Service Procedure
Replace the Passenger Air Bag Module as follows:Preliminary Steps:
1. Write down all radio station presets.
2. Remove any accessory (phone charger, etc.) from the 12V Power Outlet(s).
WARNING:
^ Do NOT use a "Computer Memory Saver" (9-volt power source), that plugs into the 12V Power Outlet(s), to retain memory settings on the computer and radio.
^ No voltage should be present in the system when performing this procedure.
3. Disconnect both battery cables.
4. Wait mat least 10 minutes before proceeding with the following steps.
Remove Glove Box Assembly:
5. Remove eight screws (includes two latch screws) from the Glove Box Assembly (see Figure 1).
6. Remove the Latch from the Glove Box Assembly (see Figure 1).
7. Carefully pull back and down on the Glove Box Assembly so you can reach the wire harnesses (that are connected to the back side of the Glove Box Assembly).
8. Disconnect the wire harnesses.
9. Remove the Glove Box Assembly and place it in a safe location.
Remove Passenger Air Bag Module:
10. Remove two smaller screws from each end (bottom side) of the Air Bag Module. See "Detail View A" and "Detail View B" in Figure 2.
11. Remove two special bolts (Torx "T50" type) from the Air Bag Module (see Figure 2).
12. Disconnect the Air Bag Module Harness Connectors (see Figure 2).
13. Carefully lift UP the Air Bag Module enough to push IN on the two metal Tabs to release the Air Bag Module from the instrument panel (see Figure 3).
14. Use both hands and carefully lift the Air Bag Module out of the instrument panel.
CAUTION:
^ Place the Air Bag Module in a safe location.
^ Always place the Air Bag Module with the "pad" side facing upward.
^ Do NOT disassemble the Air Bag Module.
^ Do NOT drop or impact the Air Bag Module.
^ Do NOT expose the Air Bag Module to temperatures exceeding 93°C (199°F)
Remove Air Bag Module Support Brackets
15. There are two Support Brackets on the Air Bag Module: one on the left side and one on the right side. See Figure 4a and 4b.
^ Remove the four screws that secure the brackets.
^ Save the screws and brackets for installation on the NEW Air Bag Module (covered in the next step).
Install NEW Passenger Air Bag Module:
16. Install (finger tight ONLY) the LH and RH Support Brackets onto the NEW Air Bag Module. See Figures 4a and 4b.
IMPORTANT:
When performing the next step, make sure the Air Bag Module harnesses are correctly routed and NOT pinched.
17. Using both hands, carefully lower the NEW Air Bag Module into the instrument panel opening.
^ Gently press DOWN on the Air Bag Module to "engage" the two metal Tabs. The module should "snap" in place.
18. Connect the Air Bag Module harnesses to the vehicle harnesses. Again, make sure the harnesses are NOT pinched.
19. Install two screws (re-use) at each end (under-side) of the Air Bag Module (refer to Figure 2).
20. Install two NEW special bolts (Torx "T50" type supplied in the kit) to the Air Bag Module (refer to Figure 2).
^ Tighten the bolts to: 15 - 25 N-m (1.5 - 2.5 Kg-m, 11 - 18 ft-lbs).
21. Tighten the screws that secure the LH and RH Support Brackets to the NEW Air Bag Module. See Figures 4a and 4b.
Re-install Glove Box Assembly:
22. Re-install the Glove Box Assembly in the reverse order that you removed it.
IMPORTANT:
^ Make sure the Glove Box Assembly harnesses are correctly routed and not pinched.
^ Confirm the Glove Box Door properly opens and closes (adjust if necessary).
Check Air Bag Module Warning Light (on Instrument Panel):
CAUTION:
Make sure the ignition key is in the OFF position and all doors are closed before re-connecting the battery cables (next step).
23. Re-connect both battery cables.
24. From the driver's side, turn the ignition key to the ON position.
a. If the Air Bag Module Warning Light turns OFF after 5 - 7 seconds, proceed to "Final Steps".
b. If the Air Bag Module Warning Light does NOT turn ON at first, does NOT turn OFF, or blinks, refer to the applicable Service Manual for diagnosis/repair. Then proceed to "Final Steps".
Final Steps:
25. Re-program all radio station presets.
26. Re-set the clock.
27. Use CONSULT-II to clear any related DTC codes.
28. Continue with "Deactivate/Dispose Old Air Bag Module" below.
Deactivate/Dispose Old Air Bag Module:
PRECAUTIONS:
^ Never dispose (throw away) an Air Bag Module that is NOT deactivated (deployed),
^ Use suitable face/eye protection when performing Air Bag Module deactivation.
^ Wear suitable hand protection when handling a deactivated Air Bag Module.
^ Use the special Deployment Tool # J-38381 to deactivate the Air Bag Module.
^ Stand at least 16 feet (5 meters) away when deactivating the Air Bag Module.
^ Do NOT touch the Air Bag Module for at least 30 minutes after it's deactivated.
^ Never apply water to a deactivated Air Bag Module.
^ Wash your hands thoroughly after deactivating an Air Bag Module.
NOTE:
The special air bag deployment tools referenced in this bulletin are contained in the Air Bag Deployment Kit # J-38381-KIT.
29. Connect the special Deployment Tool J-38381 to a "known good" 12V battery.
^ The battery must show a voltage of 9.6V or more.
^ Connect the red clip of the Deployment Tool to the positive battery post and the black clip to the negative battery post (see Figure 5).
^ After connected to the battery, the right side lamp (of the tool) marked "Deployment Tool Power" should glow green. If this light glows red, reverse the battery connections.
30. Check the Deployment Tool as follows:
A. Push the Deployment Tool switch to the ON position (see Figure 6).
^ The left-side lamp marked "Air Bag Connector Voltage" should light up. If it does not light up, replace the tool. Remember, the battery must have at least 9.6V.
^ The "Air Bag Connector Voltage" lamp should go out when the Deployment Tool switch is released (OFF position).
31. Disconnect the special Deployment Tool J-38381 from the battery at this time. And make sure the Deployment Tool Switch is released (OFF position).
32. Use 1 mm diameter wire to "secure" (attach) each end of the Air Bag Module to special tool J-41246 ("Passenger Air Bag Bracket"). See Figure 7.
33. Firmly "anchor" (attach securely) the special tool J-41246 ("Passenger Air Bag Bracket") in a vise (see Figure 7).
NOTE:
Perform the following steps on one Air Bag Module igniter at a time. There are two igniters on the Air Bag Module.
34. Connect the special Deployment Tool J-38381 to the Air Bag Module using the special Deployment Tool Adapter J-38381-30 (see Figure 8).
CAUTION:
^ Make sure the Air Bag Module is at least 16 feet (5 meters) away from the special Deployment Tool J-38381.
^ Make sure the area around the Air Bag Module is completely clear.
^ Use suitable eye/face/ear protection when performing the following steps.
35. Connect the red clip of the special Deployment Tool to the positive battery post.
36. Connect the black clip of the special Deployment Tool to the negative battery post.
^ The lamp on the right side of the tool marked "Deployment Tool Power" should glow green, not red.
37. Deploy the Air Bag Module by pressing the Deployment Tool switch to the ON position.
38. Wait at least 30 minutes before handling the Air Bag Module (to allow it to cool down).
39. Once cooled, place the Air Bag Module in a plastic bag, then dispose of ii.
^ Never apply water to a deactivated Air Bag Module.
^ Wash your hands thoroughly after deactivating an Air Bag Module.