2007 Dodge Durango Repair Manual Pdf - 2007 Dodge Durango Owners Manual - obslave.bridgebase.com
Revised (4) September 2017 Dealer Service Instructions for: Safety Recall S43 / NHTSA 16V-352 Passenger Airbag Inflator NOTE: 2009 (VB) Dodge Sprinter Models are now applicable to Canadian vehicles only. 2009 Sprinter models for the United States have been moved to Safety Recall R49. Revised Labor Operation number for 2009 Sprinter. Revised Figure 17 - Passenger Airbag Connector. Revised Parts Information and Parts Return sections. Models 2004-2008 2005-2009 2006-2009 2007-2010 2008-2010 2004-2009 2007-2009 2007-2012 2006-2010 2005-2012 2005-2008 2008-2012 2011-2012 (DR) Dodge RAM 1500/2500/3500 Pickup (DH) Dodge RAM 2500 Pickup (D1) Dodge RAM 3500 Pickup (DC) Dodge RAM 3500 Cab Chassis (DM) Dodge RAM 4500/5500 Cab Chassis (HB) Dodge Durango (HG) Chrysler Aspen (JK) Jeep Wrangler (LX) Dodge Charger (LX) Chrysler 300, 300c (LX) Dodge Magnum (LC) Dodge Challenger (LD) Dodge Charger Copyright 2017, FCA US LLC, All Rights Reserved (srg) Safety Recall S43 Passenger Airbag Inflator Page 2 Models (Continued) 2005-2011 2009 (ND) Dodge Dakota (VB) Dodge Sprinter (Canadian Vehicles Only) IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front passenger airbag inflator on about 4,600,000 of the above vehicles may rupture, due to excessive internal pressure, during normal airbag deployment events. This condition is more likely to occur if the vehicle has been exposed to high levels of absolute humidity for extended periods of time. An inflator rupture, during airbag deployment events, could result in metal fragment(s) striking the vehicle occupant(s) resulting in serious injury or death. Repair The passenger airbag inflator must be replaced. Safety Recall S43 Passenger Airbag Inflator Page 3 Parts Information NOTE: Do not destroy the replacement inflator packaging, it will be used to return the original inflator to the supplier. Part Number Description CBXZS431AA or CBXZS431AB Inflator Kit, Passenger Airbag (2004-2005 DR/DH) Inflator Kit, Passenger Airbag (2004-2005 DR/DH) Each kit contains the following components: Quantity Description 1 Inflator (with Wire Harness Jumper) 6 Nut, Mounting CBXZS432AA Inflator Kit, Passenger Airbag (2006-2010 DR/DH/DC/D1/DM) (2004-2009 HB/HG) (2005-2011 ND) (2005-2009 LX) Each kit contains the following components: Quantity Description 1 Inflator (with Wire Harness Jumper) 4 Nut, Mounting 06508531AA Bolt, Steering Shaft (2008-2011 ND only) (One bolt required per repair) (MSQ 5) CBXZS433AA Inflator Kit, Passenger Airbag (2008-2012 LC) (2010 LX) Each kit contains the following components: Quantity Description 1 Inflator (with Wire Harness Jumper) 4 Nut, Mounting Safety Recall S43 Passenger Airbag Inflator Parts Information (Continued) Page 4 CBXZS434AA Inflator Kit, Passenger Airbag (2011-2012 LX/LD) Each kit contains the following components: Quantity Description 1 Inflator 4 Nut, Mounting CBXZS435AA Inflator Kit, Passenger Airbag (2007-2012 JK) Each kit contains the following components: Quantity Description 1 Inflator 4 Nut, Mounting CBXZR262AB Inflator Kit, Passenger Airbag (2009 VB) (Canada Only) Each kit contains the following components: Quantity 1 4 Description Passenger Airbag Module Screws, Housing to Bracket 04641780 Tie Strap (2009 VB only) (Canada Only) Special Note: Dealers will not receive an initial allocation of part CBXZR262AB. Part(s) should be ordered as needed, and will arrive directly from the supplier (SSD). Dealer should confirm part has arrived before customer comes in for service visit. Safety Recall S43 Passenger Airbag Inflator Page 5 Parts Information (Continued) NOTE: Dealers should determine which inflator package is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The inflator package for the vehicle to be serviced may be determined by using the inflator kit usage chart below. Model Year 2005 Body Model Model DH Dodge RAM 2500 Pickup 2004-2005 DR Dodge RAM 1500/2500/3500 Pickup 2006-2009 2007-2010 2006-2009 2008-2010 2006-2008 2004-2009 2007-2009 2006-2009 2005-2009 2005-2008 2005-2011 2008-2012 2010 2011-2012 2011-2012 2007-2012 2009 D1 Dodge RAM 3500 Pickup DC Dodge RAM 3500 Cab Chassis DH Dodge RAM 2500 Pickup DM Dodge RAM 4500/5500 Cab Chassis DR Dodge RAM 1500/2500/3500 Pickup HB Dodge Durango HG Chrysler Aspen LX Dodge Charger LX Chrysler 300, 300c LX Dodge Magnum ND Dodge Dakota LC Dodge Challenger LX Dodge Charger Chrysler 300, 300c LD Dodge Charger LX Chrysler 300, 300c JK Jeep Wrangler VB Dodge Sprinter Part Number CBXZS431AA or CBXZS431AB CBXZS432AA CBXZS433AA CBXZS434AA CBXZS435AA CBXZR262AB Safety Recall S43 Passenger Airbag Inflator Page 6 Parts Return Use the procedure on this page to package the original inflator in the replacement kit box and return. Shipping/return instructions are provided with each inflator kit. International (including Mexico), Hawaii, Alaska, Puerto Rico, and US Virgin Islands: No parts return required. Destroy the original inflator using locally approved methods. Safety Recall S43 Passenger Airbag Inflator Page 7 Special Tools The following special tools are required to perform this repair: NPN wiTECH micro pod II NPN Laptop Computer NPN wiTECH Software Safety Recall S43 Passenger Airbag Inflator Page 8 Service Procedure A. Replace Passenger Airbag Inflator NOTE: Click on the links below to go to the desired procedure. Links at the top of each Section will return you to this page, Section A. For 2004 2005 DR and DH model vehicles, continue with Section B. Replace Passenger Airbag Inflator: 2004 2005 DR, DH (Page 9) For 2006 2010 DR, DH, DC, DM, and D1 model vehicles, continue with Section C. Replace Passenger Airbag Inflator: 2006 2010 DR, DH, DC, DM, D1 (Page 31) For HB and HG model vehicles, continue with Section D. Replace Passenger Airbag Inflator: HB, HG (Page 42) For 2005 2010 LX model vehicles, continue with Section E. Replace Passenger Airbag Inflator: 2005-2010 LX (Page 52) For 2011 2012 LX and LD model vehicles, continue with Section F. Replace Passenger Airbag Inflator: 2011-2012 LX, LD (Page 60) For 2008 2012 LC model vehicles, continue with Section G. Replace Passenger Airbag Inflator: 2008-2012 LC (Page 70) For 2005 2007 ND model vehicles, continue with Section H. Replace Passenger Airbag Inflator: ND (Page 87) For 2008 2011 ND model vehicles, continue with Section I. Replace Passenger Airbag Inflator: ND (Page 96) For JK model vehicles, continue with Section J. Replace Passenger Airbag Inflator: JK (Page 116) For VB model vehicles, continue with Section K. Replace Passenger Airbag Inflator: VB (Page 132) Safety Recall S43 Passenger Airbag Inflator Page 9 Service Procedure (Continued) B. Replace Passenger Airbag Inflator: 2004 2005 DR, DH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. At no time should any source of electricity be permitted near the inflator on the back of a non-deployed airbag or seat belt tensioner. When carrying a non-deployed airbag, the trim cover or airbag cushion side of the unit should be pointed away from the body to minimize injury in the event of an accidental deployment. 1. Disconnect and isolate the battery negative cable(s). Wait two minutes for the system capacitor to discharge before further service. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. INSTRUMENT PANEL SIDE COVER 2. Using a trim stick, from the notch on the bottom, remove the right instrument panel side cover (Figure 1). TRIM STICK Figure 1 - Instrument Panel Side Cover Safety Recall S43 Passenger Airbag Inflator Page 10 Service Procedure (Continued) 3. Use the following steps to remove the right side cowl trim panel. a. Using a trim stick, disengage the retaining tabs of the cowl trim panel from the retainer clips in the door sill (Figure 2). b. Pull the cowl trim panel rearward and remove it from the vehicle. RIGHT SIDE COWL TRIM PANEL DOOR SILL Figure 2 Right Side Cowl Trim Panel 4. Use the following steps to remove the glove box: a. Remove and save the glove box contents. b. Release the two glove box stops and lower the glove box downward past the stops (Figure 3). GLOVE BOX STOPS c. Disengage the glove box hinges from the instrument panel and remove the glove box. GLOVE BOX DOOR Figure 3 Glove Box Safety Recall S43 Passenger Airbag Inflator Page 11 Service Procedure (Continued) 5. Use the following steps to remove the center bezel. a. Remove the two lower screws from the steering column opening cover then release the two retainer clips that secure the top of the steering column opening cover to the instrument panel and remove the cover (Figure 4). b. Open the ashtray and the cup holder. STEERING COLUMN OPENING COVER LOWER SCREWS Figure 4 Steering Column Opening Cover c. Remove and save the retaining screw that secures the instrument panel center bezel to the instrument panel (Figure 5). d. Using a trim stick, disengage the retainer clips that secure the instrument panel center bezel to the instrument panel (Figure 5). INSTRUMENT PANEL CENTER BEZEL TRIM STICK RETAINING SCREW Figure 5 Instrument Panel Center Bezel Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) WIRE HARNESS CONNECTORS Page 12 INSTRUMENT PANEL CENTER BEZEL Figure 6 Center Bezel Wire Harness Connectors e. Disconnect the wire harness connectors and remove the instrument panel center bezel from the vehicle (Figure 6). If the vehicle is equipped with a cup holder, continue with Step 6. If the vehicle is equipped with a storage bin, continue with Step 7. NOTE: A storage bin replaces the cup holder in the instrument panel when the vehicle is equipped with a floor console and manual transmission. Safety Recall S43 Passenger Airbag Inflator Page 13 Service Procedure (Continued) 6. Use the following steps to remove the cup holder, if equipped: CUP HOLDER a. Remove the Airbag Control Module (ACM) cover using a trim stick or another suitable wide flat-bladed tool. Gently pry each side of the ACM cover away from the instrument panel at each side of the center bracket on the floor panel transmission tunnel far enough to disengage the two snap clip retainers from the instrument panel receptacles (Figure 7). ACM COVER Figure 7 Airbag Control Module (ACM) Cover b. Remove and save the two upper screws that secure the cup holder to the instrument panel (Figure 8). UPPER SCREWS CUP HOLDER Figure 8 Upper Cup Holder Screws Safety Recall S43 Passenger Airbag Inflator Page 14 Service Procedure (Continued) c. Remove and save the two lower screws that secure the cup holder to the instrument panel (Figure 9). CUP HOLDER d. Open the cup holder and cup holder door then remove and save the two center screws that secure the cup holder to the instrument panel (Figure 10). e. Remove the cup holder from the vehicle and continue with Step 8. LOWER SCREWS Figure 9 Lower Cup Holder Screws UPPER SCREW LOCATIONS CENTER SCREWS Figure 10 Center Cup Holder Screws CUP HOLDER DOOR Safety Recall S43 Passenger Airbag Inflator Page 15 Service Procedure (Continued) 7. Use the following steps to remove the storage bin, if equipped with a manual transmission. a. Remove the 4WD gear shift boot, if equipped. b. Remove the transmission gear shift lever extension, if equipped with a manual transmission. c. Using a trim stick, disengage the retaining tabs that secure the manual transmission gear shift boot or storage bin (depending on application) to the floor console and remove the boot or storage bin. d. Remove the three inserts from the floor console. e. Remove and save the three bolts that secure the floor console to the floor panel. f. Lift up the rear of the floor console to clear the gear shift lever, if equipped. g. Slide the floor console rearward and remove it from the instrument panel. h. Remove and save the four screws that secure the storage bin to the instrument panel and remove the storage bin. Safety Recall S43 Passenger Airbag Inflator Page 16 Service Procedure (Continued) 8. Use the following steps to remove the ash receiver: a. Open the ash receiver and apply force in a downward motion to disengage the locking tabs from the instrument panel. b. Roll the ash receiver further downward and remove it from the instrument panel. AIRBAG DOOR INSTRUMENT PANEL LOWER SUROUND Figure 11 Instrument Panel Lower Surround 9. Remove and save the twenty one screws that secure the instrument panel lower surround to the instrument panel and support (Figure 11 and 12). INSTRUMENT PANEL LOWER SUROUND 21 SCREW LOCATIONS Figure 12 - Instrument Panel Lower Surround Screw Locations Safety Recall S43 Passenger Airbag Inflator Page 17 Service Procedure (Continued) 10. Disconnect the wire harness connectors for the 12V power outlet and the glove box switch then remove the instrument panel lower surround. PASSENGER AIRBAG DOOR 11. Remove and save the screw that secures the mounting tab of the panel outlet housing to the upper glove box opening reinforcement (Figure 13). 12. Remove and save the six mounting screws that secure the inboard and lower flanges of the passenger airbag door to the instrument panel (Figure 14). MOUNTING TAB Figure 13 Panel Outlet Housing Mounting Tab 13. Reach through and above the glove box opening to access andPrAeSmSEoNGvEeRaAnIRdBAsGavDOeOR the two screws that secure the passenger airbag rear brackets to the upper glove box opening reinforcement (Figure XX). 14. Reach through and above the glove box opening to access and remove and save the two screws that secure the passenger airbag front brackets to the instrument panel structural support (Figure XX). 15. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper and outboard edges of the passenger airbag door away from the instrument panel far enough to disengage the seven snap features on the door from the receptacles in the instrument panel base trim (Figure XX). 16. Pull the passenger airbag housing and door unit straight back from the instrument panel far enough to access the instrument panel wire harness take out and connector for the airbag located on the inboard side of the airbag ShIXoMuOsUinNTgIN(GFSiCgRuErWeSXX). Figure 14 Passenger Airbag Door Mounting Screws Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) FRONT AIRBAG BRACKET SCREWS Page 18 REAR AIRBAG BRACKET SCREW LOCATIONS (SCREWS ARE NOT VISIBLE IN PICTURE) Figure 15 Passenger Airbag Bracket Screws 13. Reach through and above the glove box opening to access and remove the two screws that secure the passenger airbag rear brackets to the upper glove box opening reinforcement (Figure 15). 14. Reach through and above the glove box opening to access and remove the two screws that secure the passenger airbag front brackets to the instrument panel structural support (Figure 15). Safety Recall S43 Passenger Airbag Inflator Page 19 Service Procedure (Continued) 15. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper and outboard edges of the passenger airbag door away from the instrument panel far enough to disengage the seven snap features on the door from the receptacles in the instrument panel base trim (Figure 16). 16. Pull the passenger airbag housing and door assembly straight back from the instrument panel far enough to access the instrument panel wire harness take out and connector for the airbag located on the inboard side of the airbag assembly (Figure 16). INSTRUMENT PANEL RECEPTICLES PASSENGER AIRBAG HOUSING AND DOOR ASSEMBLY Figure 16 Passenger Airbag Housing and Door Unit Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) Page 20 AIRBAG CONNECTOR RED CPA LOCK Figure 17 Passenger Airbag Connector 17. Use the following steps to disconnect the passenger airbag pigtail wire harness connector from the instrument panel wire harness connector for the airbag. a. If equipped, slide the red Connector Position Assurance (CPA) lock on the connector toward the side of the connector (Figure 17). b. Depress the connector latch tab and pull the two halves of the connector straight away from each other. 18. Remove the passenger airbag and airbag door from the instrument panel as a unit. Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 19. Use the following procedure to retrofit the passenger side airbag assembly (2004 through 2005 DR and 2005 DH models only). a. Place the passenger airbag assembly on a soft surface to prevent damage. Page 21 HOUSING b. Disengage the wire harness jumper from the housing clips in two places (Figure 18). HOUSING CLIPS WIRE HARNESS JUMPER Figure 18 - Wire Harness Clips c. Disconnect the first inflator connector from the end of the inflator using pliers (Figure 19). INFLATOR CONNECTOR Figure 19 Inflator Connector Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) INFLATOR ASSEMBLY Page 22 HOUSING BRACKET THREE WAY INLINE CONNECTOR Figure 20 Yellow Three Way Connector d. Remove the yellow three way inline connector from the housing bracket (Figure 20). e. Disconnect the second inflator connector from the end of the inflator using pliers (Figure 21). f. Remove and discard the wire harness jumper (Figure 21). WIRE HARNESS JUMPER INFLATOR CONNECTOR Figure 21 Inflator Connector Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) AIRBAG MODULE CLIPS Page 23 AIRBAG COVER WINDOWS Figure 22 Airbag Cover Clips g. Disengage the airbag module clips from the airbag cover windows on all sides (Figure 22). h. Remove the airbag module from the airbag cover once the cover clips are disengaged. i. Remove and discard the six mounting nuts (Figure 23). MOUNTING NUTS Figure 23 Six Mounting Nuts Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) INFLATOR Page 24 CUSHION ERROR PROOFING TAB LOCATED ON THE TOP OF THE HOUSING ON CERTAIN 2004 MY VEHICLES INFLATOR KEYED END ERROR PROOFING TAB LOCATED ON THE BOTTOM OF THE HOUSING Figure 24 Inflator to Cushion j. Slide the cushion out of the housing and remove the inflator. NOTE: Use care as to not disturb the cushion fold. k. Install the new inflator to the cushion noting keyed end alignment (Figure 24). NOTE: Ensure proper inflator fit. Note error proofing tab when reassembling to cushion (Figure 24). NOTE: Certain 2004 model year vehicles have the error proofing tab on the top of the housing as shown (Figure 24). Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) Page 25 l. Install the cushion/inflator assembly into housing while feeding the wire harness jumper through the housing as shown. Ensure cushion fold is not disturbed (Figure 25). NOTE: Ensure proper inflator assembly fit. Note error proofing tab when reassembling to cushion (Figure 26). CUSHION/INFLATOR ASSEMBLY HOUSING WIRE HARNESS JUMPER Figure 25 Cushion/Inflator Assembly ERROR PROOFING TAB m. Install the six new mounting nuts and tighten to 88 in. lbs. (10 N·m) (Figure 26). MOUNTING NUTS Figure 26 Mounting Nuts Safety Recall S43 Passenger Airbag Inflator Page 26 Service Procedure (Continued) n. Connect the yellow inflator wire connector (Figure 27). NOTE: The yellow inflator wire connectors are oriented in opposite directions depending on the location of the error proofing tab (Figure 27). o. Connect the yellow three way inline connector to the mounting points on the housing (Figure 27). WITH ERROR PROOFING TAB LOCATED ON THE TOP OF THE HOUSING THREE WAY YELLOW CONNECTOR WITH ERROR PROOFING TAB LOCATED ON THE BOTTOM OF THE HOUSING INFLATOR CONNECTOR WIRE DRESSED TOWARD THE THREE WAY YELLOW CONNECTOR INFLATOR CONNECTOR WIRE DRESSED AWAY FROM THE THREE WAY YELLOW CONNECTOR Figure 27 Inflator Wire Connector Safety Recall S43 Passenger Airbag Inflator Page 27 Service Procedure (Continued) NOTE: The wire harness jumper routing is different depending on the location of the error proofing tab (Figure 28). p. Route the wire harness jumper on the housing (Figure 28). For vehicles using optional inflator kit number CBXZS431AB, clip the wire harness jumper to the housing in two places (Figure 28). For vehicles using optional inflator kit number CBXZS431AA with the error proofing tab located on the top of the housing, route the wire harness jumper to the housing as shown and tape in two places as shown (Figure 28). NOTE: Use tape part number 68303542AB or equivalent. One 68303542AB patch can be cut into two pieces approximately 1.5 x 4 inches (Figure 28). JUMPER HARNESS ROUTING FOR INFLATOR KIT CBXZS431AB JUMPER HARNESS ROUTING FOR INFLATOR KIT CBXZS431AA WITH ERROR PROOFING TAB LOCATED ON THE TOP OF THE HOUSING ROUTE THE JUMPER HARTNESS BETWEEN THE HOUSING STUDS AND THE INFLATOR AS SHOWN CLIP JUMPER HARNESS IN TWO PLACES SECURE THE JUMPER HARNESS WITH TWO 1.5 X 4 INCH PIECES OF TAPE IN TWO PLACES Figure 28 Wire Jumper Routing Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) q. Install the airbag cover to the airbag module ensuring all clips are fully engaged in the windows on both sides (Figure 29). Page 28 WARNING: To avoid personal injury or death, the passenger ENSURE ALL CLIPS AND WINDOWS ARE FULLY ENGAGED ON BOTH SIDES airbag door must never be painted. Replacement Figure 29 Airbag Cover and Airbag Module 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. WARNING: To avoid personal injury or death, the trim bezel on the lower edge of the passenger airbag door on SRT-10 models must never be removed or transferred to another passenger airbag door. Replacement passenger airbag units are serviced with doors that include a replacement trim bezel. Failure to observe this warning could result in trim bezel separation and occupant injuries upon airbag deployment. WARNING: To avoid personal injury or death, 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. Safety Recall S43 Passenger Airbag Inflator Page 29 Service Procedure (Continued) 20. Carefully position the passenger airbag assembly to the instrument panel as a unit. 21. Connect the passenger airbag pigtail wire connector to the instrument panel wire harness connector for the airbag. This connector is secured to the inboard side of the airbag housing. Be certain that the latch on the connector and the red Connector Position Assurance (CPA) lock, if equipped, are each fully engaged (Figure 17). 22. Position the passenger airbag housing and door unit into the instrument panel. 23. Using hand pressure, press firmly and evenly over each of the seven snap features on the upper and outboard edges of the passenger airbag door until they snap into their receptacles in the instrument panel base trim. 24. Reach through and above the glove box opening to install and tighten the two screws that secure the passenger airbag front brackets to the instrument panel structural support. Tighten the screws to 55 in. lbs. (6 N·m) (Figure 15). 25. Reach through and above the glove box opening to install and tighten the two screws that secure the passenger airbag rear brackets to the upper glove box opening reinforcement. Tighten the screws to 55 in. lbs. (6 N·m) (Figure 15). 26. Install and tighten the six mounting screws that secure the inboard and lower flanges of the passenger airbag door to the instrument panel. Tighten the screws to 20 in. lbs. (2 N·m) (Figure 14). 27. Install and tighten the screw that secures the mounting tab of the panel outlet housing to the upper glove box opening reinforcement. Tighten the screw to 20 in. lbs. (2 N·m) (Figure 13). 28. Position the instrument panel lower surround to the instrument panel and connect the wire harness connectors for the 12V power outlet and the glove box switch. Safety Recall S43 Passenger Airbag Inflator Page 30 Service Procedure (Continued) 29. Install the instrument panel lower surround onto the instrument panel and install the twenty one screws. Tighten the screws to 20 in. lbs. (2 N·m) (Figures 11 and 12). 30. Install the cup holder or storage bin, if equipped (Figures 8, 9 and 10). 31. Install the center bezel. a. Connect all electrical connectors (Figure 6). b. Position and gently clip into place. c. Install one screw on right side (Figure 5). 32. Install the ACM cover (Figure 7). 33. Install the ash receiver. 34. Install the steering column opening cover (Figure 4). 35. Install the glove box (Figure 3). 36. Install the right side cowl trim panel (Figure 2). 37. Install the right instrument panel side cover (Figure 1). 38. Do not connect the battery negative cable at this time. Continue with Section L. Supplemental Restraint System (SRS) Verification Test. Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) Page 31 C. Replace Passenger Airbag Inflator: 2006 - 2010DR, DH, DC, DM, D1 WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. At no time should any source of electricity be permitted near the inflator on the back of a non-deployed airbag or seat belt tensioner. When carrying a non-deployed airbag, the trim cover or airbag cushion side of the unit should be pointed away from the body to minimize injury in the event of an accidental deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. Safety Recall S43 Passenger Airbag Inflator Page 32 Service Procedure (Continued) 2. Using a trim stick C-4755 or equivalent, disengage the eight retainer clips that secure the rear of the instrument panel top cover to the top of the instrument panel (Figure 30). 3. Pull the instrument panel top cover rearward to release the five retainer clips that secure the front of the instrument panel top cover to the top of the instrument panel and remove the cover. INSTRUMENT PANEL TOP COVER RETAINER CLIPS Figure 30 Instrument Panel Top Cover Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 4. Remove the glove box from the instrument panel. Page 33 5. Disconnect the antenna cable and electrical connector, if equipped (Figure 31). 6. Remove the three mounting fasteners securing the receiver to the bracket if equipped (Figure 31). 7. Remove the satellite receiver, if equipped (Figure 31). ANTENNA CABLE PASSENGER AIRBAG MODULE FASTENERS SATELITE RECEIVER ELECTRICAL CONNECTOR Figure 31 Satelite Receiver (if equipped) (View through glove box opening) Safety Recall S43 Passenger Airbag Inflator Page 34 Service Procedure (Continued) 8. Reach up into the instrument panel between the upper glove box opening reinforcement and the cross car beam to access and disconnect the instrument panel wire electrical connector from the airbag inflator pigtail wire connector on the right side of the instrument panel airbag support bracket (Figure 32). To disconnect the connector: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the connector. b. Depress the connector latch tab and pull the two halves of the connector straight away from each other. 9. Remove and save the two screws that secure the passenger airbag lower bracket to the instrument panel airbag support bracket (Figure 32). 10. Disengage the airbag inflator pigtail wire connector from the instrument panel airbag support bracket (Figure 32). SCREW LOCATIONS ELECTRICAL CONNECTOR INSTRUMENT PANEL AIRBAG SUPPORT BRACKET Figure 32 Airbag Module (View through glove box opening) Safety Recall S43 Passenger Airbag Inflator Page 35 Service Procedure (Continued) 11. Using a trim stick or another suitable wide flat-bladed tool, gently pry the airbag door forward, then the outboard edges of the passenger airbag door away from the instrument panel far enough to disengage the snap features on the door from the receptacles in the instrument panel base trim (Figure 33). 12. Remove the passenger airbag and airbag door from the instrument panel as a unit. PASSENGER AIRBAG DOOR SNAP FEATURES Figure 33 Passenger Airbag Removal Safety Recall S43 Passenger Airbag Inflator Page 36 Service Procedure (Continued) 13. Use the following procedure to retrofit the passenger side airbag assembly. a. Place the passenger airbag assembly on a soft surface to prevent damage using the foam block provided with the inflator kit. WIRE HARNESS JUMPER b. Disconnect the single yellow wire inflator connector from the end of the inflator using pliers (Figure 34). INFLATOR CONNECTOR Figure 34 Inflator Connector WIRE HARNESS JUMPER c. Disengage the wire harness jumper from the housing clips in three places (Figure 35). HOUSING CLIPS Figure 35 Wire Harness Jumper Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) STOPPER PLATE Page 37 MOUNTING NUTS Figure 36 Mounting Nuts and Stopper Plate d. Remove and discard the four mounting nuts and remove and save the stopper plate from the passenger airbag module (Figure 36). INFLATOR e. Slide the inflator out of the passenger airbag module (Figure 37). PASSENGER AIRBAG MODULE Figure 37 Inflator Removal Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) Page 38 f. Slide the NEW inflator into the passenger airbag module housing. The keyed end is inserted first; therefore the white stripe on the NEW inflator will be located at the open end (Figure 38). NOTE: The inflator is keyed to fit into the housing (Figure 38). INFLATOR WHITE STRIPE ON NEW INFLATOR GOES TO OPEN END OF HOUSING KEYED FIT PASSENGER AIRBAG MODULE HOUSING Figure 38 Passenger Inflator Installation Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) g. Install the stopper plate to the airbag module (Figure 36). Page 39 h. Install the four NEW mounting nuts to the airbag module and tighten to 53 in. lbs. (6 N·m) (Figure 36). i. Connect the single yellow wire inflator connector to the end of the inflator after removing the protective tape from the end of the inflator (Figure 34). j. Engage the wire harness jumper under the housing clips in three places (Figure 35). k. Retrofit is complete. WARNING: To avoid personal injury or death, 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. WARNING: To avoid personal injury or death, 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. Safety Recall S43 Passenger Airbag Inflator Page 40 Service Procedure (Continued) 14. Carefully position the passenger airbag and airbag door through the opening in the top of the instrument panel. Be certain that the rear edge of the passenger airbag lower bracket is engaged in the hook formation of the instrument panel airbag support bracket, and the anti-rotation tabs on either side of the hook are engaged in the two holes in the airbag lower bracket. 15. Install and tighten the two screws that secure the passenger airbag lower bracket to the instrument panel airbag support bracket. Tighten the screws to 55 in. lbs. (6 N·m). 16. Connect the airbag inflator pigtail wire connector onto the side of the instrument panel airbag support bracket. 17. Connect the instrument panel wire harness connector to the passenger airbag pigtail wire connector on the right side of the airbag lower mounting bracket. Be certain that the latch on the connector and the red Connector Position Assurance (CPA) lock are each fully engaged. 18. Engage the interlocking tabs on the rear edge of the passenger airbag door into the corresponding slots in the instrument panel base trim. 19. Using hand pressure, push down on the passenger airbag door over each snap feature on both sides and the forward edge of the airbag door until it snaps into its receptacle in the instrument panel base trim. Safety Recall S43 Passenger Airbag Inflator Page 41 Service Procedure (Continued) 20. Position satellite receiver and install mounting fasteners, if equipped. Tighten fasteners securely. 21. Connect antenna cable and electrical harness connector to receiver, if equipped. 22. Install the glove box into the instrument panel. 23. Install the top cover onto the top of the instrument panel. 24. 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. 25. Do not connect the battery negative cable at this time. Continue with Section L. Supplemental Restraint System (SRS) Verification Test. Safety Recall S43 Passenger Airbag Inflator Page 42 Service Procedure (Continued) D. Replace Passenger Airbag Inflator: HB, HG WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. At no time should any source of electricity be permitted near the inflator on the back of a non-deployed airbag or seat belt tensioner. When carrying a non-deployed airbag, the trim cover or airbag cushion side of the unit should be pointed away from the body to minimize injury in the event of an accidental deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. Safety Recall S43 Passenger Airbag Inflator Page 43 Service Procedure (Continued) 2. Use the following steps to remove the defroster grille from the top of the instrument panel. a. Using a trim stick, remove the driver side A-pillar trim. b. Open the trim covers in the passenger side A-pillar grab handle and remove and save the two bolts (Figure 39). c. Remove the passenger side A-pillar trim. d. Using a trim stick, remove the instrument panel defroster grille (Figure 40). e. Disconnect the sun sensor electrical connector from the center of the instrument panel defroster grille. A-PILLAR TRIM BOLTS TRIM COVERS Figure 39 Passenger Side A-Pillar Trim INSTRUMENT PANEL DEFROSTER GRILLE TRIM STICK Figure 40 Instrument Panel Defroster Grille Safety Recall S43 Passenger Airbag Inflator Page 44 Service Procedure (Continued) 3. Use the following steps to remove the glove box. PASSENGER AIRBAG BRACKET a. Release the two glove box stops and lower the glove box downward past the stops. b. Disengage the glove box hinges from the instrument panel and remove the glove box. 4. Reach up into the instrument panel glove box opening and through the access holes to remove and save the two ACCESS HOLES MOUNTING BOLTS mounting bolts that secure the passenger airbag bracket to the Figure 41 Airbag Mounting Screws and Bracket instrument panel support structure (Figure 41) (Figure 42). ACCESS HOLE LOCATIONS Figure 42 - Passenger Airbag Mounting Bolt Access Holes Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 5. Using a trim stick or another suitable wide flat bladed tool, gently pry the forward and side edges of the passenger airbag door away from the top of the instrument panel far enough to disengage the snap features on the airbag door from the receptacles in the instrument panel top pad (Figure 43). PASSENGER AIRBAG DOOR Page 45 SNAP FEATURES INSTRUMENT PANEL 6. Pull the passenger airbag Figure 43 Passenger Airbag Door out of the instrument panel far enough to access and disconnect the instrument panel wire harness connector from the passenger airbag inflator pigtail connector on the LATCH TAB right side of the passenger airbag mounting bracket. a. Slide the red Connector Position Assurance (CPA) lock on the connector toward the side of the connector (Figure 44). b. Depress the connector latch tab and pull the two halves of the connector straight away from each other. CPA LOCK Figure 44 Airbag Inflator Pigtail Connector Safety Recall S43 Passenger Airbag Inflator Page 46 Service Procedure (Continued) 7. Remove the passenger airbag and airbag door from the instrument panel as a unit. 8. Use the following procedure to retrofit the passenger airbag assembly. a. Place the passenger airbag assembly on a soft surface to prevent damage using the foam block provided with the inflator kit. b. Disengage the wire harness jumper from the housing clips in two places (Figure 45). c. Disconnect the single yellow wire inflator connector from the end of the inflator (Figure 45). SINGLE YELLOW WIRE INFLATOR CONNECTOR WIRE HARNESS JUMPER INFLATOR Figure 45 Passenger Airbag Assembly HOUSING CLIPS Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) HOUSING BRACKET Page 47 WIRE HARNESS JUMPER YELLOW THREE WAY INLINE CONNECTOR Figure 46 Inflator Connectors d. Release the yellow three way inline connector from the housing bracket (Figure 46). Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) WIRE HARNESS JUMPER Page 48 STOPPER PLATE FOUR MOUNTING NUTS Figure 47 Mounting Nuts and Stopper Plate e. Remove and discard the four mounting nuts and remove and save the stopper plate from the housing (Figure 47) STOPPER PLATE INFLATOR f. Slide the inflator out of the housing (Figure 48). HOUSING Figure 48 Inflator Removal Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) g. Slide the new inflator into the housing (Figure 49). NOTE: The inflator is keyed to fit into the housing. Page 49 INFLATOR KEYED TO HOUSING INFLATOR Figure 49 Inflator Installation HOUSING Safety Recall S43 Passenger Airbag Inflator Page 50 Service Procedure (Continued) h. Install the stopper plate to the passenger airbag module (Figure 47). i. Install the four new mounting nuts to the passenger airbag module and tighten to 53 in. lbs. (6 N·m) (Figure 47). j. Install the yellow three way inline connector to the housing bracket (Figure 46). k. Connect the single yellow wire inflator connector to the end of the inflator after removing the protective tape from the end of the inflator (Figure 45). l. Engage the wire jumper to the housing clips in two places (Figure 45). WARNING: To avoid personal injury or death, 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. WARNING: To avoid personal injury or death, 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. 9. Carefully position the passenger airbag and airbag door to the instrument panel as a unit. 10. Connect the instrument panel wire harness connector for the airbag to the passenger airbag inflator pigtail wire connector on the right side of the airbag mounting bracket. Be certain that the latch on the connector and the red Connector Position Assurance (CPA) lock are each fully engaged (Figure 44). Safety Recall S43 Passenger Airbag Inflator Page 51 Service Procedure (Continued) 11. Carefully lower the passenger airbag unit into the instrument panel, being certain that the airbag mounting bracket is properly positioned to the instrument panel support structure. 12. Reach into the glove box opening to install and tighten the two mounting bolts that secure the passenger airbag mounting bracket to the instrument panel support structure through the access holes. Tighten the mounting bolts to 55 in. lbs. (6 N·m). 13. Align and insert the rearward tabs of the passenger airbag door into the slots in the instrument panel top pad. 14. Using hand pressure, push down on the passenger airbag door over each snap feature until it snaps into its receptacle in the instrument panel base trim. 15. Install the glove box into the instrument panel. 16. Connect the sun sensor connector to the sun sensor. 17. Install the defroster grille onto the top of the instrument panel. 18. Install the passenger side A-pillar trim. 19. Install the passenger side grab handle. 20. Install the driver's side A-pillar trim. 21. Do not connect the battery negative cable at this time. Continue with Section L. Supplemental Restraint System (SRS) Verification Test. Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) E. Replace Passenger Airbag Inflator: 2005-2010 LX Page 52 WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. At no time should any source of electricity be permitted near the inflator on the back of a non-deployed airbag or seat belt tensioner. When carrying a non-deployed airbag, the trim cover or airbag cushion side of the unit should be pointed away from the body to minimize injury in the event of an accidental deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. Safety Recall S43 Passenger Airbag Inflator Page 53 Service Procedure (Continued) 2. Use the following steps to remove the right side instrument panel silencer pad. a. Remove and save the two push-pins that secure the instrument panel silencer to the instrument panel (Figure 50). b. Pull the right side silencer pad rearward to disengage it from the brackets located near the dash panel. c. Remove the right side silencer pad from the vehicle. 3. Use the following steps to remove the glove box. a. Remove the check strap from the right side of the glove box (Figure 51). b. Release the two glove box stops and lower the glove box downward past the stops. c. Disengage the glove box hinges from the instrument panel and remove the glove box. INSTRUMENT PANEL SILENCER PAD PUSH-PINS Figure 50 Instrument Panel Silencer GLOVE BOX DOOR CHECK STRAP Figure 51 Check Strap Safety Recall S43 Passenger Airbag Inflator Page 54 Service Procedure (Continued) 4. Remove and save the three mounting screws to the inner glove box shield, if equipped (Figure 52). MOUNTING SCREWS GLOVE BOX INNER SHIELD Figure 52 Inner Glove Box Shield Safety Recall S43 Passenger Airbag Inflator Page 55 Service Procedure (Continued) 5. Remove and save the two inboard mounting bolts to the passenger airbag assembly just below the distribution duct and to the left of the distribution housing (Figure 53). 6. Remove and save the two outboard mounting bolts to the passenger airbag assembly just below the distribution duct (Figure 53). 7. Remove and save the two passenger airbag assembly mounting bolts to the crosscar beam (Figure 53). PASSENGER AIRBAG ASSEMBLY CROSSCAR BEAM INBOARD MOUNTING BOLTS PASSENGER AIRBAG MOUNTING BOLTS OUTBOARD MOUNTING BOLTS Figure 53 Passenger Airbag Mounting Locations Safety Recall S43 Passenger Airbag Inflator Page 56 Service Procedure (Continued) 8. Pull the passenger airbag assembly out of the instrument panel far enough to access and disconnect the instrument panel wire harness connector from the wire harness jumper connector on the right side of the airbag mounting bracket. CPA LOCK WIRE HARNESS JUMPER CONNECTOR a. Slide the red Connector Position Assurance (CPA) lock on the connector toward the side of the connector (Figure 54). LATCH TAB b. Depress the connector latch tab and pull the two halves of the Figure 54 Wire Harness Jumper connector straight away from each other. 9. Remove the passenger airbag from the instrument panel as a unit. 10. Use the following procedure to retrofit the passenger airbag assembly. WIRE HARNESS JUMPER a. Place the passenger airbag assembly on a soft surface to prevent damage. b. Disengage the wire harness jumper from the housing clips in two places (Figure 55). c. Disconnect the single yellow wire inflator connector from the end of the inflator using pliers (Figure 55). INFLATOR CONNECTOR HOUSING CLIPS Figure 55 Wire Harness Jumper Safety Recall S43 Passenger Airbag Inflator Page 57 Service Procedure (Continued) d. Remove the yellow three way wire harness jumper connector from the housing bracket (Figure 56). FOUR MOUNTING NUTS e. Remove and discard the four mounting nuts, then remove the stopper plate from the passenger airbag module (Figure 56). f. Slide the inflator out of the passenger airbag module (Figure 57). g. Slide the new inflator into the passenger airbag module (Figure 57). WIRE HARNESS JUMPER CONNECTOR STOPPER PLATE Figure 56 Airbag Module NOTE: The inflator is keyed to fit into the housing (Figure 57). INFLATOR PASSENGER AIRBAG MODULE KEYED FIT Figure 57 Passenger Airbag Inflator to Housing Safety Recall S43 Passenger Airbag Inflator Page 58 Service Procedure (Continued) h. Install the stopper plate to the passenger airbag module (Figure 56). i. Install the four new mounting nuts to the passenger airbag module and tighten to 53 in. lbs. (6 N·m) (Figure 56). j. Install the yellow three way wire harness jumper connector to the retaining clip (Figure 56). k. Connect the single yellow inflator connector to the end of the passenger airbag inflator (Figure 55). l. Engage the wire jumper to the housing in two places (Figure 55). WARNING: To avoid personal injury or death, 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. WARNING: To avoid personal injury or death, 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. Safety Recall S43 Passenger Airbag Inflator Page 59 Service Procedure (Continued) 11. Place the passenger airbag into the cavity of the passenger airbag door. 12. Connect the instrument panel wire harness connector for the airbag to the passenger airbag inflator pigtail wire connector on the right side of the airbag mounting bracket. Be certain that the latch on the connector and the red Connector Position Assurance (CPA) lock are each fully engaged . 13. Install the two passenger airbag mounting bolts to the crosscar beam. Torque bolts to 103 in. lbs. (11.6 N·m). 14. Install the two inboard mounting bolts to the passenger airbag just below the distribution duct and to the left of the distribution housing. Torque the screws to 25 in. lbs. (2.8 N·m). 15. Install the two outboard mounting bolts to the passenger airbag just below the distribution duct. Torque the screws to 25 in. lbs. (2.8 N·m). 16. Install the inner glove box silencer shield using the three mounting screws. 17. Install the glove box into the instrument panel. 18. Install the right side instrument panel silencer pad. 19. Do not connect the battery negative cable at this time. Continue with Section L. Supplemental Restraint System (SRS) Verification Test. Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) Page 60 F. Replace Passenger Airbag Inflator: 2011-2012 LX, LD WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. At no time should any source of electricity be permitted near the inflator on the back of a non-deployed airbag or seat belt tensioner. When carrying a non-deployed airbag, the trim cover or airbag cushion side of the unit should be pointed away from the body to minimize injury in the event of an accidental deployment. 1. Disconnect and isolate the battery negative cable then remove the two Airbag Module fuses from the Power Distribution Center (PDC), see the PDC cover for the fuse locations. Wait two minutes for the system capacitor to discharge before further service (Figure 58). BATTERY NEGATIVE WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. PDC Figure 58 Battery Negative Safety Recall S43 Passenger Airbag Inflator Page 61 Service Procedure (Continued) 2. Use the following steps to remove the glove box from the instrument panel. LED HARNESS CONNECTOR INSTRUMENT PANEL SILENCER a. Remove the right side instrument panel end cap. b. Remove the right side sill plate (Figure 59). c. Remove the three pushpins that secure the instrument panel silencer to the instrument panel (Figure 59). d. Disconnect the harness connector(s) and remove the right side instrument panel silencer (Figure 59). SILL PLATE Figure 59 Instrument Panel Silencer e. Open the glove box door. f. Remove the two side screws from the glove box compartment (Figure 60). SIDE SCREWS g. Remove the six screws from the glove box compartment (Figure 60). h. Disconnect the wiring harness connectors and remove the glove box compartment. SCREWS Figure 60 Glove Box Compartment Safety Recall S43 Passenger Airbag Inflator Page 62 Service Procedure (Continued) 3. Disconnect all of the electrical connectors from the Body Control Module (BCM) receptacles. 4. Remove and save the two fasteners at the bottom of the BCM (Figure 61). 5. Loosen the top fastener. This fastener only has to be loosened to allow removal of the BCM. It does not need to be completely removed in order to remove the module (Figure 61). 6. Pull the module away from the side bulk head and down and remove and save the module. TOP FASTENER LOCATION BCM BOTTOM FASTENERS Figure 61 Body Control Module Safety Recall S43 Passenger Airbag Inflator Page 63 Service Procedure (Continued) 7. Disconnect the electrical connector from the HVAC module, located on the air inlet housing (Figure 62). NOTE: It is not necessary to fully remove the two front HVAC module retaining screws. The front HVAC module retaining tabs are slotted to aid in module service. 8. Release the wire harness connectors from the bracket (Figure 62). 9. Loosen the two screws that secure the front of the HVAC module to the air inlet housing (Figure 62). 10. Remove the one screw that secures the rear of the HVAC module to the air inlet housing (Figure 62). 11. Slide the HVAC module rearward to disengage the module from the two front retaining screws and remove the module. HVAC MODULE ELECTRICAL CONNECTOR FRONT SCREW LOCATIONS REAR SCREW BRACKET WIRE HARNESS CONNECTORS Figure 62 HVAC Module Safety Recall S43 Passenger Airbag Inflator Page 64 Service Procedure (Continued) 12. Reach through the instrument panel glove box opening to access and disconnect the two instrument panel electrical connectors from the two Passenger Airbag (PAB) initiators, one at each side of the PAB inflator canister (Figure 63). 13. Reach through the instrument panel glove box opening to access and remove and save the two screws that secure the PAB lower bracket to the instrument panel structural support (Figure 63). 14. Remove and save the four screws that secure the two upper PAB mounting brackets to the U-nuts on each side of the PAB retainer or chute on the underside of the instrument panel cover (Figure 63). SCREWS SCREWS ELECTRICAL CONNECTOR INSTRUMENT PANEL STRUCTURAL SUPPORT SCREWS ELECTRICAL CONNECTOR PASSENGER AIRBAG Figure 63 Passenger Airbag Safety Recall S43 Passenger Airbag Inflator Page 65 Service Procedure (Continued) 15. Remove the PAB from the instrument panel cover. 16. Use the following procedure to retrofit the passenger side airbag assembly. a. Place the passenger airbag assembly on a soft surface to prevent damage. INFLATOR MOUNTING NUTS b. Remove and discard the four inflator mounting nuts (Figure 64). Figure 64 Mounting Nuts STOPPER PLATE c. Remove and save stopper plate from housing (Figure 65). Figure 65 Stopper Plate Safety Recall S43 Passenger Airbag Inflator Page 66 Service Procedure (Continued) d. Slide the inflator out of the passenger airbag module housing (Figure 66). IMPORTANT: Do NOT discard old inflator. Follow the parts return policy and instructions at the beginning of this document. AIRBAG MODULE HOUSING INFLATOR SLIDE THE INFLATOR OUT OF HOUSING IN THIS DIRECTION Figure 66 Remove Airbag Inflator Safety Recall S43 Passenger Airbag Inflator Page 67 Service Procedure (Continued) e. Slide the NEW inflator into the passenger airbag module housing. The keyed end is inserted first; therefore the white stripe on the NEW inflator will be located at the open end (Figure 67). INFLATOR END KEYED TO AIRBAG MODULE HOUSING NOTE: The inflator's key MUST line up with the housing's key. f. Position the stopper plate to the airbag housing (Figure 65). g. Install the four NEW mounting nuts to the airbag housing and tighten to 53 in. lbs. (6 N·m) (Figure 64). WHITE STRIPE ON NEW INFLATOR GOES TO OPEN END OF HOUSING AIRBAG MODULE HOUSING Figure 67 Install New Inflator to Housing h. Passenger airbag retrofit is complete (Figure 68). WHITE STRIPE INDICATES NEW INFLATOR IS INSTALLED Figure 68 Retrofit Complete Safety Recall S43 Passenger Airbag Inflator Page 68 Service Procedure (Continued) WARNING: To avoid personal injury or death, 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. WARNING: To avoid personal injury or death, 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. 17. Carefully position the PAB housing into the PAB retainer receptacle. 18. Install and tighten the four screws that secure the PAB upper mounting brackets to the U-nuts on the retainer. Tighten the screws to 27 in. lbs. (3 N·m). 19. Reach through the instrument panel glove box opening to install and tighten the two screws that secure the PAB lower bracket to the instrument panel structural support. Tighten the screws to 103 in. lbs. (12 N·m). 20. Reach through the instrument panel glove box opening to access and connect the two instrument panel wire harness connectors to the two PAB initiators, one at each side of the PAB inflator canister. Be certain the connectors are each fully engaged and locked. 21. Position the HVAC module to the air inlet housing and engage the module to the two front retaining screws. 22. Loosely install the screw that secures the rear of the HVAC module to the air inlet housing. 23. Tighten all the screws that secure the HVAC module to the air inlet housing to 2 N·m (17 in. lbs.). 24. Connect the wire harness connector to the HVAC module. Safety Recall S43 Passenger Airbag Inflator Page 69 Service Procedure (Continued) 25. Secure the wire harness connectors to the bracket. 26. Slide the BCM into position so that the top mounting tab on the BCM is properly aligned to the mounting weld stud and the lower mounting tabs slide into their respective mounting weld studs. 27. Install the two lower fasteners, and tighten securely. 28. Tighten the upper fastener securely. 29. Connect the electrical connectors to the BCM receptacles. 30. Connect the electrical connectors to the glove box. 31. Install the glove box into the instrument panel. Tighten all eight fasteners securely. 32. Connect the electrical connectors to the instrument panel silencer. 33. Secure the instrument panel silencer to the instrument panel. 34. Install the right side sill plate. 35. Install the right side instrument panel end cap. 36. Do not connect the battery negative cable at this time. Continue with Section L. Supplemental Restraint System (SRS) Verification Test. Safety Recall S43 Passenger Airbag Inflator Page 70 Service Procedure (Continued) G. Replace Passenger Airbag Inflator: 2008-2012 LC WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. At no time should any source of electricity be permitted near the inflator on the back of a non-deployed airbag or seat belt tensioner. When carrying a non-deployed airbag, the trim cover or airbag cushion side of the unit should be pointed away from the body to minimize injury in the event of an accidental deployment. 1. Position the front wheels straight ahead. 2. Fully extend the telescoping column. 3. Apply the parking brake. 4. Turn the ignition switch to the On position, apply the service brakes and place the gear selector lever into the Neutral position. 5. Turn the ignition switch to the Off position and release the service brakes. 6. Disconnect and isolate the battery negative cable then remove the two Airbag Module fuses from the Power Distribution Center (PDC), see the PDC cover for the fuse locations. Wait two minutes for the system capacitor to discharge before further service. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 7. Using a small flat bladed tool or equivalent, separate the retaining ring and slide down the shifter shaft (Figure 69). SHIFTER KNOB 8. Pull up on the shifter knob and remove from the shifter shaft (Figure 69). Page 71 SHIFTER BEZEL 9. Remove the shifter bezel and/or shifter boot (Figure 69). 10. Open the lid of the console rear bin and remove the mat from the rear bin. 11. Using a trim stick, unsnap the console bezel from the console (Figure 70). RETAINING RING Figure 69 Shifter Knob 12. Disconnect the electrical connectors and remove the bezel. CONSOLE BEZEL Figure 70 - Console Bezel Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 13. Remove the four fasteners from the rear bin that secure the console to the floor panel transmission tunnel (Figure 71). Page 72 14. Remove the two fasteners that secure the front of the console to the instrument panel (Figure 71). FRONT CONSOLE FASTENERS 15. Slide the console rearward and disconnect the electrical connectors. FASTENS IN REAR CONSOLE BIN 16. Remove the floor console from the vehicle. Figure 71 Floor Console Safety Recall S43 Passenger Airbag Inflator Page 73 Service Procedure (Continued) 17. Using a trim stick C-4755 or equivalent, remove the right and left side lower A-pillar trim (Figure 72). 18. Using a trim stick C-4755 or equivalent, release the right and left side upper A-pillar trim then release the airbag tether and remove the trim (Figure 72). 19. Using a trim stick C-4755 or equivalent, remove the right and left side scuff panel trim (Figure 72). 20. Using a trim stick C-4755 or equivalent, remove the right and left side kick panel trim (Figure 72). UPPER A-PILLAR TRIM LOWER A-PILLAR TRIM SCUFF PANEL TRIM KICK PANEL TRIM Figure 72 Door Opening Trim (Right Side Shown, Left Side Similar) Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) Page 74 21. Remove the two pushpins that secure the passenger side instrument panel silencer to the instrument panel bracket (Figure 73). SILENCER 22. Pull the passenger side instrument panel silencer rearward to disengage it from the brackets located near the dash panel. 23. Remove the passenger side instrument panel silencer from the vehicle. PUSHPINS 24. Open the glove box bin. Figure 73 Passenger Side Silencer 25. Remove the support strap and retainer assembly from the outboard end of the bin (Figure 74). GLOVE BOX BIN SUPPORT STRAP AND RETAINER LOCATION 26. Push in on both sides of glove box bin to disengage the glove box stops and lower the bin. 27. Pivot the glove box bin downward and disengage the glove box hinge hooks from the instrument panel hinge brackets located at each end of the bin (Figure 74). 28. Remove the glove box bin from the vehicle. Figure 74 Glove Box Bin Safety Recall S43 Passenger Airbag Inflator Page 75 Service Procedure (Continued) 29. Disconnect the instrument panel wire harness connector from the PAB pigtail wire connector (Figure 75). 30. Remove the two screws that secure the PAB lower bracket to the instrument panel structural support (Figure 75). 31. Remove the four screws that secure the PAB upper brackets to the sides of the PAB retainer or chute on the underside of the instrument panel cover (Figure 75). 32. Allow the PAB housing, inflator and cushion as a unit to remain on the underside of the instrument panel cover until Step 40. Do not pry or force the unit from the vehicle at this time. UPPER BRACKET SCREWS WIRE HARNESS CONNECTOR LOWER BRACKET SCREWS STRUCTURAL SUPPORT Figure 75 PAB Housing, Inflator and Cushion to be Removed a Unit (View through Glove Box Opening) Safety Recall S43 Passenger Airbag Inflator Page 76 Service Procedure (Continued) 33. Remove the defroster grille to access the instrument panel top retaining bolts then remove and save the two M8 bolts and two M6 screws (Figure 76). WARNING: Metal retaining clips may remain in the instrument panel. Remove the clips from the panel and install them on the defroster grille before grille installation. CAUTION: Use extreme care to avoid damage to the windshield when removing the top four fasteners. M8 BOLT LOCATIONS M6 SCREW LOCATIONS Figure 76 Top Instrument Panel Fasteners Safety Recall S43 Passenger Airbag Inflator Page 77 Service Procedure (Continued) 34. Remove and save the instrument panel side support bolts (Figure 77). 35. Remove and save the bolts that secure the bottom of the instrument panel (Figure 77). CAUTION: Place a protective cover over the shifter assembly during the next step to avoid damage to the instrument panel center stack. 36. With the help of an assistant lift the instrument panel assembly up and off of the supports approximately 2-3 inches then pivot the right side of the instrument panel assembly rearward enough to gain clearance needed to remove the PAB. CAUTION: To avoid damage to the PAB unit, be prepared to catch the PAB unit when pivoting the instrument panel assembly during step 36. 37. Remove the PAB housing, inflator and cushion as a unit. SIDE BOLTS BOTTOM BOLTS SIDE BOLTS Figure 77 Side and Bottom Retaining Bolts Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 38. Use the following procedure to retrofit the passenger side airbag assembly. a. Place the passenger airbag assembly on a soft surface to prevent damage. Page 78 b. Use pliers to grasp the single yellow wire inflator connector then wiggle as you pull up until it is disconnected from the inflator (Figure 78). INFLATOR CONNECTOR (SINGLE YELLOW WIRE) Figure 78 Inflator Connector INFLATOR HOUSING c. Release the yellow wire harness connector from the inflator housing bracket (Figure 79). YELLOW HARNESS CONNECTOR Figure 79 Wire Harness Connector Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) d. Release the white wire from the three housing hooks (Figure 80). Page 79 STOPPER PLATE WHITE WIRE HOUSING HOOKS Figure 80 White Wire Harness e. Remove and discard the four inflator mounting nuts (Figure 81). MOUNTING NUT LOCATIONS f. Remove and save stopper plate from housing (Figures 80 and 81). MOUNTING NUTS STOPPER PLATE Figure 81 Mounting Nuts and Stopper Plate Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) g. Slide the inflator out of the housing (Figure 82). Page 80 IMPORTANT: Do NOT discard old inflator. Follow the parts return policy and instructions at the beginning of this document. HOUSING OLD INFLATOR Figure 82 Passenger Airbag Inflator Removal Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) h. Slide the NEW inflator into the passenger airbag module housing. The keyed end is inserted first; therefore the white stripe on the NEW inflator will be located at the open end (Figures 83 and 84). WHITE STRIPE ON NEW INFLATOR GOES TO OPEN END OF HOUSING Page 81 NOTE: The inflator's key MUST line up with the housing's key. HOUSING Figure 83 Install New Inflator to Housing INFLATOR KEYED END Figure 84 Inflator End Position Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) i. Position the stopper plate to the airbag housing (Figure 85). STOPPER PLATE Page 82 NUTS j. Install the four NEW mounting nuts to the airbag housing and tighten to 53 in. lbs. (6 N·m) (Figure 85). WHITE STRIPE ON NEW INFLATOR GOES TO OPEN END OF HOUSING Figure 85 Stopper Plate and Nuts k. Ensure that the inflator's key is still lined up with the housing's key (Figure 86). CORRECT INFLATOR KEY ALIGNMENT Figure 86 Check for Inflator Key Alignment Safety Recall S43 Passenger Airbag Inflator Page 83 Service Procedure (Continued) l. Attach the white wire to the three hooks on the housing (Figure 87). m. Install the yellow three way inline connector to the airbag housing bracket. CAUTION: Use extra care when aligning the single yellow wire inflator connector to the inflator receptacle as there are no alignment tang features. n. Connect the single yellow wire inflator connector to the end of the inflator after removing the protective tape from the end of the inflator (Figure 87). o. Passenger airbag retrofit is complete (Figure 87). WARNING: To avoid personal injury or death, 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. INFLATOR CONNECTOR WHITE WIRE WARNING: To avoid personal injury or death, HOOKS use extreme care to prevent any foreign Figure 87 Retrofit Complete 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. Safety Recall S43 Passenger Airbag Inflator Page 84 Service Procedure (Continued) 39. Carefully position the PAB into the instrument panel with the upper brackets aligned with the mounting provisions of the PAB retainer or chute on the underside of the instrument panel cover, and the lower bracket aligned with the mounting provisions on the instrument panel structural support. 40. Hand start the two screws that secure the PAB lower bracket to the instrument panel structural support. 41. With the help of an assistant position the instrument panel assembly into the dash panel and install the instrument panel onto the supports. 42. Loosely install all the bolts that secure the instrument panel to the body. Tighten the bolts/screws in the following order: Tighten the two top instrument panel bolts to 8 N·m (70 in. lbs.). Tighten the two top instrument panel screws securely. Tighten the six (right and left) side support bolts to 8 N·m (70 in. lbs.). Tighten the two bottom instrument panel bolts to 6 N·m (53 in. lbs.). 43. Install the four screws that secure the PAB upper brackets to each side of the PAB retainer or chute on the underside of the instrument panel cover. For vehicles equipped with M8 screws tighten to 27 in. lbs. (3 N·m). For vehicles equipped with M6 screws tighten securely. 44. Tighten the two screws that secure the PAB lower bracket to the instrument panel structural support to 103 in. lbs. (11.6 N·m). 45. Connect the instrument panel wire harness connector to the PAB pigtail wire connector. Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 46. Install the glove box. Page 85 47 Install the passenger side instrument panel silencer. 48. Install the right and left side upper A-pillar trim panels. 49. Install the right and left side kick panels. 50. Install the left and right side lower A-pillar trim panels. 51. Install the right and left side sill plates. 52. Install the defroster grille to the top of the instrument panel. Safety Recall S43 Passenger Airbag Inflator Page 86 Service Procedure (Continued) 53. Use the following steps to install the center floor console. a. Position the floor console into the vehicle and connect the electrical connectors. b. Install the fasteners at the front of the center console. Tighten the screws to 3 N·m (27 in. lbs.). c. Install the fasteners into the rear bin. Tighten the bolts to 5 N·m (44 in. lbs.). d. Position the console shifter bezel into the vehicle. e. Connect the electrical connectors. f. Position the mat into the console rear bin. g. Install the shifter boot and bezel. h. Slide the retaining ring over the shifter shaft and slide the shift knob onto the shaft and slide down into place fully. i. Seat the retaining ring up onto the shifter knob and seat fully. j. Place the gear selector lever into the Park position. k. Release the park brake. 54. Do not connect the battery negative cable at this time. Continue with Section L. Supplemental Restraint System (SRS) Verification Test. Safety Recall S43 Passenger Airbag Inflator Page 87 Service Procedure (Continued) H. Replace Passenger Airbag Inflator: 2005 2007 ND WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. At no time should any source of electricity be permitted near the inflator on the back of a non-deployed airbag or seat belt tensioner. When carrying a non-deployed airbag, the trim cover or airbag cushion side of the unit should be pointed away from the body to minimize injury in the event of an accidental deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. Safety Recall S43 Passenger Airbag Inflator Page 88 Service Procedure (Continued) 2. Use the following steps to remove the defroster grille from the top of the instrument panel. a. Open the trim covers in the driver side A-pillar grab handle and remove and save the bolts (Figure 88). A-PILLAR TRIM b. Remove the driver's side A-pillar trim (Figure 88). TRIM COVERS Figure 88 A-Pillar Trim c. Open the trim covers in the passenger side A-pillar grab handle and remove and save the bolts. d. Remove the passenger side A-pillar trim panel. INSTRUMENT PANEL DEFROSTER GRILLE e. Using a trim stick, remove the instrument panel defroster grille (Figure 89). PASSENGER AIRBAG DOOR TRIM STICK Figure 89 Instrument Panel Defroster Grille Safety Recall S43 Passenger Airbag Inflator Page 89 Service Procedure (Continued) 3. Use the following steps to remove the glove box. AIRBAG MOUNTING BRACKET a. Release the two glove box stops and lower the glove box downward past the stops. b. Disengage the glove box hinges from the instrument panel and remove the glove box. 4. Reach up into the instrument panel glove box opening and through the access holes to remove and save the two bolts BOLT LOCATIONS that secure the passenger airbag bracket to the instrument panel Figure 90 Passenger Airbag Mounting Bracket support structure (Figure 90) (Figure 91). INSTRUMENT PANEL SUPPORT STRUCTURE INSTRUMENT PANEL MOUNTING BRACKET FORWARD EDGE OF AIRBAG DOOR OPENING AIRBAG MOUNTING BRACKET BOLT HOLES Figure 91 Instrument Panel Mounting Bracket Viewed through Windshield and Airbag Door Opening Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 5. Using a trim stick or another suitable wide flat bladed tool, gently pry the forward and side edges of the passenger airbag door away from the top of the instrument panel far enough to disengage the snap features on the door from the receptacles in the instrument panel top pad (Figure 92). PASSENGER AIRBAG DOOR Page 90 TRIM STICK Figure 92 Passenger Airbag Door 6. Pull the passenger airbag out of the instrument panel far enough to access and disconnect the instrument panel wire harness connector from the airbag inflator pigtail connector on the right side of the airbag PASSENGER AIRBAG mounting bracket. a. Slide the red Connector Position Assurance (CPA) lock on the connector toward the side of the connector (Figure 93). LATCH TAB b. Depress the connector latch tab and pull the two halves of the connector straight away from each other. CPA LOCK Figure 93 Airbag Inflator Pigtail Connector Safety Recall S43 Passenger Airbag Inflator Page 91 Service Procedure (Continued) 7. Remove the passenger airbag and airbag door from the instrument panel as a unit. 8. Use the following procedure to retrofit the passenger side airbag assembly. a. Place the passenger airbag assembly on a soft surface to prevent damage using the foam block provided with the inflator kit. WIRE HARNESS JUMPER b. Disengage the wire harness jumper from the housing clips in two places (Figure 94). HOUSING CLIPS Figure 94 Passenger Airbag Assembly c. Disconnect the single yellow wire inflator connector from the end of the inflator using pliers (Figure 95). YELLOW THREE WAY INLINE CONNECTOR d. Remove the yellow three way inline connector from the housing bracket (Figure 95). INFLATOR CONNECTOR Figure 95 Inflator Connectors Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) STOPPER PLATE Page 92 MOUNTING NUTS Figure 96 Mounting Nuts and Stopper Plate e. Remove and discard the four mounting nuts and stopper plate from the passenger airbag module (Figure 96). INFLATOR PASSENGER AIRBAG MODULE f. Slide the inflator out of the passenger airbag module (Figure 97). Figure 97 Inflator Removal Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) Page 93 g. Slide the new inflator into the passenger airbag module (Figure 98). NOTE: The inflator is keyed to fit into the housing (Figure 98). INFLATOR PASSENGER AIRBAG MODULE Figure 98 Passenger Inflator Installation KEYED FIT Safety Recall S43 Passenger Airbag Inflator Page 94 Service Procedure (Continued) h. Install the stopper plate to the airbag module (Figure 96). i. Install the four new mounting nuts to the airbag module and tighten to 53 in. lbs. (6 N·m) (Figure 96). j. Install the yellow three way inline connector to the housing bracket (Figure 95). k. Connect the single yellow wire inflator connector to the end of the inflator after removing the protective tape from the end of the inflator (Figure 93). l. Engage the wire harness jumper under the housing clips in two places (Figure 94). WARNING: To avoid personal injury or death, 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. WARNING: To avoid personal injury or death, 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. 9. Carefully position the passenger airbag and airbag door to the instrument panel as a unit. 10. Connect the instrument panel wire harness connector for the airbag to the passenger airbag inflator pigtail wire connector on the right side of the airbag mounting bracket. Be certain that the latch on the connector and the red Connector Position Assurance (CPA) lock are each fully engaged. Safety Recall S43 Passenger Airbag Inflator Page 95 Service Procedure (Continued) 11. Carefully lower the passenger airbag unit into the instrument panel, being certain that the passenger airbag mounting bracket is properly positioned to the instrument panel support structure . 12. Reach into the glove box opening to install and tighten the two bolts that secure the passenger airbag mounting bracket to the instrument panel support structure through the access holes. Tighten the screws to 55 in. lbs. (6 N·m). 13. Align and insert the rearward tabs of the passenger airbag door into the slots in the instrument panel top pad. 14. Using hand pressure, push down on the passenger airbag door over each snap feature until it snaps into its receptacle in the instrument panel base trim. 15. Install the glove box into the instrument panel. 16. Install the defroster grille onto the top of the instrument panel. 17. Install the passenger side A-pillar trim. 18. Install the passenger side grab handle. 19. Install the driver's side A-pillar trim. 20. Install the driver side grab handle. 21. Do not connect the battery negative cable at this time. Continue with Section L. Supplemental Restraint System (SRS) Verification Test. Safety Recall S43 Passenger Airbag Inflator Page 96 Service Procedure (Continued) I. Replace Passenger Airbag Inflator: 2008 2011 ND WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. At no time should any source of electricity be permitted near the inflator on the back of a non-deployed airbag or seat belt tensioner. When carrying a non-deployed airbag, the trim cover or airbag cushion side of the unit should be pointed away from the body to minimize injury in the event of an accidental deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 2. Remove the floor console. MINI FLOOR CONSOLE a. If equipped, remove the shift boot. Page 97 b. Remove the rubber liners. c. Remove the screws that secure the floor console to the floor panel and remove the floor console. SCREW FULL FLOOR CONSOLE a. Remove the rubber liner. TWO SCREWS LOCATED UNDER CUP HOLDERS b. Remove the cup holder. c. Remove the tray. d. Remove the screws that secure the floor console to the floor panel (Figure 99). FOUR SCREWS LOCATED UNDER ARMREST e. Disconnect the console assembly wire harness connector located underneath the floor console and remove the floor console from the vehicle. Figure 99 Floor Console (ATX Shown) Safety Recall S43 Passenger Airbag Inflator Page 98 Service Procedure (Continued) 3. Remove the driver and passenger side door sill trim cover (Figure 100). STEERING OPENING COVER 4. Remove the driver and passenger side instrument panel end caps (Figure 100). END CAP DOOR SILL TRIM COVER 5. Remove the steering column opening cover and disconnect the parking brake linkage (Figure 100). Figure 100 Door Sill Trim (Driver Side Shown) REINFORCEMENT PLATE 6. Remove the steering column reinforcement plate (Figure 101). 7. Remove the two hood release handle screws and position the handle to the side (Figure 101). HOOD RELEASE HANDLE Figure 101 Steering Column Reinforcement Plate Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 8. Position the front wheels straight ahead. UPPER SHROUD Page 99 9. Remove the steering column tilt lever knob (Figure 102). 10. Remove the three screws from the lower steering column shroud and remove the upper and lower shrouds (Figure 102). LOWER SHROUD TILT LEVER Figure 102 Steering Column Shrouds 11. Disconnect the brake switch electrical connector (Figure 103). WARNING: During installation depress the brake pedal while loading the steering column to the studs or damage may occur to the brake pedal switch. BRAKE SWITCH Figure 103 - Brake Switch Connector (Column out of Vehicle for Photographic Purposes) Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 12. Disconnect the wiring harness electrical connectors from the column (Figure 104). a. Disconnect the accelerator position sensor electrical connector (Figure 106). Page 100 ELECTRICAL CONNECTORS Figure 104 Column Electrical Connectors SHIFT LEVER PIN 13. Disconnect the gearshift cable from the column (Figure 105). a. Disconnect the BTSI wiring connector. b. Disconnect cable at lower column bracket and shift lever pin. CABLE TO LOWER COLUMN BRACKET BTSI CONNECTOR Figure 105 Gear Shift Cable Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 14. Remove and discard the upper steering shaft coupler bolt from the column (Figure 106). STEERING COLUMN Page 101 ACCELERATOR PEDAL POSITION SENSOR CONNECTOR 15. Separate the shaft from the coupler. WARNING: Secure the steering wheel appropriately to avoid rotation and damage to the clockspring. STEERING SHAFT COUPLER BOLT Figure 106 Steering Shaft Coupler MOUNTING NUT LOCATIONS 16. Remove the four steering column mounting nuts (Figures 107 and 108). 17. Remove the steering column assembly from the vehicle. Figure 107 - Steering Column Mounting (Column Removed for Photographic Purposes) Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 18. Remove the bolts from the pedal support (Figure 108). Page 102 PEDAL SUPPORT BOLTS STEERING COLUMN MOUNTING NUT LOCATIONS Figure 108 Pedal Support Bolts Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 19. Loosen the screws and disconnect the electrical connectors (Figure 109). ELECTRICAL CONNECTORS Page 103 20. Remove the bolt and the ground from the left A-pillar (Figure 110). Figure 109 Electrical Connectors GROUND WIRE Figure 110 Bolt and Ground Location Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 21. Disconnect one ORC module electrical connector (Figure 111). Page 104 ORC MODULE CONNECTOR 22. Disconnect the HVAC electrical connector (Figure 111). 23. Disconnect the satellite antenna connector (Figure 111). HVAC CONNECTOR 24. Remove the two center support bolts (Figure 112). 25. Remove the two left support bolts (Figure 112). SATELLITE ANTENNA CONNECTOR Figure 111 ORC Module LEFT SUPPORT BOLTS Figure 112 - Support Bolts CENTER SUPPORT BOLTS Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 26. Remove the bolt and nut and disconnect the grounds on the right A-pillar (Figure 113). Page 105 ANTENNA CABLE 27. Disconnect the antenna cable (Figure113). GROUND WIRES 28. Remove the right and left side A-pillar trim (Figure 114). Figure 113 Ground Bolt and Nut 29. Disconnect the right side A-pillar electrical connector (Figure 114). 30. Remove the defroster grille. ELECTRICAL CONNECTOR RIGHT A-PILLAR TRIM Figure 114 A-Pillar Trim (Right Side Shown) Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 31. Remove the five upper fence line bolts (Figure 115). Page 106 FENCE LINE BOLT LOCATIONS Figure 115 - Fence Line Bolts Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 32. Remove the right side support bolts and with the help of another person, remove the instrument panel assembly from the vehicle and place on a soft clean surface (Figure 116). Page 107 BOLTS 33. Remove and save the two bolts that secure the passenger airbag bracket to the instrument panel support structure (Figure 117). Figure 116 - Right Side Support Bolts INSTRUMENT PANEL SUPPORT STRUCTURE AIRBAG INFLATOR CONNECTOR HVAC DUCT AIRBAG MOUNTING BRACKET BOLTS Figure 117 Instrument Panel Mounting Bracket Safety Recall S43 Passenger Airbag Inflator Page 108 Service Procedure (Continued) 34. Disconnect the instrument panel wire harness connector from the airbag inflator pigtail connector on the right side of the airbag mounting bracket (Figures 117 and 118). a. Slide the red Connector Position Assurance (CPA) lock on the connector toward the side of the connector (Figure 118). b. Depress the connector latch tab and pull the two halves of the connector straight away from each other. LATCH TAB CPA LOCK Figure 118 - Airbag Inflator Pigtail Connector 35. Using a trim stick or another suitable wide flat bladed tool, gently pry the forward and side edges of the passenger airbag door away from the top of the instrument panel far enough to disengage the snap features on the door from the receptacles in the instrument panel top pad (Figure 119). PASSENGER AIRBAG DOOR TRIM STICK Figure 119 Passenger Airbag Door Safety Recall S43 Passenger Airbag Inflator Page 109 Service Procedure (Continued) 36. Remove the passenger airbag and airbag door from the instrument panel as a unit. 37. Use the following procedure to retrofit the passenger side airbag assembly. a. Place the passenger airbag assembly on a soft surface to prevent damage using the foam block provided with the inflator kit. WIRE HARNESS JUMPER b. Disengage the wire harness jumper from the housing clips in two places (Figure 120). HOUSING CLIPS Figure 120 Passenger Airbag Assembly c. Disconnect the single yellow wire inflator connector from the end of the inflator using pliers (Figure 121). YELLOW THREE WAY INLINE CONNECTOR d. Remove the yellow three way inline connector from the housing bracket (Figure 121). INFLATOR CONNECTOR Figure 121 Inflator Connectors Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) STOPPER PLATE Page 110 MOUNTING NUTS Figure 122 Mounting Nuts and Stopper Plate e. Remove and discard the four mounting nuts and stopper plate from the passenger airbag module (Figure 122). INFLATOR PASSENGER AIRBAG MODULE f. Slide the inflator out of the passenger airbag module (Figure 123). Figure 123 Inflator Removal Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) Page 111 g. Slide the new inflator into the passenger airbag module (Figure 124). NOTE: The inflator is keyed to fit into the housing (Figure 124). INFLATOR PASSENGER AIRBAG MODULE Figure 124 Passenger Inflator Installation KEYED FIT Safety Recall S43 Passenger Airbag Inflator Page 112 Service Procedure (Continued) h. Install the stopper plate to the airbag module. i. Install the four new mounting nuts to the airbag module and tighten to 53in.lbs. (6 N·m). j. Install the yellow three way inline connector to the housing bracket. k. Connect the single yellow wire inflator connector to the end of the inflator after removing the protective tape from the end of the inflator. l. Engage the wire harness jumper under the housing clips in two places. WARNING: To avoid personal injury or death, 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. WARNING: To avoid personal injury or death, 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. 38. Carefully position the passenger airbag and airbag door to the instrument panel as a unit. 39. Carefully lower the passenger airbag unit into the instrument panel, being certain that the passenger airbag mounting bracket is properly positioned to the instrument panel support structure. Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) Page 113 40. Install and tighten the two bolts that secure the passenger airbag mounting bracket to the instrument panel support structure. Tighten the screws to 55 in. lbs. (6 N·m). 41. Connect the instrument panel wire harness connector for the airbag to the passenger airbag inflator pigtail wire connector on the right side of the airbag mounting bracket. Be certain that the latch on the connector and the red Connector Position Assurance (CPA) lock are each fully engaged. 42. Align and insert the rearward tabs of the passenger airbag door into the slots in the instrument panel top pad. 43. Using hand pressure, push down on the passenger airbag door over each snap feature until it snaps into its receptacle in the instrument panel base trim. 44. Install the instrument panel into the vehicle and guide onto the a-pillar studs. 45. Install the right side bolts. 46. Install the fence line bolts. 47. Install the bolts into the pedal support bracket and tighten securely. 48. Install the left side support bolts. 49. Install the center support bolts. 50. Tighten the left side support bolts to 12 N·m (105 in. lbs.). 51. Tighten the right side support bolts to 12 N·m (105 in. lbs.). 52. Tighten the center support bolts to 12 N·m (105 in. lbs.). 53. Tighten the pedal support bracket bolts to 14 N·m (10 ft. lbs.). 54. Tighten the fence line bolts to 9.5 N·m (85 in. lbs.). Safety Recall S43 Passenger Airbag Inflator Page 114 Service Procedure (Continued) 55. Install the defroster grille. 56. Install the right and left A-pillar trim covers. Tighten fasteners securely. 57. Connect the satellite antenna connector, if equipped. 58. Install the right side grounds and install the bolt and nut. Tighten securely. 59. Connect the antenna cable. 60. Install the passenger side end cap. 61. Install the passenger door sill trim cover. 62. Position the center wire harness back and connect the ABS module connectors and grounds. 63. Install the left side ground and install the bolts. Tighten securely. 64. Connect the two electrical connectors on the left side and tighten the screws to 5 N·m (40 in. lbs.). 65. Connect the HVAC electrical connector and accelerator pedal position sensor connector. NOTE: Torque the upper left nut first then the lower right nut. Then torque the lower left nut then the upper right nut. 66. Position the steering column on the dash panel support and loosely install the mounting nuts. 67. Firmly slide the steering column upward against the studs in dash panel and hand tighten the nuts. 68. Center steering column in dash opening and tighten mounting nuts to 28 N·m (21 ft. lbs.). WARNING: Depress the brake pedal while positioning the steering column to the studs or damage may occur to the brake pedal switch. Safety Recall S43 Passenger Airbag Inflator Page 115 Service Procedure (Continued) 69. Install the steering shaft coupler on the steering shaft and loosely install a NEW bolt. NOTE: A NEW bolt must be used for reinstallation. 70. Tighten the coupler bolt to 57 N·m (42 ft. lbs.). 71. Install the shifter cable to the steering column. 72. Connect the wiring harness electrical connectors to the column. 73. Install the steering column shrouds. 74. Install the lilt lever knob. Tighten the screw securely. 75. Connect the brake switch electrical connector. 76. Install the steering column opening cover. Tighten the three screws securely. 77. Install the driver side door sill trim cover. 78. Install the passenger side end cap. 79. Install the floor console. Tighten the seven screws securely then install all cup holders and mats. 80. Do not connect the battery negative cable at this time. Continue with Section L. Supplemental Restraint System (SRS) Verification Test. Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) Page 116 J. Replace Passenger Airbag Inflator: JK WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. At no time should any source of electricity be permitted near the inflator on the back of a non-deployed airbag or seat belt tensioner. When carrying a non-deployed airbag, the trim cover or airbag cushion side of the unit should be pointed away from the body to minimize injury in the event of an accidental deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. For 2007 through 2010 JK vehicles, continue with Step 2. For 2011 and 2012 JK vehicles, continue with Step 11. Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 2. Remove the trim plug from the access hole in the top of the instrument panel between the windshield and the forward edge of the passenger airbag door (Figure 125). LOOSEN NUT THROUGH ACCESS HOLE TRIM PLUG Page 117 Figure 125 Trim Plug Access Hole 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 (Figure 125). NOTE: The nut that secures the passenger airbag upper bracket does not need to be completely removed. Safety Recall S43 Passenger Airbag Inflator Page 118 Service Procedure (Continued) 4. Remove the grab handle above the glove box door from the instrument panel. a. Using a trim stick C-4755 or equivalent, slide the grab handle trim caps off the trim handle. b. Remove and save the two bolts and remove the grab handle (Figure 126). GRAB HANDLE BOLT LOCATIONS 5. Remove the glove box from the instrument panel. a. Open the glove box and squeeze the stop tabs inward. b. Lower the glove box and release the hinges and remove the glove box. Figure 126 Grab Handle Bolts NUTS 6. Reach up into the instrument panel glove box opening to access and remove and save the two nuts that secure the passenger airbag lower studs to the instrument panel armature on each side of the glove box latch striker (Figure 127). INSTRUMENT PANEL ARMATURE Figure 127 Lower Passenger Airbag Nuts Safety Recall S43 Passenger Airbag Inflator Page 119 Service Procedure (Continued) 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 in the instrument (Figure 128). 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. 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. PASSENGER AIRBAG DOOR Figure 128 Passenger Airbag Door Safety Recall S43 Passenger Airbag Inflator Page 120 Service Procedure (Continued) 9. Disconnect the instrument panel wire harness connectors from the airbag inflator. 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 (Figure 129). 10. Remove the passenger airbag and airbag door from the instrument panel as a unit and continue with Step 31. INFLATOR ELECTRICAL CONNECTORS ON EACH END OF INFLATOR Figure 129 Airbag Inflator Electrical Connectors Safety Recall S43 Passenger Airbag Inflator Page 121 Service Procedure (Continued) 11. Remove the three HVAC outlets (Figure 130). a. Each air outlet is secured by a retaining tab located on the outlet, and a stop tab located on the back of the trim panel. Access the retaining tab from the inside of the air outlet, through the square openings provided (Figure 130). b. Rotate the louvers of the air outlet in the instrument panel to the eleven-o-clock position. c. Adjust the louvers partly downward for best access. d. Working from inside of the air outlet, place a small screwdriver or equivalent through the square opening, located at the twelvethirty position. NOTE: Illustration shown with air outlet removed for clarity. e. Carefully pry the retaining tab toward the center of the air outlet and rotate the outlet counterclockwise (Figure 131). NOTE: If the foam seal on the air outlet is deformed or damaged, the seal must be replaced. f. Pull the air outlet straight out of the instrument panel. HVAC OUTLETS Figure 130 HVAC Outlets PRY RETAINING TAB HERE THROUGH THE OPENING Figure 131 - HVAC Outlet Tab Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 12. Position the steering wheel into the ELECTRICAL full down position. CONNECTOR 13. Remove the steering column opening cover. POWER WINDOW SWITCH Page 122 14. If equipped with power windows, using a Trim Stick C-4755 or a suitable flat bladed tool, gently pry the switch assembly away from the instrument cluster bezel (Figure 132). 15. For vehicles without power windows, using a Trim Stick C-4755 or a suitable flat bladed tool, gently pry the storage bin assembly away from the bezel and remove. SCREW Figure 132 Power Window Switch STORAGE BIN 16. Disconnect the switch assembly electrical connector and remove the switch (Figure 132). 17. Remove the screw from the power window switch opening (Figure 132). TOP SCREW LOCATION 18. Remove the storage bin mat and remove the top screw (Figure 133). Figure 133 Center Bezel Screws Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 19. Remove the two screws below the cluster on both sides of the steering column (Figure 134). CLUSTER BEZEL CAUTION: Do not use tools to release the lower bezel retaining clips or damage to the bezel and reinforcement ring can occur. Page 123 20. Without the use of tools reach into the IP cavity through the vent openings and firmly grasp the lower bezel behind the bezel reinforcement ring and carefully pull the bezel back to release the lower retaining clips. SCREW LOCATION SCREW LOCATION Figure 134 Cluster Bezel Screws 21. Release the remaining retaining clips and remove the bezel. BOLT LOCATIONS 22. Remove the glove box from the instrument panel. 23. Using a trim stick C-4755 or equivalent, separate and remove the grab handle trim cover (Figure 135). 24. Remove the two bolts and remove the grab handle (Figure 135). GRAB HANDLE TRIM COVER Figure 135 Grab Handle Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 25. Remove the trim plug from the access hole in the top of the instrument panel between the windshield and the forward edge of the Passenger Airbag (PAB) door. Page 124 26. Working through the access hole, loosen the nut that secures the PAB upper bracket and the instrument panel armature to the stud near the windshield fence line (Figure 136). UPPER BRACKET NUT LOCATION Figure 136 PAB Upper Bracket Nut INSTRUMENT PANEL ARMATURE 27. Reach up into the instrument panel glove box opening to access and remove and save the two nuts that secure the PAB lower studs to the instrument panel armature on each side of the glove box latch striker (Figure 137). NUT LOCATIONS Figure 137 PAB Lower Nuts Safety Recall S43 Passenger Airbag Inflator Page 125 Service Procedure (Continued) 28. Grasp the lower edge of the PAB door and pull the door and PAB unit rearward far enough to access the two instrument panel wire harness connections to the PAB inflators at each side of the PAB housing (Figure 138). 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. 29. Disconnect the two panel wire electrical connectors from the PAB inflators. Firmly grasp and pull the lock straight out from the connector insulator, then pull the insulators straight out from the inflator to disconnect them from the connector receptacles (Figure 138). 30. Remove the PAB and door from the instrument panel as a unit. PAB AND DOOR UNIT PAB INFLATOR ELECTRICAL CONNECTORS Figure 138 Electrical Connectors Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 31. Use the following procedure to retrofit the passenger side airbag assembly. a. Place the passenger airbag assembly on a soft surface to prevent damage using the foam block provided with the inflator kit. MOUNTING NUTS Page 126 b. Remove and discard the four mounting nuts from the passenger airbag module (Figure 139). STOPPER PLATE Figure 139 Mounting Nuts c. Remove and save the stopper plate from the passenger airbag module (Figure 140). STOPPER PLATE Figure 140 Stopper Plate Safety Recall S43 Passenger Airbag Inflator Page 127 Service Procedure (Continued) d. Slide the old inflator out of the passenger airbag module housing NOTE: The inflator is keyed to fit into the housing. Ensure that when the new inflator is inserted, the keyed end goes in first (Figure 141). e. Slide the NEW inflator into the passenger airbag module housing. The keyed end is inserted first; therefore the white stripe on the NEW inflator will be located at the open end (Figure 141). WHITE PROTECTIVE COVER INFLATOR END KEYED TO AIRBAG MODULE HOUSING WHITE STRIPE ON NEW INFLATOR GOES TO OPEN END OF HOUSING Figure 141 Inflator Installation AIRBAG MODULE HOUSING Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) Page 128 f. Install the stopper plate to the airbag module (Figure 139). g. Install the four new mounting nuts to the airbag module and tighten to 62 in. lbs. (7 N·m) (Figure 139). h. Passenger airbag retrofit is complete (Figure 142). WARNING: To avoid personal injury or death, 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. WARNING: To avoid personal injury or death, 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. STOPPER PLATE WHITE STRIPE INDICATES NEW INFLATOR IS INSTALLED Figure 142 Retrofit Complete MOUNING NUTS Safety Recall S43 Passenger Airbag Inflator Page 129 Service Procedure (Continued) 32. Remove the white protective covers from the ends of the new inflator. 33. Position the passenger airbag and airbag door to the opening in the face of the instrument panel base trim as a unit. 34. Connect the two electrical connectors of the instrument panel wire harness take outs to the airbag inflator connector receptacles on each side of the airbag inflator 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. 35. 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. 36. Install and tighten the two nuts that secure the passenger airbag lower studs to the instrument panel armature. Tighten the nuts to 80 in. lbs. (9 N·m). 37. 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. Safety Recall S43 Passenger Airbag Inflator Page 130 Service Procedure (Continued) 38. Install the grab handle onto the instrument panel. Tighten the bolts to 10 ft. lbs. (15 N·m). 39. Install the grab handle trim cover(s). 40. Install the glove box into the instrument panel. 41. Working through the access hole in the top of the instrument panel between the windshield and the forward edge of the passenger airbag door, 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 106 in. lbs. (12 N·m). 42. Install the trim plug into the access hole in the top of the instrument panel. 43. For 2007 through 2010 vehicles continue with Step 45. 44. For 2011 and 2012 vehicles complete the following Steps. a. Position the cluster bezel into place and seat all clips fully. b. Install the two screws on both sides of the steering column and tighten securely. c. Install the screw in the switch/bin opening. d. Install the storage bin screw and position the bin mat back into place. e. Position the window switch assembly and connect electrical harness connectors. f. Position the switch and press into place, engaging the integrated latches. Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) g. Position the storage bin, if equipped, back and seat fully. h. Install the three HVAC outlets. i. Install the steering column opening cover. Page 131 45. Do not connect the battery negative cable at this time. Continue with Section L. Supplemental Restraint System (SRS) Verification Test. Safety Recall S43 Passenger Airbag Inflator Page 132 Service Procedure (Continued) K. Replace Passenger Airbag Module: VB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting this service procedure. 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. At no time should any source of electricity be permitted near the inflator on the back of a non-deployed airbag or seat belt tensioner. When carrying a non-deployed airbag, the trim cover or airbag cushion side of the unit should be pointed away from the body to minimize injury in the event of an accidental deployment. 1. Use the following steps to disconnect and isolate the battery negative cable(s). CAUTION: Some vehicles may be equipped with an auxiliary battery located under the hood. Be sure to disconnect both battery negative cables if equipped. RUBBER MAT DOOR SILL SCUFF PLATE a. Remove and save the three screws from the door sill scuff plate and remove the door sill scuff plate (Figure 143). b. Remove the rubber mat (Figure 143). SCREW LOCATIONS Figure 143 Door Sill Scuff Plate Safety Recall S43 Passenger Airbag Inflator Page 133 Service Procedure (Continued) c. Remove and save the four screws from the battery cover and remove the battery cover (Figure 144). d. Disconnect and isolate the battery negative cable(s). Wait two minutes for the system capacitor to discharge before further service (Figure 144). BATTERY COVER BATTERY NEGATIVE CABLE SCREWS Figure 144 Battery Location Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 2. Open the glove box, push up on the two rear stops and fold the box down completely (Figure 145). HINGE SCREWS Page 134 TRIM 3. Remove and save the hinge screws and remove the glove box (Figure 142). 4. Remove and save the screw securing the trim below the right outboard air outlet bezel and remove the trim (Figure 145). GLOVE BOX REAR STOPS Figure 145 Glove Box Hinge Screws COOLER AIR HOSE GLOVE BOX LIGHT ELECTRICAL CONNECTOR INNER COMPARTMENT LINER 5. Remove and save the three inner compartment liner screws and remove the inner compartment liner (Figure 146). 6. Disconnect the glove box light electrical connector and remove the cooler air hose (Figure 146). SCREW LOCATIONS Figure 146 Inner Compartment Liner Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 7. Remove the right front speaker grill (Figure 147). RIGHT FRONT SPEAKER GRILL Page 135 8. Partially remove the right front door seal near the A-Pillar (Figure 148). RIGHT A-PILLAR TRIM Figure 147 Right Front Speaker Grill TETHER STRAP 9. Remove the right A-Pillar trim and position off to the side (Figure 148). NOTE: The A-Pillar A-PILLAR POSITIONED OFF TO SIDE DOOR SEAL tether strap does not need to be disconnected. RIGHT A-PILLAR TRIM Figure 148 Right A-Pillar Trim Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 10. Remove and save the three right side air outlet bezel screws and remove the right air outlet bezel (Figure 149). SCREWS Page 136 RIGHT AIR OUTLET BEZEL 11. Remove the center radio bezel and position to the side (Figure 150). Figure 149 Right Air Outlet Bezel CENTER RADIO BEZEL Figure 150 Center Radio Bezel Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 12. Remove and save the two center air outlet bezel screws and remove the bezel (Figure 151). SCREWS Page 137 CENTER AIR OUTLET BEZEL 13. Remove and save the four screws that secure the tabs on the inboard and outboard ends of the passenger airbag door to the instrument panel base trim (Figure 152). Figure 151 Center Air Outlet Bezel PASSENGER AIRBAG DOOR SCREWS Figure 152 Passenger Airbag Door Safety Recall S43 Passenger Airbag Inflator Page 138 Service Procedure (Continued) 14. Reach up into the instrument panel glove box opening to access and remove the four screws that secure the stanchions on the back of the passenger airbag module to the brackets on the instrument panel support structure. Discard the removed screws (Figure 153). INSTRUMENT PANEL SUPPORT STRUCTURE SCREW LOCATIONS Figure 153 Mounting Screw Locations (Passenger Airbag Module Removed for Photographic Purposes) Safety Recall S43 Passenger Airbag Inflator Page 139 Service Procedure (Continued) 15. Pull the passenger airbag module rearward far enough to access the airbag electrical connector on the inboard end of the unit (Figure 154 and 155). CAUTION: Do not pull on the wires to disengage the connector from the passenger airbag inflator connector receptacle. Improper removal of the connector insulator can result in damage to the airbag circuits or the connector insulator. 16. Disconnect the airbag electrical connector from the airbag inflator connector receptacle, which is located on the inboard end of the passenger airbag housing. To disconnect the connector: a. Slide the orange Connector Position Assurance (CPA) lock on the connector toward the top of the connector. b. Depress the connector latch tab and pull the connector straight away from the inflator initiator. PASSENGER AIRBAG MODULE AIRBAG ELECTRICAL CONNECTOR Figure 154 Passenger Airbag Module Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 17. Remove and discard the tie strap securing the yellow ground wire jumper electrical connector to the instrument panel wire harness (Figure 155). GROUND WIRE JUMPER Page 140 TIE STRAP 18. Disconnect the yellow ground wire jumper electrical connector from the instrument panel wire harness (Figure 155). 19. Remove the passenger airbag and airbag door from the instrument panel as a unit. AIRBAG ELECTRICAL CONNECTOR GROUND WIRE JUMPER ELECTRICAL CONNECTOR 20. Carefully position the passenger airbag module and airbag door unit on a soft surface to prevent damage. Figure 155 Ground Wire Jumper PASSENGER AIRBAG MODULE 21. Release the passenger airbag module hooks from the airbag door windows (Figure 156). HOOKS AND WINDOWS 22. Gently pull the passenger airbag module up slowly making sure that the hooks are clear from the windows on all sides. AIRBAG DOOR Figure 156 Release Passenger Airbag Module Safety Recall S43 Passenger Airbag Inflator Page 141 Service Procedure (Continued) 23. Install the NEW passenger airbag module to the original airbag door cover by first inserting the bottom hooks into the windows. 24. Snap the remaining hooks on the opposite side into place. 25. Carefully position the passenger airbag module and airbag door unit to the instrument panel. 26. Connect the yellow ground wire jumper electrical connector to the instrument panel wire harness. 27. Secure the ground wire jumper electrical connector to the instrument panel wire harness using a NEW tie strap. 28. Connect the airbag electrical connector to the airbag inflator connector receptacle, which is located on the inboard end of the passenger airbag housing. Be certain that the latch on the connector and the orange Connector Position Assurance (CPA) lock are each fully engaged. Safety Recall S43 Passenger Airbag Inflator Page 142 Service Procedure (Continued) 29. Slide the passenger airbag module fully forward into the instrument panel opening. 30. Reach up into the instrument panel glove box opening to access, install and tighten the four NEW screws to secure the stanchions on the back of the passenger airbag housing to the brackets on the instrument panel support structure. Never reuse the old screws. Tighten the screws to 71 in. lbs. (8 N·m). 31. Install and tighten the four screws on the inboard and outboard ends of the passenger airbag door to the instrument panel base trim. Tighten the screws securely. 32. Position the center air outlet bezel to the instrument panel and install the two screws. Tighten the screws securely. 33. Install the center radio bezel. 34. Position the right air outlet bezel to the instrument panel and install the three screws. Tighten the screws securely. 35. Install the A-Pillar trim panel. 36. Install the right front door seal to the A-Pillar. Safety Recall S43 Passenger Airbag Inflator Service Procedure (Continued) 37. Install the right front speaker grill. Page 143 38. Install the cooler air hose to the inner glove box liner and connect the glove box light electrical connector. 39. Install the inner glove box liner and install the three screws. Tighten the screws securely. 40. Install the glove box and install the three hinge screws then tighten securely. 41. Position the glove box up into the instrument panel and engage the rear retaining stop tabs. 42. Install the trim panel below the air outlet. 43. Do not connect the battery negative cable at this time. Continue with Section L. Supplemental Restraint System (SRS) Verification Test. Safety Recall S43 Passenger Airbag Inflator Page 144 Service Procedure (Continued) L. Supplemental Restraint System (SRS) Verification Test NOTE: During the following test, the negative battery cable remains disconnected and isolated during steps 1 and 2 of the Supplemental Restraint System (SRS) Verification Test. NOTE: The wiTECH scan tool must be used to perform this recall. The wiTECH software is required to be at the latest release level before performing this procedure. 1. Connect the wiTECH micro pod II to the vehicle data link connector located under the steering column. 2. For vehicles equipped with a keyed ignition switch, turn the ignition switch to the "ON" position and exit the vehicle then continue with Step 4. 3. For vehicles equipped with keyless ignition node, check to be certain that nobody is in the vehicle then connect the battery negative cable(s) and turn the ignition switch to the "ON" position then continue with Step 5. 4. Check to be certain that nobody is in the vehicle, then connect the battery negative cable(s). 5. Install the airbag module fuses, if applicable. 6. Open the wiTECH Diagnostic application. 7. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using, then select "Next". 8. Enter your "User id" and "Password", then select "Finish". NOTE: If wiTECH is unable to identify the connected vehicle, click on the Launch DRB III button and use the DRB III Emulator tool. Safety Recall S43 Passenger Airbag Inflator Page 145 Service Procedure (Continued) 9. Clear all DTC's in all modules using either the wiTECH or the DRB III mode. NOTE: Any active Diagnostic Trouble Codes (DTC's) may require an additional key cycle from "ON" to "OFF" to change DTC status from "active" to "stored". 10. Turn the ignition switch to the "OFF" position for about 15 seconds, and then back to the "ON" position. Observe the airbag indicator in the instrument cluster. The airbag indicator in the instrument cluster should illuminate for six to eight seconds, and then go out. This indicates that the SRS is functioning normally and that the repairs are complete. Turn the ignition to the "OFF" position. If the airbag indicator fails to light or the light and stays ON, there is still an active SRS fault or malfunction. Refer to the appropriate diagnostic information to diagnose the problem. 11. Close the hood and remove the wiTECH micro pod II. 12. Use the procedure on pages 5 to return the original inflator. 13. Return the vehicle to the customer. Safety Recall S43 Passenger Airbag Inflator Page 146 Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims payment will be used by FCA US LLC to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace Passenger Airbag Inflator and Conduct Supplemental Restraint System Verification Test (HB/HG) 08-S4-31-82 0.8 hours Replace Passenger Airbag Inflator and Conduct Supplemental Restraint System Verification Test (2005-2010 LX) 08-S4-31-82 0.9 hours Replace Passenger Airbag Inflator and Conduct Supplemental Restraint System Verification Test (2011-2012 LX/LD) 08-S4-31-82 0.9 hours Replace Passenger Airbag Inflator and Conduct Supplemental Restraint System Verification Test (2008-2012 LC) 08-S4-31-82 1.5 hours Replace Passenger Airbag Inflator and Conduct Supplemental Restraint System Verification Test (2005-2007 ND) 08-S4-31-82 0.9 hours Replace Passenger Airbag Inflator and Conduct Supplemental Restraint System Verification Test (2008-2011 ND) 08-S4-31-82 1.9 hours Replace Passenger Airbag Inflator and Conduct Supplemental Restraint System Verification Test (2004-2005 DR/DH) 08-S4-31-82 1.1 hours Safety Recall S43 Passenger Airbag Inflator Page 147 Completion Reporting and Reimbursement (Continued) Labor Operation Time Number Allowance Replace Passenger Airbag Inflator and Conduct Supplemental Restraint System Verification Test (2006-2010 DR/DH/DC/DM/D1) Replace Passenger Airbag Inflator and Conduct Supplemental Restraint System Verification Test (2007-2010 JK) Replace Passenger Airbag Inflator and Conduct Supplemental Restraint System Verification Test (2011-2012 JK) Replace Passenger Airbag Inflator and Conduct Supplemental Restraint System Verification Test (2009 VB) (Canadian Vehicles Only) Optional Equipment Equipped with Manual Transmission (2004-2005 DR/DH only) Equipped with Police Group (sales code AHB only) (2005-2012 MY only) 08-S4-31-82 0.8 hours 08-S4-31-82 0.5 hours 08-S4-31-82 0.6 hours 08-S4-31-83 0.8 hours 08-S4-31-60 0.2 hours 08-S4-31-61 0.5 hours NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Safety Recall S43 Passenger Airbag Inflator Page 148 Owner Notification and Service Scheduling All involved vehicle owners known to FCA US LLC are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is attached. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services / Field Operations FCA US LLC This notice applies to your vehicle, [Model Year and Model] VIN XXXXXXXXXXXXXXXXX S43/NHTSA 16V-352 LOGO VEHICLE PICTURE YOUR SCHEDULING OPTIONS 1. RECOMMENDED OPTION Call your authorized Chrysler / Dodge / Jeep® / RAM Dealership 2. Call the FCA Recall Assistance Center at 1-866-220-6765. An agent can confirm part availability and help schedule an appointment 3. Visit our Recall Website, recalls.mopar.com or scan below. QR Code You can find your nearest dealer and review all your scheduling options from this website. You will be asked to provide your Vehicle Identification Number (VIN) to protect and verify your identity. The last eight characters of your VIN are provided above. DEALERSHIP INSTRUCTIONS Please reference Safety Recall S43. IMPORTANT SAFETY RECALL Passenger Airbag Inflator Dear [Name], This notification is being sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. FCA has decided that a defect, which relates to motor vehicle safety, exists in certain [2007-09 Chrysler Aspen, 2005-12 Chrysler 300, 2008-12 Dodge Challenger, 2006-12 Dodge Charger, 2005-11 Dodge Dakota, 2004-09 Dodge Durango, 2005-08 Dodge Magnum, 2004-10 Dodge RAM, 2007-12 Jeep Wrangler and 2009 Dodge Sprinter] vehicles. It is extremely important to take steps now to repair your vehicle to ensure the safety of you and your passengers. WHY DOES MY VEHICLE NEED REPAIRS? The front passenger airbag inflator on your vehicle [1] may rupture, due to excessive internal pressure, during normal airbag deployment events. This condition is more likely to occur if your vehicle has been exposed to high levels of absolute humidity for extended periods of time. An inflator rupture, during airbag deployment events, could result in metal fragment(s) striking the vehicle occupant(s) resulting in serious injury or death. HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE FCA will repair your vehicle [2] free of charge (parts and labor). To do this, your dealer will replace your passenger airbag inflator. In addition, your dealer will require your vehicle for proper check-in, preparation, and check-out during your visit. Your time is important to us; please be aware that these steps may require more time. The estimated repair time is two hours. We recommend that you schedule a service appointment to minimize your inconvenience. Please bring this letter with you to your dealership. TO SCHEDULE YOUR FREE REPAIR CALL 1-866-220-6765 OR YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED? If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [3] Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed. We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter. Customer Assistance/Field Operations Fiat Chrysler Automobiles US LLC Mr. Mrs. Customer 1234 Main Street Hometown, MI 48371 [1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-866-220-6765 to update your information. [2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to safercar.gov. [3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 218004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement. Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days.Microsoft Word 2016