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RESTRAINT SYSTEMS

CONTENTS

page page

AIRBAGSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . 3

AIRBAG SYSTEM

WARNING: THIS SYSTEM IS A SENSITIVE, COM-

PLEX ELECTRO-MECHANICAL UNIT. BEFORE AT-

TEMPTING TO DIAGNOSE, REMOVE OR INSTALL

THE AIRBAG SYSTEM OR RELATED STEERING

WHEEL AND STEERING COLUMN COMPONENTS

YOU MUST FIRST DISCONNECT AND ISOLATE THE

BATTERY NEGATIVE (GROUND) CABLE. THEN

WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO

DISCHARGE BEFORE FURTHER SYSTEM SERVICE.

FAILURE TO DO SO COULD RESULT IN ACCIDEN-

TAL DEPLOYMENT AND POSSIBLE PERSONAL IN-

JURY.

WARNING: THE AIRBAG MODULE INFLATOR AS-

SEMBLY CONTAINS SODIUM AZIDE AND POTAS-

SIUM NITRATE. THESE MATERIALS ARE

POISONOUS AND EXTREMELY FLAMMABLE. CON-

TACT WITH ACID, WATER OR HEAVY METALS MAY

PRODUCE HARMFUL AND IRRITATING GASES (SO-

DIUM HYDROXIDE IS FORMED IN THE PRESENCEOF MOISTURE) OR COMBUSTIBLE COMPOUNDS.

DO NOT ATTEMPT TO DISMANTLE THE MODULE

OR TAMPER WITH ITS INFLATOR. DO NOT PUNC-

TURE, INCINERATE OR BRING INTO CONTACT

WITH ELECTRICITY. DO NOT STORE AT TEMPERA-

TURES EXCEEDING 200F.

WARNING: REPLACE AIRBAG SYSTEM COMPO-

NENTS WITH PARTS SPECIFIED IN THE CHRYSLER

MOPAR PARTS CATALOG ONLY. SUBSTITUTE

PARTS MAY APPEAR INTERCHANGEABLE, BUT IN-

TERNAL DIFFERENCES MAY RESULT IN INFERIOR

OCCUPANT PROTECTION. THE FASTENERS,

SCREWS, AND BOLTS ORIGINALLY USED FOR THEAIRBAG COMPONENTS HAVE SPECIAL COATINGS

AND ARE SPECIFICALLY DESIGNED FOR THE AIR-

BAG SYSTEM. THEY MUST NEVER BE REPLACED

WITH ANY SUBSTITUTES. ANYTIME A NEW FAS-

TENER IS NEEDED, REPLACE WITH THE CORRECT

FASTENERS PROVIDED IN THE SERVICE PACKAGE

OR SPECIFIED IN THE CHRYSLER MOPAR PARTS

CATALOG.

WARNING: WHEN A STEERING COLUMN HAS AN

AIRBAG MODULE ATTACHED, NEVER PLACE THE

COLUMN ON THE FLOOR OR OTHER SURFACEWITH THE STEERING WHEEL OR AIRBAG MODULE

FACE DOWN.

GENERAL INFORMATION

The airbag system is a standard equipment safety

device on Dakota models. I t is designed to protect the

driver from serious injury, caused by a frontal impactof the vehicle. To inspect this system use Ai rbag Sys-

tem - Body Diagnostic P rocedures manual. I f the air-

bag module assembly is defective and non-deployed,

refer to Chrysler Corporation current return list for

proper handling procedures.

Following are general descriptions of the major

components in the Dakota airbag system. Refer to

Group 8W - Wiri ng Diagrams for complete circuit de-

scriptions and diagrams.

AIRBAG MODULEThe airbag module protective cover is the most vis-

ible part of the system. T he module is mounted di-rectly to the steering wheel. Under the airbag

module cover, the airbag cushion and i ts supporti ng

components are contained. The airbag module con-tains a housing to which the cushion and inflator areattached and sealed. The airbag module is non-ser-viceable, and must be replaced if deployed or dam-aged in any way.

The inflator assembly is mounted to the back of themodule. The inflator seals the hole in the airbagcushion so it can discharge the gas it produces di-rectly into the cushion when supplied with the

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proper electri cal signal. The protective cover is fittedto the front of the airbag module and forms a deco-rative cover in the center of the steering wheel. Uponairbag deployment, this cover will split horizontally.

STORAGE

The airbag module must be stored in its original,special container until used for service. Also, it mustbe stored in a clean, dry environment; away fromsources of extreme heat, sparks, and high electricalenergy. Always place or store the module on a surfacewith the tr im cover facing up to minimize movementin case of accidental deployment.

IMPACTSENSORThe impact sensors provide verification of the di-

rection and severity of the impact. Three impact sen-sors are used. One is called a safing sensor. I t islocated inside the airbag control module (ACM),which i s mounted to a bracket under the instrument

panel above the heater and A/C housing. The othertwo sensors are mounted on the radiator closurepanel on the left and right side of the vehicle.

The impact sensors are threshold sensitiveswitches that complete an electrical circuit when animpact provides a sufficient deceleration force toclose the switch. The sensors are calibrated for thespecifi c vehicle, and r eact to the severity and direc-tion of the impact.

CLOCKSPRINGThe clockspring is mounted on the steering column

behind the steering wheel. I t is used to maintain a

continuous electri cal circuit between the wiring har-

ness and the drivers side airbag module. This assem-

bly consists of a flat, ribbon-like electrically

conductive tape which winds and unwinds with the

steering wheel rotation.

AIRBAG CONTROL MODULEThe airbag control module (ACM) contains the saf-

ing sensor, and monitors the system to determine its

readiness. The ACM contains on-board diagnostics

(OBD), and will light the airbag warning lamp in the

instrument cluster when a monitored airbag system

fault occurs.

The ACM also contains an energy storage capacitor.

This capacitor stores enough electrical energy to de-

ploy the airbag for up to 2 minutes following a bat-

tery disconnect or failure. The purpose of this unit isto provide airbag protection in a severe secondary

impact if the initial impact has damaged or discon-

nected the battery, but was not severe enough to de-

ploy the airbag.

DIAGNOSIS

A DRB scan tool is required for diagnosis of the air-

bag system. Refer to Airbag System - Body Diagnos-tic P rocedures manual for more information.

AIRBAG SYSTEM CHECK(1) Disconnect battery negative cable and isolate.(2) Connect DRB scan tool to ACM diagnostic

6-way connector. The connector is located under theinstrument panel on the reinforcement behind thesteeri ng column cover/knee blocker.

(3) From right side of vehicle (away from airbag incase of accidental deployment), turn the ignitionswitch to the ON position. Exit vehicle with DRB.

Use the latest version of the proper DRB cartridge.(4) After checking that nobody i s inside the vehi-cle, reconnect the negative battery terminal.

(5) Using the DRB, read and record active diagnos-tic trouble code (DTC) data.

(6) Read and record any stored DT C.

(7) Refer to the Airbag System - Body DiagnosticTest P rocedures manual, if any DTC is found in steps5 or 6.

(8) Erase stored DTC, if there are no active faultcodes. I f problems remain, DTC will not erase.

(9) With the ignition switch in the ON position,make sure nobody is in the vehicle.

(10) From right side of vehicle, turn the ignitionswitch to OFF then ON. Observe airbag warninglamp on the instrument cluster. I t should light for 6to 8 seconds, then go out; indicating system is func-tioning normally.

If the airbag warning lamp fails to light, orlights and stays on, there is a system malfunc-tion. Refer to the Airbag System - Body Diag-nostic Test Procedures manual to diagnose theproblem.

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SERVICE PROCEDURES

AIRBAG SYSTEM SERVICE (DEPLOYED)Any vehicle which is to be returned to use after an

airbag deployment, must have the airbag module and

clockspri ng replaced. These are one-time components

and cannot be reused. Other airbag system compo-

nents are replaced as r equired by the extent of dam-age.

AIRBAG MODULE HANDLING

UNDEPLOYED

At no time should any source of electricity be per-

mitted near the inflator on the back of the module.

When carrying an undeployed module, the tri m cover

should be pointed away from the body to minimize

injury in the event of accidental deployment. I f the

module i s placed on a bench or other surface, the

plastic trim cover should be face up to minimizemovement in case of accidental deployment.

DEPLOYED

Following an airbag deployment, the vehicle inte-

rior will contain a powdery residue. This residue is

primaril y sodium bicarbonate (baking soda), used as

an air bag cushion l ubricant. However, there will also

be traces of sodium hydroxide powder, a chemical

byproduct of the generant used for airbag deploy-

ment. Since this powder can irritate the skin, eyes,

nose or throat, be sure to wear safety glasses, rubbergloves and a long-sleeved shirt during cleanup (Fig.

1).

If you experience skin irritation duringcleanup, run cool water over the affected area.Also, if you experience irritation of the nose orthroat, exit the vehicle for fresh air until the ir-ritation ceases. If irritation continues, see aphysician.

CLEANUP PROCEDUREBegin cleanup by putting tape over the airbag ex-

haust vent (Fig. 2) so that no more powder will find

its way into the vehicle interior. Then remove the air-

bag and airbag module from the vehicle.

Use a vacuum cleaner to remove any residual pow-

der from the vehicle interior. Clean from outside the

vehicle and work your way inside, so that you avoid

kneeling or sitting on an uncleaned area.

Be sure to vacuum the heater and A/C outlets as

well (Fig. 3). Run the blower on low and vacuum any

powder expelled from the plenum. You may need to

vacuum the interior of the car a second time to re-cover all of the powder.

Pl ace the deployed airbag and module in your ve-

hicular scrap pile.

Fig. 1 Wear Safety Glasses And Rubber Gloves

Fig. 2 Airbag Exhaust Vent Sealing

Fig. 3 Vacuum Heater And A/C Outlets


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AIRBAG MODULE REMOVE/INSTALL

WARNING: THIS SYSTEM IS A SENSITIVE, COM-

PLEX ELECTRO-MECHANICAL UNIT. BEFORE AT-

TEMPTING TO DIAGNOSE, REMOVE OR INSTALL

THE AIRBAG SYSTEM COMPONENTS YOU MUST

FIRST DISCONNECT AND ISOLATE THE BATTERY

NEGATIVE (GROUND) CABLE. THEN WAIT 2 MIN-UTES FOR SYSTEM CAPACITOR TO DISCHARGE

BEFORE FURTHER SYSTEM SERVICE. FAILURE TO

DO SO COULD RESULT IN ACCIDENTAL DEPLOY-

MENT AND POSSIBLE PERSONAL INJURY.

When removing a deployed airbag module, rub-

ber gloves, eye protection and long-sleeved shirt

should be worn. There may be deposits on the air-

bag module and other interior surfaces, which can

cause irritation to the skin and eyes in large doses.

(1) Disconnect battery negative cable and isolate.

I f airbag module is undeployed, wait 2 minutes for

system capacitor to discharge before further service.

(2) Fr om underside of steering wheel, remove

speed control switch mounting screws (Fig. 4), if

equipped.

(3) Pull switches from wheel and unplug connector

(Fig. 5).

(4) Using a small screwdriver, remove right rear

steeri ng wheel cover (Fig. 6).

(5) Remove 4 nuts attaching airbag module to

steering wheel (Fi g. 7).

(6) Remove air bag module from steering wheel.

(7) Unplug electrical connector from airbag module.

(8) When installing, connect clockspring wiring

connector to the module by pressing straight in on

the connector. The connector should latch securely

beneath the module connector locking clip to assure

positive connection.

(9) I nstall 4 nuts and torque to 9 to 11 N m (80 to

100 in. lbs.).

(10) Do not connect negative battery cable at this

time. See Airbag System Check for proper procedure.

IMPACT SENSOR REMOVE/INSTALLThe impact sensors are located on the radia-

tor support behind the grille opening reinforce-ment.

LEFT SIDE


I f airbag module is undeployed, wait 2 minutes forsystem capacitor to discharge before further service.

(2) Remove battery holddown (Fig. 8) and movebattery rearward.

(3) Unplug connector from sensor.(4) Remove 3 nuts holding left sensor to closure

panel support (Fig. 9) and remove sensor.

Fig. 4 Speed Control Switch Remove/Install

Fig. 5 Speed Control Switch Connector Remove/Install

Fig. 6 Right Rear Steering Wheel Cover Remove/Install


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If stud plate needs to be replaced, remove

push nut from stud and discard. Always use

new push nut (Fig. 9) when installing stud

plate.

(5) When installing, mount sensor (arrow pointed

forward) using 3 nuts provided with new sensor.

Torque nuts to 3 to 4 N

m (24 - 36 in. lbs.).(6) Connect left sensor wiring l ead from harness to

connector on body of sensor.

(7) I nstall battery making sure that it is properly

positioned in battery tray (Fig. 8).

(8) I nstall battery holddown strap, making sure

that it is properly positioned on battery. Tighten bolts

to 2.2 Nm (20 in. lbs.)



RIGHT SIDE


I f airbag module is undeployed, wait 2 minutes forsystem capacitor to discharge before further service.

(2) Pul l air cleaner inlet tube off radiator support.

(3) Unplug connector from right sensor.

(4) Remove 3 nuts holding right sensor to radiator

support (Fig. 9) and remove sensor.

If stud plate needs to be replaced, remove

push nut from stud and discard. Always use

new push nut (Fig. 9) when installing stud

plate.

(5) When installing, mount sensor (arrow pointed

forward) using 3 nuts provided with new sensor.

Torque nuts to 3 to 4 N

m (24 - 36 in. lbs.).(6) Connect sensor wiring lead from harness to

connector on body of sensor.

(7) I nstall air cleaner inlet tube to radiator sup-

port.



Fig. 7 Airbag Module Remove/Install

Fig. 8 Battery Holddown Remove/Install

Fig. 9 Airbag Impact Sensor (Typical)


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AIRBAG CONTROL MODULE REMOVE/INSTALL

WARNING: THE ACM CONTAINS ONE OF THE IMPACT

SENSORS WHICH ENABLE THE SYSTEM TO DEPLOY

THE AIRBAG. TO AVOID ACCIDENTAL DEPLOYMENT,

NEVER CONNECT ACM ELECTRICALLY TO THE SYS-

TEM UNLESS IT IS BOLTED TO VEHICLE. BEFORE

BEGINNING ANY AIRBAG SYSTEM REMOVAL OR IN-STALLATION PROCEDURES, REMOVE AND ISOLATE

THE BATTERY NEGATIVE (-) CABLE FROM THE VEHI-

CLE BATTERY. THEN WAIT 2 MINUTES FOR SYSTEM

CAPACITOR TO DISCHARGE BEFORE FURTHER SYS-

TEM SERVICE. THIS IS THE ONLY SURE WAY TO DIS-

ABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS

COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-

MENT, AND POSSIBLE PERSONAL INJURY.

(1) Disconnect battery negative cable and isolate.I f airbag is undeployed, wait 2 minutes for systemcapacitor to discharge before further service.

(2) Remove screws along bottom edge of kneeblocker (Fig. 10).

(3) Pull knee blocker down to disengage slide tabsand remove.

(4) Column shift vehicles, place gear shift lever in1 position and r emove indicator cable (Fig. 11).

(5) Remove 2 nuts holding steering column supportbracket to instrument panel.

(6) Remove both cowl kick tri m panels.(7) Remove both door hinge pillar trim panels.(8) Remove 5 upper instrument panel retaining screws.

(9) L oosen lower instrument panel retainingscrews. Roll instrument panel rearward.

(10) Unplug 2 electrical connectors from ACM (Fig. 12).(11) Remove 4 screws holding ACM .(12) Remove ACM .(13) When installing, position the ACM with the

arrow pointing forward.(14) Attach the ACM to the bracket with the 4

screws. Torque to 3 to 5 N m (25-45 in. lbs.).(15) Connect wiring at ACM, making sure both

connectors are seated and locking tabs are engaged.(16) Raise and install instrument panel.

(17) Ti ghten lower instrument panel screws.

(18) I nstall both door hinge pillar trim pieces.

(19) I nstall both cowl kick trim panels.

(20) I nstall the steering column. Tighten nuts to

12 Nm (105 in. lbs.) torque.(21) Do not connect battery negative cable at this


CLOCKSPRINGREMOVE/INSTALL(1) Pl ace the front wheels in the straight-ahead po-

sition before starting the repair.(2) Disconnect battery negative cable and isolate.

I f airbag is undeployed, wait 2 minutes for systemcapacitor to discharge before further service.

(3) Remove the airbag module. See Airbag ModuleRemove/Install .

(4) Remove speed control switch and connector, ifequipped.

Fig. 10 Knee Blocker Remove/Install

Fig. 11 Indicator Cable Remove/Install

Fig. 12 Airbag Control Module Remove/Install


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(5) Remove the steering wheel with steering wheel

puller tool (C-3428B).

(6) Unplug wiring connectors from horn switches.

(7) Remove upper and lower steering column

shrouds to gain access to clockspring wiring (Fig. 13).(8) Disconnect the 2-way connector between the

clockspring and the instrument panel wiring harnessat the base of the steering column.

(9) To remove, pull clockspring assembly fromsteering column by l ifting locating fingers as neces-sary. The clockspring cannot be repaired. I t must bereplaced if faulty, or if airbag has been deployed.

(10) When installing, snap clockspring onto thesteering column. I f the clockspring is not properly po-sitioned, see Clockspring Centering before installingsteering wheel.

(11) Connect the clockspring assembly to the in-strument panel wiring harness. Make sure wiring lo-cator clips are properly seated on the outside of thewiring trough and locking tabs are engaged.

(12) Reinstall steering column shrouds. Be sureairbag wire is inside the shrouds.

(13) Front wheels should still be in the straight-aheadposition. I nstall steering wheel making sure to fit the

flats on the hub of the steering wheel with the forma-tions on the inside of clockspring. Pull the horn wiringthrough the upper, smaller hole in steering wheel hub.Pull the airbag and speed control wiring through the bot-

tom, larger hole in the steering wheel hub. Make surenot to pinch wiring between the steering wheel and nut.

(14) Connect the horn switch wire, then the airbagwire to the airbag module. To assure complete con-nection, latching arms must be visibly on top of con-nector housing.

(15) I nstall the airbag module, and torque nuts to9 to 11 Nm (80 to 100 in. lb.).

(16) Do not connect negative battery cable at thistime. See Airbag System Check for proper procedure.

CLOCKSPRINGCENTERINGI f the rotating tape within the clockspring is not

positioned properly in relation to the steering wheeland the front wheels, the clockspring may fail duringuse. The clockspring MUST BE CENT ERE D, if it isnot known to be properly positioned, or if the frontwheels were moved from the straight-ahead position.

(1) Pl ace front wheels in the straight-ahead posi-tion.

(2) Disconnect battery negative cable and isolate.I f airbag is undeployed, wait 2 minutes for systemcapacitor to discharge before further service.

(3) Remove airbag module. Remove steeri ng wheelwith steering wheel puller tool (C-3428B).

(4) Depress the two plastic auto-locking tabs (Fig.

14).

(5) K eeping locking mechanism disengaged, rotate

the clockspring rotor CL OCK WISE to the end of itstravel. Do not apply excessive torque.(6) From the end of travel, rotate the rotor two and

one-half turns COUNTE R CLOCK WISE. The horn wire

should end up at the top, and the airbag wire at the bot-tom.

(7) Reinstall steering wheel.(8) I nstall airbag module. Torque nuts to 9 to 11

Nm (80 to 100 in. lbs.).(9) Do not connect battery negative cable at this


Fig. 13 Steering Column Shrouds Remove/Install

Fig. 14 Clockspring Auto-Locking Tabs


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