95ZJ_8M.PDF

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95ZJ_8M.PDF

  1. 1. ZJ RESTRAINT SYSTEMS 8M - 1 RESTRAINT SYSTEMS CONTENTS page pageAIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . 4 AIRBAG SYSTEMWARNING: THIS SYSTEM IS A SENSITIVE, COM- WARNING: REPLACE AIRBAG SYSTEM COMPO-PLEX ELECTRO-MECHANICAL UNIT. BEFORE AT- NENTS WITH PARTS SPECIFIED IN THE CHRYSLERTEMPTING TO DIAGNOSE, REMOVE OR INSTALL MOPAR PARTS CATALOG ONLY. SUBSTITUTETHE AIRBAG SYSTEM OR RELATED STEERING PARTS MAY APPEAR INTERCHANGEABLE, BUT IN-WHEEL AND STEERING COLUMN COMPONENTS TERNAL DIFFERENCES MAY RESULT IN INFERIORYOU MUST FIRST DISCONNECT AND ISOLATE THE OCCUPANT PROTECTION. THE FASTENERS,BATTERY NEGATIVE (GROUND) CABLE. THEN SCREWS, AND BOLTS ORIGINALLY USED FOR THEWAIT 2 MINUTES FOR SYSTEM CAPACITOR TO AIRBAG COMPONENTS HAVE SPECIAL COATINGSDISCHARGE BEFORE FURTHER SYSTEM SERVICE. AND ARE SPECIFICALLY DESIGNED FOR THE AIR-FAILURE TO DO SO COULD RESULT IN ACCIDEN- BAG SYSTEM. THEY MUST NEVER BE REPLACEDTAL DEPLOYMENT AND POSSIBLE PERSONAL IN- WITH ANY SUBSTITUTES. ANYTIME A NEW FAS-JURY. TENER IS NEEDED, REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGEWARNING: THE AIRBAG MODULE INFLATOR AS- OR SPECIFIED IN THE CHRYSLER MOPAR PARTSSEMBLY CONTAINS SODIUM AZIDE AND POTAS- CATALOG.SIUM NITRATE. THESE MATERIALS AREPOISONOUS AND EXTREMELY FLAMMABLE. CON-TACT WITH ACID, WATER OR HEAVY METALS MAY WARNING: WHEN A STEERING COLUMN HAS ANPRODUCE HARMFUL AND IRRITATING GASES (SO- AIRBAG MODULE ATTACHED, NEVER PLACE THEDIUM HYDROXIDE IS FORMED IN THE PRESENCE COLUMN ON THE FLOOR OR OTHER SURFACEOF MOISTURE) OR COMBUSTIBLE COMPOUNDS. WITH THE STEERING WHEEL OR AIRBAG MODULEDO NOT ATTEMPT TO DISMANTLE THE MODULE FACE DOWN.OR TAMPER WITH ITS INFLATOR. DO NOT PUNC-TURE, INCINERATE OR BRING INTO CONTACTWITH ELECTRICITY. DO NOT STORE AT TEMPERA-TURES EXCEEDING 200°F. GENERAL INFORMATION The airbag system is a standard equipment safety Following are general descriptions of the majordevice on Grand Cherokee models. It is designed to components in the airbag system. Refer to Group 8Wprotect the driver from serious injury, caused by a - Wiring Diagrams for complete circuit descriptionsfrontal impact of the vehicle. To inspect this system and diagrams.use Airbag System - Body Diagnostic Proceduresmanual. If the airbag module assembly is defective AIRBAG MODULEand non-deployed, refer to Chrysler Corporation cur- The airbag module protective cover is the most vis-rent return list for proper handling procedures. ible part of the system. The module is mounted di- rectly to the steering wheel. Under the airbag
  2. 2. 8M - 2 RESTRAINT SYSTEMS ZJmodule cover, the airbag cushion and its supporting The impact sensors are threshold sensitivecomponents are contained. The airbag module con- switches that complete an electrical circuit when antains a housing to which the cushion and inflator are impact provides a sufficient deceleration force toattached and sealed. The airbag module is non-ser- close the switch. The sensors are calibrated for theviceable, and must be replaced if deployed or dam- specific vehicle, and react to the severity and direc-aged in any way. tion of the impact. The inflator assembly is mounted to the back of themodule. The inflator seals the hole in the airbag CLOCKSPRINGcushion so it can discharge the gas it produces di- The clockspring is mounted on the steering columnrectly into the cushion when supplied with the behind the steering wheel. It is used to maintain aproper electrical signal. The protective cover is fitted continuous electrical circuit between the wiring har-to the front of the airbag module and forms a deco- ness and the driver’s side airbag module. This assem-rative cover in the center of the steering wheel. Upon bly consists of a flat, ribbon-like electricallyairbag deployment, this cover will split horizontally. conductive tape which winds and unwinds with theSTORAGE steering wheel rotation. The airbag module must be stored in its original,special container until used for service. Also, it must AIRBAG CONTROL MODULEbe stored in a clean, dry environment; away from The airbag control module (ACM) contains the saf-sources of extreme heat, sparks, and high electrical ing sensor, and monitors the system to determine itsenergy. Always place or store the module on a surface readiness. The ACM contains on-board diagnosticswith the trim cover facing up to minimize movement (OBD), and will light the airbag warning lamp in thein case of accidental deployment. instrument cluster when a monitored airbag system fault occurs.IMPACT SENSOR The ACM also contains an energy storage capacitor. The impact sensors provide verification of the di- This capacitor stores enough electrical energy to de-rection and severity of the impact. Three impact sen- ploy the airbag for up to 2 minutes following a bat-sors are used. One is called a safing sensor. It is tery disconnect or failure. The purpose of this unit islocated inside the airbag control module (ACM), to provide airbag protection in a severe secondarywhich is mounted under the center floor console. The impact if the initial impact has damaged or discon-other two sensors are mounted on the radiator clo- nected the battery, but was not severe enough to de-sure panel on the left and right side of the vehicle. ploy the airbag.
  3. 3. ZJ RESTRAINT SYSTEMS 8M - 3 DIAGNOSIS A DRB scan tool is required for diagnosis of the air- (6) Read and record any stored DTC.bag system. Refer to Airbag System - Body Diagnos- (7) Refer to the Airbag System - Body Diagnostictic Procedures manual for more information. Procedures manual, if any DTC is found in steps 5 or 6.AIRBAG SYSTEM CHECK (8) Erase stored DTC, if there are no active fault (1) Disconnect battery negative cable and isolate. codes. If problems remain, DTC will not erase. (2) Connect DRB scan tool to ACM diagnostic (9) With the ignition switch in the ON position,6-way connector. The connector is located under the make sure nobody is in the vehicle.right front seat at the forward left corner of the seat (10) From right side of vehicle, turn the ignitionriser, under the floor carpet. switch to OFF then ON. Observe airbag warning (3) From right side of vehicle (away from airbag in lamp on the instrument cluster. It should light for 6case of accidental deployment), turn the ignition to 8 seconds, then go out; indicating system is func-switch to the ON position. Exit vehicle with DRB. tioning normally.Use the latest version of the proper DRB cartridge. If the airbag warning lamp fails to light, or (4) After checking that nobody is inside the vehi- lights and stays on, there is a system malfunc-cle, reconnect the negative battery terminal. tion. Refer to the Airbag System - Body Diag- (5) Using the DRB, read and record active diagnos- nostic Procedures manual to diagnose thetic trouble code (DTC) data. problem.
  4. 4. 8M - 4 RESTRAINT SYSTEMS ZJ SERVICE PROCEDURESAIRBAG SYSTEM SERVICE (DEPLOYED) If you experience skin irritation during Any vehicle which is to be returned to use after an cleanup, run cool water over the affected area.airbag deployment, must have the airbag module and Also, if you experience irritation of the nose orclockspring replaced. These are one-time components throat, exit the vehicle for fresh air until the ir-and cannot be reused. Other airbag system compo- ritation ceases. If irritation continues, see anents are replaced as required by the extent of dam- physician.age. In addition, the airbag module should be disarmed CLEANUP PROCEDUREwhenever the steering wheel or steering column re- Begin cleanup by putting tape over the airbag ex-quires service or removal. Failure to observe this haust vent (Fig. 2) so that no more powder will findwarning could result in accidental airbag deployment its way into the vehicle interior. Then remove the air-and possible personal injury. Refer to Group 19 - bag and airbag module from the vehicle.Steering for additional service procedures on steeringwheel and steering column.AIRBAG MODULE HANDLINGUNDEPLOYED At no time should any source of electricity be per-mitted near the inflator on the back of the module.When carrying an undeployed module, the trim covershould be pointed away from the body to minimizeinjury in the event of accidental deployment. If themodule is placed on a bench or other surface, theplastic trim cover should be face up to minimizemovement in case of accidental deployment.DEPLOYED Following an airbag deployment, the vehicle inte-rior will contain a powdery residue. This residue is Fig. 2 Airbag Exhaust Vent Sealingprimarily sodium bicarbonate (baking soda), used asan airbag cushion lubricant. However, there will also Use a vacuum cleaner to remove any residual pow-be traces of sodium hydroxide powder, a chemical der from the vehicle interior. Clean from outside thebyproduct of the generant used for airbag deploy- vehicle and work your way inside, so that you avoidment. Since this powder can irritate the skin, eyes, kneeling or sitting on an uncleaned area.nose or throat, be sure to wear safety glasses, rubber Be sure to vacuum the heater and A/C outlets asgloves and a long-sleeved shirt during cleanup (Fig. well (Fig. 3). Run the blower on low and vacuum any1). powder expelled from the plenum. You may need to vacuum the interior of the car a second time to re- cover all of the powder. Place the deployed airbag and module in your ve- hicular scrap pile. AIRBAG MODULE REMOVE/INSTALL WARNING: THIS SYSTEM IS A SENSITIVE, COM- PLEX ELECTRO-MECHANICAL UNIT. BEFORE AT- TEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIRBAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT 2 MIN- UTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOY- Fig. 1 Wear Safety Glasses And Rubber Gloves MENT AND POSSIBLE PERSONAL INJURY.
  5. 5. ZJ RESTRAINT SYSTEMS 8M - 5 the connector. The connector should latch securely beneath the module connector locking clip to assure positive connection. (7) Install 4 nuts and torque to 9-11 N⅐m (80-100 in. lbs.). (8) Do not connect negative battery cable at this time. Refer to Airbag System Check for proper proce- dure. IMPACT SENSOR REMOVE/INSTALL The impact sensors are located on the wheel- house extensions behind the grille opening re- inforcement. (1) Disconnect battery negative cable and isolate. If airbag module is undeployed, wait 2 minutes for system capacitor to discharge before further service. Fig. 3 Vacuum Heater and A/C Outlets (2) Remove the 3 screws and the grille (Fig. 5) When removing a deployed airbag module, from the grille opening reinforcement.rubber gloves, eye protection and long-sleevedshirt should be worn. There may be deposits onthe airbag module and other interior surfaces,which can cause irritation to the skin and eyesin large doses. (1) Disconnect battery negative cable and isolate.If airbag module is undeployed, wait 2 minutes forsystem capacitor to discharge before further service. (2) Remove 4 nuts attaching airbag module fromback side of steering wheel (Fig. 4). Fig. 5 Grille Remove/Install (3) Remove turn signal, side marker and head lamps. Refer to Group 8L - Lamps for procedures. (4) Remove 6 retainers at front fascia (Fig. 6). Fig. 4 Airbag Module (3) Lift module, and unplug electrical connector byspreading apart the external latching arms and pry-ing upward on the connector. (4) Remove module. (5) If replacing a deployed module, the clockspringmust also be replaced. Refer to Airbag ClockspringService for proper procedure. (6) When installing, connect clockspring wiringconnector to the module by pressing straight in on Fig. 6 Lower Fascia Remove/Install
  6. 6. 8M - 6 RESTRAINT SYSTEMS ZJ (5) Remove 3 push-in retainers at each front wheelopening (Fig. 7). Fig. 9 Airbag Impact Sensor Connector AIRBAG CONTROL MODULE REMOVE/INSTALL Fig. 7 Wheel Opening Retainers (6) Slide fascia off retainer pegs at side of lower WARNING: THE ACM CONTAINS ONE OF THE IM-crossmember. Using a small screwdriver, pull up on PACT SENSORS WHICH ENABLE THE SYSTEM TOlocating tangs under turn signal lamp mounting loca- DEPLOY THE AIRBAG. TO AVOID ACCIDENTAL DE-tions. PLOYMENT, NEVER CONNECT ACM ELECTRICALLY (7) Remove fascia from lower crossmember (Fig. 6). TO THE SYSTEM UNLESS IT IS BOLTED TO VEHI- (8) Remove 3 screws holding sensor to front wheel- CLE. BEFORE BEGINNING ANY AIRBAG SYSTEMhouse extension. Remove sensor (Fig. 8). REMOVAL OR INSTALLATION PROCEDURES, RE- MOVE AND ISOLATE THE BATTERY NEGATIVE (-) CABLE FROM THE VEHICLE BATTERY. THEN WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DIS- CHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, AND POSSIBLE PERSONAL INJURY. (1) Disconnect battery negative cable and isolate. If airbag is undeployed, wait 2 minutes for system capacitor to discharge before further service. (2) Remove 2 screws from bottom of center console storage bin (Figs. 10, 11 and 12). (3) Remove transmission shift handle by pulling it up sharply. (4) Remove transmission shift bezel, there are 2 Fig. 8 Airbag Impact Sensor - Typical snap clips on each side. (9) Unplug connector from sensor and remove sen- (5) Remove lamp from bezel.sor (Fig. 9). (6) Remove 4 screws under transmission shift bezel (10) To install, plug impact sensor wiring harness (Fig. 13).into connector on body of sensor. (7) Remove bezel under parking brake handle. (11) Mount sensor (arrow pointed forward) using 3 (8) Move transfer case and transmission shift le-screws provided with new sensor. Tighten screws to vers rearward.4-5 N⅐m (35-45 in. lbs.). (9) Lift console up to remove it. There is a lamp at (12) Install fascia and grille by reversing the re- the rear end of the transfer case bezel.moval procedures. (10) Disconnect wiring at ACM (Fig. 14). (13) Do not connect negative battery cable at this (11) Remove 4 screws holding the ACM.time. Refer to Airbag System Check for proper proce- (12) Remove ACM. (13) To install, position the ACM with the arrowdure. pointing forward.
  7. 7. ZJ RESTRAINT SYSTEMS 8M - 7 Fig. 12 Parking Brake Bezel Remove/Install Fig. 10 Center Console Fig. 13 Center Console Forward Mounting Screws (16) Install center floor console. (17) Do not connect negative battery cable at this time. Refer to Airbag System Check for proper proce- dure. Fig. 11 Console Remove/Install CLOCKSPRING REMOVE/INSTALL (14) Attach the ACM to the park brake bracket (1) Place the front wheels in the straight-ahead po-and floor pan with the 4 screws supplied. Tighten sition before starting the repair.screws to 5.5-7 N⅐m (50-60 in. lbs.). (2) Disconnect battery negative cable and isolate. (15) Connect wiring at ACM, making sure both If airbag is undeployed, wait 2 minutes for systemconnectors are seated and locking tabs engaged. capacitor to discharge before further service.
  8. 8. 8M - 8 RESTRAINT SYSTEMS ZJ (8) Disconnect the 2-way connector between the clockspring and the instrument panel wiring harness at the base of the steering column. (9) To remove, pull clockspring assembly from steering column by lifting locating fingers as neces- sary. The clockspring cannot be repaired. It must be replaced if faulty, or if airbag has been deployed. (10) When installing, snap clockspring onto the steering column. If the clockspring is not properly po- sitioned, see Clockspring Centering before installing steering wheel. (11) Connect the clockspring assembly to the in- strument panel wiring harness. Make sure wiring lo- cator clips are properly seated on the outside of the wiring trough and locking tabs are engaged. (12) Reinstall steering column shrouds. Be sure airbag wire is inside the shrouds. (13) Front wheels should still be in the straight- ahead position. Install steering wheel making sure to fit the flats on the hub of the steering wheel with the formations on the inside of clockspring. Pull the horn Fig. 14 Airbag Control Module wiring through the upper, smaller hole in steering wheel hub. Pull the airbag and speed control wiring (3) Remove the airbag module. See Airbag Module through the bottom, larger hole in the steering wheelRemove/Install. hub. Make sure not to pinch wiring between the (4) Remove speed control switch and connector, if steering wheel and nut.equipped. (14) Connect the horn switch wire, then the airbag (5) Remove the steering wheel with steering wheel wire to the airbag module. To assure complete con-puller tool (C-3428B). nection, latching arms must be visibly on top of con- (6) Unplug wiring connectors from horn switches. nector housing. (7) Remove upper and lower steering column (15) Install the airbag module, and torque nuts toshrouds to gain access to clockspring wiring (Fig. 15). 9 to 11 N⅐m (80 to 100 in. lb.). (16) Do not connect negative battery cable at this time. See Airbag System Check for proper procedure. CLOCKSPRING CENTERING If the rotating tape within the clockspring is not positioned properly in relation to the steering wheel and the front wheels, the clockspring may fail during use. The clockspring MUST BE CENTERED, if it is not known to be properly positioned, or if the front wheels were moved from the straight-ahead position. (1) Place front wheels in the straight-ahead posi- tion. (2) Disconnect battery negative cable and isolate. If airbag is undeployed, wait 2 minutes for system capacitor to discharge before further service. (3) Remove airbag module. Remove steering wheel with steering wheel puller tool (C-3428B). (4) Depress the two plastic auto-locking tabs (Fig. 16). (5) Keeping locking mechanism disengaged, rotate the clockspring rotor CLOCKWISE to the end of its Fig. 15 Steering Column Shrouds Remove/Install travel. Do not apply excessive torque.
  9. 9. ZJ RESTRAINT SYSTEMS 8M - 9 (7) Reinstall steering wheel. (8) Install airbag module. Torque nuts to 9 to 11 N⅐m (80 to 100 in. lbs.). (9) Do not connect battery negative cable at this time. See Airbag System Check for proper procedure. Fig. 16 Clockspring Auto-Locking Tabs (6) From the end of travel, rotate the rotor two andone-half turns COUNTER CLOCKWISE. The hornwire should end up at the top, and the airbag wire atthe bottom.

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