Service Procedure
A. Supplemental Front Airbag Sensor Replacement1. Lower the driver's window completely.
2. Open the hood.
3. Disconnect and isolate the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure.
4. Raise the vehicle on a suitable hoist.
5. Disconnect the wiring harness connector to the right and left supplemental front airbag sensor. The sensors are located on the outside of the right and left frame rails at the radiator lower crossmember (Figure 1).
6. Remove the right and left supplemental front airbag sensors and discard the sensors and retaining bolts.
CAUTION:
If the retaining bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose from the radiator lower crossmember. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensor retaining bolts, continue with Step 9.
7. Use the following procedure, if required, to replace a spun riv-nut:
a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps.
b. Remove the four screws (two each side) that secure the left and right wheelhouse splash shield to the front fascia.
c. Remove the right and left side fascia-to-fender bolts.
d. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember.
e. Partially lower the vehicle.
f. Remove the right and left fascia bolts from the upper radiator crossmember (Figure 2).
g. Pull the wheelhouse shield back from the front fascia and remove the right and left nuts holding the front fascia to the front lip of the fender (Figure 3).
h. Carefully remove the front fascia and set it aside.
CAUTION:
Be careful not to scratch the painted surfaces of the front fascia and front fenders.
i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard.
j. Using a cut-off wheel, remove the head of the airbag sensor mounting bolt.
k. Remove and discard the supplemental front airbag sensor bushing.
l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember.
CAUTION:
Do not distort the structural sheet metal surface where the riv-nut is attached.
m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool.
NOTE:
Be sure to completely remove the riv-nut from the lower radiator crossmember.
n. Pre-assemble the new riv-nut by installing the installation nut and the riv-nut onto the installation bolt as shown in Figure 4.
o. Insert the new riv-nut-bolt/nut assembly into the original riv-nut hole in the lower radiator crossmember.
p. Using a 10mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5).
q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut.
r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely).
8. For vehicles that had the front fascia removed, use the following procedure to install the front fascia:
a. Position the front fascia onto the vehicle.
b. Install the right and left upper fascia bolts finger tight (Figure 6).
c. Install the right and left nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m).
d. Install and tighten the two fascia-to-fender bolts.
e. Install the four screws (two on each side) that secure the right and left wheelhouse shield to the front fascia.
f. Using new push pins if necessary, install the air dam to the lower radiator crossmember.
g. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps.
h. Continue with Step 9.
9. Inspect the right and left supplemental front airbag sensor wiring connectors.
> If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B. Airbag Sensor Harness Connector Replacement.
> If there is no corrosion on either terminal of the harness connectors, continue with Section C. Supplemental Front Airbag Sensor Installation.
B. Airbag Sensor Harness Connector(s) Replacement
NOTE:
Only those harness connector(s) that exhibit terminal corrosion, as described in Section A, require replacement.
1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector.
2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness.
3. Remove 1/2 inch (13 mm) of insulation from each wire.
4. Cut the new harness connector wires so that the final length is equal to the old harness.
5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire.
6. Slide one piece of heat shrink tubing onto each of the harness connector wires.
7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just enough to hold the splice band in place.
8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows:
> For the right (passenger side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the purple (w/blue tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the white (w/blue tracer) wire on the body wiring harness.
> For the left (driver's side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the blue (w/purple tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the blue (w/white tracer) wire on the body wiring harness.
CAUTION:
Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp.
9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band.
10. Crimp the splice band and wires together by squeezing the crimping tool handles.
NOTE:
The tool will release once the proper crimping force has been achieved.
11. Solder the connection together using only rosin core type solder.
CAUTION:
DO NOT use acid core solder.
12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing.
CAUTION:
Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure.
13. Continue with Section C. Supplemental Front Airbag Sensor Installation.
C. Supplemental Front Airbag Sensor Installation
1. Clean the supplemental front airbag sensor mounting surface for both sensors.
2. Install the new supplemental front airbag sensors using the fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091.
NOTE:
Use the bolts with a blue thread locker patch on the threads. Discard the pointed self tapping screws and flat washers. They will not be used in this repair procedure.
3. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts.
4. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m).
5. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector (Figure 7).
NOTE:
Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor wiring harness connector.
6. Connect the wiring harness connectors to the right and left supplemental front airbag sensors.
7. Lower the vehicle from the hoist.
8. For vehicles that had the Fascia removed, tighten the upper fascia bolts to 50 in. lbs. (5 N.m).
9. Connect the negative battery cable to the battery.
10. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "RUN" position. Wait 10 seconds:
> If the airbag warning light is not illuminated, the repair has been completed. No further action is required, return the vehicle to the customer.
> If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 11 to clear the Diagnostic Trouble Codes (DTC's).
11. Use the following procedure to clear DTC's:
a. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle.
NOTE:
The DRBIII must be at software Version 64.0 or later.
b. Turn the ignition key to the "RUN" position.
c. Press the "YES" button after the DRBIII powers up.
d. Select "DRBIII STANDALONE" and press "ENTER".
e. Select "1998-2007 DIAGNOSTICS" and press "ENTER".
f. Select "ALL" and press "ENTER".
g. Select "PASSIVE RESTRAINT" and press "ENTER".
h. Select "AIRBAG" and press "ENTER".
i. Select "READ DTC's" and press "ENTER".
j. Select "STORED" and press "ENTER".
k. Press the "PAGE BACK" button and follow the screen prompts.
l. Disconnect and remove the DRBIII from the vehicle and return the vehicle to the customer.