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Pedestrian Protection System: Service and Repair





SERVICE AFTER A PEDESTRIAN PROTECTION DEPLOYMENT

COMPONENT REPLACEMENT AND INSPECTION REQUIREMENTS

There are two types of Electronic Pedestrian Protection (EPP) system deployments that may occur: pedestrian and non-pedestrian. Following either type of deployment, the Electronic Vehicle Information Center (EVIC) within the Instrument Cluster (IC) (also known as the Common Instrument Cluster/CIC) will display a SERVICE ACTIVE HOOD message and the airbag indicator will be illuminated. To ensure continued system integrity, certain components must be replaced or inspected following a deployment based upon the deployment type.

PEDESTRIAN DEPLOYMENT

The following components must be replaced following a pedestrian deployment:

- Right and left EPP hood hinge actuators
- Right and left active hood hinges
- Hood panel

Following three Electronic Pedestrian Protection (EPP) system deployments the Electronic Pedestrian Protection Module (EPPM) will log a DEPLOYMENT DATA RECORD FULL Diagnostic Trouble Code (DTC). This DTC cannot be overwritten or cleared. In this instance, the EPPM must also be replaced with a new unit.

The following components must be closely inspected, then replaced if any damage is visually evident following a pedestrian deployment:

- EPP impact sensors
- EPP impact sensor wiring
- Front bumper energy absorber foam material (inspect for compression, cracks and any other signs of deformation or deterioration)
- Front bumper support beam (reinforcement)
- Front fascia
- Front fascia brackets
- Hood latch/secondary catch unit
- Hood latch striker
- Pedestrian bar (see NOTE 2)

NOTE:
1. In order to guarantee continued Electronic Pedestrian Protection (EPP) system integrity, the active hood hinges and hood panel MUST be replaced following three EPP deployments, regardless of how the active hood is deployed or the results of any visual inspection.
2. The pedestrian bar MUST be inspected and replaced if visually damaged following ANY frontal vehicle impact, regardless of whether the active hood is deployed or how the impact occurred.

NON-PEDESTRIAN DEPLOYMENT

The following components must be replaced following a non-pedestrian deployment:

- Right and left EPP hood hinge actuators
- Right and left active hood hinge reset buttons
- Right and left active hood hinge shear rivets (see NOTE 1)

Following three Electronic Pedestrian Protection (EPP) system deployments the Electronic Pedestrian Protection Module (EPPM) will log a DEPLOYMENT DATA RECORD FULL Diagnostic Trouble Code (DTC). This DTC cannot be overwritten or cleared. In this instance, the EPPM must also be replaced with a new unit.

The following components must be closely inspected, then replaced if any damage is visually evident following a non-pedestrian deployment:

- EPP impact sensors
- EPP impact sensor wiring
- Front bumper energy absorber foam material (inspect for compression, cracks and any other signs of deformation or deterioration)
- Front bumper support beam (reinforcement)
- Front fascia
- Front fascia brackets
- Hood hinges
- Hood latch/secondary catch unit
- Hood latch striker
- Hood panel
- Pedestrian bar (see NOTE 2)

NOTE:
1. In order to guarantee continued Electronic Pedestrian Protection (EPP) system integrity, the active hood hinges and hood panel MUST be replaced following three EPP deployments, regardless of how the active hood is deployed or the results of any visual inspection.
2. The pedestrian bar MUST be inspected and replaced if visually damaged following ANY frontal vehicle impact, regardless of whether the active hood is deployed or how the impact occurred.

ACTIVE HOOD HINGE RESET PROCEDURE

If the vehicle remains otherwise safely operable following an EPP deployment, a customer reset position for the active hood hinges is provided to restore adequate forward visibility to drive the vehicle to the nearest dealer for service. Proceed as follows to engage the deployed active hood hinges in the reset position:

1. Push downward on one rear corner of the hood panel.

NOTE: The initial 15 millimeters (0.60 inch) of travel will require significant effort, up to 300 Newtons (68 pounds) of force. After the initial travel, the deployed EPP actuators will vent and the required force to push the hood downward will be reduced.

2. Continue pushing the hood downward until the active hinge reset mechanism engages. The rear edge of the hood will be raised about 5 millimeters (0.20 inch) higher than the fender when the active hood hinge is in the reset position.
3. Repeat Steps 1 and 2 on the opposite rear corner of the hood panel.

ACTIVE HOOD HINGE SHEAR RIVET REPLACEMENT





In order to guarantee continued Electronic Pedestrian Protection (EPP) system integrity the active hood hinge shear rivet and the reset button in each active hood hinge must be replaced following any non-pedestrian deployment using only replacement parts specified in the Chrysler Mopar(R) Parts Catalog and the following procedure.

WARNING: Following a pedestrian deployment or three non-pedestrian deployments, both active hood hinges and the hood panel MUST be replaced with new units. Hood Hinge - Removal . Failure to comply with these instructions could result in an improper or incomplete active hood deployment and increased or fatal pedestrian injuries.

1. Open and prop the hood up in the open position.
2. Remove the remnants of the used shear rivets (3) from both the right and left hinge mid-straps (2) using one of the following methods:
a. Firmly grasp the end of the shear rivet with side cutters and pull it out of the mid-strap using care not to damage or enlarge the hole from which the rivet is removed.
b. Use a punch no larger than 4.76 millimeters (0.187 inch) to drive the remnant of the used shear rivet out of the mid-strap using care not to damage or enlarge the hole from which the rivet is removed.
3. Disengage the reset cap (6) from the mid-strap by pushing inward on the cap through the reset hole (4) and pulling lightly upward on the rear corner of the hood panel.
4. Place the concave surface of the new reset button (5) against the convex surface of the reset cap protruding from the hinge hood bracket (1).
5. While holding the reset button against the reset cap, push the rear corner of the hood panel downward far enough to capture the button between the hood bracket and the mid-strap, preventing the spring-actuated reset cap from engaging in the reset hole.
6. Move the rear corner of the hood panel up or down as needed to align the shear rivet holes in the hinge hood bracket and the mid-strap.
7. Insert the new shear rivet through the outboard side of the mid-strap, then through the hood bracket.

WARNING: Be certain to hold the blind rivet installation tool so that the head of the shear rivet remains flush against the hinge mid-strap during rivet expansion. Do not twist the installation tool or rock it from side-to-side to break the rivet mandrel. The rivet mandrel must be broken in tension to ensure the mandrel does not extend through the shear joint, which will prevent the hood from lifting as designed during a subsequent deployment. Failure to comply with these instructions could result in improper or incomplete active hood deployment and increased or fatal pedestrian injuries.

8. Expand the shear rivet using a blind rivet installation tool and nose piece with adequate capacity to break the rivet mandrel in tension.
9. Following shear rivet installation, verify that the rivet mandrel is at least 5.5 millimeters (0.22 inch) below the head of the rivet by measuring the depth that a pin or drill bit less that 2.5 millimeters (0.10 inch) in diameter can be inserted into the mandrel hole in the head of the rivet.

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