brake pedal support
bracket to instrument panel.
(33) Align left A-pillar lower extension trim over
retaining slots and firmly snap into place.
(34) Install knee blocker and retaining screws.
(35) Install Data Link Connector (DLC) into bot-
tom of knee blocker.
(36) Align parking brake lever and snap into place
on knee blocker reinforcement.
(37) Install lower steering column cover and four
retaining screws
(38) Align left cowl panel over retaining slots and
firmly snap into place.
(39) Align left front door sill plate over retaining
slots and firmly snap into place.
(40) Install center console bin between front seats.
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE
CABLE.
REFER
TO
ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
(41) Close hood.
(42) Verify system and vehicle operation.
SEAT AIRBAG
DESCRIPTION
The side impact airbag system Seat Airbags are
located in the outboard side of the front seat backs.
One in each front seat. The seat airbag inflator
assembly is within the airbag housing (Fig. 3). Each
airbag is mounted to the seat back frame. If deployed
or defective, the entire seat back assembly must be
replaced.
Fig. 3 SEAT AIRBAG - TYPICAL
8O - 10
RESTRAINTS
RS
PASSENGER AIRBAG (Continued)
OPERATION
Only the Side Impact Airbag Control Module
(SIACM) can deploy the side airbags. When supplied
with the proper electrical signal, the seat airbag
inflator will produce a gas and discharge the bag
directly between the occupant and the side of the
vehicle, protecting the occupant. Upon deployment,
the seat back trim cover will tear open and allow the
side airbag to fully inflate and quickly deflate.
SEAT BELT BUCKLE - FRONT
INBOARD
REMOVAL
The seat belt tensioners are integral to the front
seat belt buckles. They are not serviceable and must
be replaced after a frontal impact event. The entire
front seat belt buckle assembly must be replaced as
an assembly.
(1) Disconnect and isolate the battery negative
cable.
(2) Wait two minutes for the system reserve capac-
itor to discharge before beginning any airbag compo-
nent service procedure.
(3) Remove screws attaching front inboard side
cover to seat cushion frame.
(4) Remove side cover from vehicle.
(5) Disconnect the tensioner wire connector from
seat belt buckle.
(6) Remove bolt attaching seat belt buckle to front
seat track.
(7) Remove buckle from vehicle.
INSTALLATION
The seat belt tensioners are integral to the front
seat belt buckles. They are not serviceable and must
be replaced after a frontal impact event. The entire
front seat belt buckle assembly must be replaced as
an assembly.
(1) Place buckle into position.
(2) Install bolt attaching seat belt buckle to front
seat track. Torque bolt to 39 N·m (29 ft. lbs.).
(3) Connect the seat belt tensioner electrical con-
nector.
(4) Install side cover into position.
(5) Install screws attaching front inboard side
cover to seat cushion frame.
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE
CABLE.
REFER
TO
ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
SEAT BELT BUCKLE - FIRST
ROW INBOARD - QUAD
BUCKET
REMOVAL
(1) Remove seat from vehicle.
(2) Remove screws attaching inboard side cover to
seat cushion.
(3) Remove side cover from seat.
(4) Remove bolts attaching recliner bracket to seat
cushion.
(5) Remove recliner bracket from seat.
(6) Remove bolt attaching seat belt buckle to seat
track (Fig. 4).
(7) Remove buckle from vehicle.
INSTALLATION
(1) Place buckle into position.
(2) Install bolt attaching seat belt buckle to seat
track. Torque bolt to 39 N·m (29 ft. lbs.).
(3) Install recliner bracket onto the seat.
(4) Install bolts attaching recliner bracket to seat
cushion.
(5) Install side cover from seat.
(6) Install screws attaching inboard side cover to
seat cushion.
(7) Install seat into position.
Fig. 4 SEAT BELT BUCKLE - FIRST ROW INBOARD
- QUAD BUCKET
1 - SEAT CUSHION
2 - SEAT BELT BUCKLE
3 - SEAT TRACK
RS
RESTRAINTS
8O - 11
SEAT AIRBAG (Continued)
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