Air Bag Warning Lamp - Continuously Illuminated
NO.:08-13-92
GROUP:
Electrical
DATE:
Jul. 27, 1992
SUBJECT:
Air Bag Warning Lamp Continuously Illuminated
MODELS:
1991 (AS) Caravan/GrandCaravan/Caravan CV
Voyager/Grand Voyager/Town & Country
(Built After MDH 010606 - Jan. 6, 1991)
1992 (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town & Country
(Short Wheelbase Vehicles Built Prior To MDH 032406 - Mar. 24, 1992, And Long Wheelbase Vehicles Built Prior To MDH 040306 - Apr. 3, 1992)
SYMPTOM/CONDITION:
The air bag warning lamp may continuously illuminate when the vehicle's ignition is in the ON position. This condition may be due to corrosion caused by water being ingested into the air bag six-way connector (located in the engine compartment near the right shock tower).
DIAGNOSIS:
1. With the ignition in the OFF position, disconnect the battery negative cable.
2. Remove the six-way connector's end seals and separate the two connector halves.
3. Inspect both ends of the connector for moisture or corrosion.
4. If moisture or corrosion is present, perform the following repair procedure. If corrosion or moisture is not present, refer to the appropriate Passive Restraint System Diagnostic Procedures Manual.
PARTS REQUIRED:
1 Wiring Repair Package 4728378
Consisting Of:
1 Wiring Jumper Assembly K4728377
9 Heat Shrink Tubing K4419644
1 Instruction Sheet K6853038
REPAIR PROCEDURE:
This bulletin outlines replacement of the air bag six-way connector with a revised fourway connector.
1. Remove approximately 50 mm (two inches) of tape from the wire harness on both sides of the six-way connector.
2. Remove the six-way connector from the wiring harness by cutting the wires that lead to both halves of the connector at staggered lengths.
3. Cut the matching wires of the large half of the four-way connector (PN K4728377) and the instrument panel wiring harness so that their final length will be the same as the original.
4. Strip one inch of insulation from the wires on the instrument panel wiring harness and slide a piece of heat shrink tubing (PN K4419644) onto one of the two yellow wires and onto each of the other four remaining wires.
5. Strip one inch of insulation from the wires of the large half of the four-way connector and twist the bare ends together with the matching instrument panel harness wires. Twist the bare ends of the two yellow wires together.
6. Discard the two yellow wires (wiring loop) from the engine compartment wiring harness.
7. Cut the matching wires of the small half of the four-way connector (PN K4728377) and the engine compartment wiring harness so that their final length will be the same as the original.
8. Strip one inch of insulation from the four remaining wires on the engine compartment wiring harness and slide a piece of heat shrink tubing (PN K4419644) onto each wire.
9. Strip one inch of insulation from the wires of the small half of the four-way connector and twist the bare ends together with the matching engine compartment harness wires.
10. Solder all nine joints together using a ROSIN CORE SOLDER.
11. Center the heat shrink tubing over each joint and heat until the tubing is tightly sealed and sealant comes out of both ends.
12. Connect the four-way connector and retape the wiring harness.
13. Connect the battery negative cable.
14. Perform the verification test procedure found in the appropriate Passive Restraint System Diagnostic Procedures Manual.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 08-45-09-90 . . . . . . . .0.6 Hrs.
FAILURE CODE:
21 - Connection Defect