B. Airbag Sensor Harness Connector Replacement
NOTE:Only those harness connectors 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 the tool just
CAUTION:
The crimp jaw must be installed in the crimp tool frame as shown in Figure 7. The crimp jaw wire gauge numbers must be on the same side. When installing the crimp jaw into the tool frame, orient the upper die with the arrow pointed "up" and the lower die with the arrow pointed forward.
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, match the new harness connector wire colors to the same color wire on the existing body wire harness.
> For the left (driver's side) supplemental front airbag sensor, match the new harness connector wire colors to same tracer (stripe) color wire on the existing body wire harness.
CAUTION:
Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 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 (Figure 8).
10. Crimp the splice band and wires together by squeezing the crimping tool handles. The tool will release once the proper crimping force has been achieved (Figure 8).
11. Solder the connection together using only rosin-core type solder (Figure. 9).
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 (Figure 10).
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. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector.
NOTE:
Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector.
14. Connect harness connectors to the right and left supplemental front airbag sensors.
15. For vehicles with the front fascia removed:
a. Position the front fascia onto the vehicle.
b. Install the right and left upper fascia bolts and tighten to 50 in. lbs. (5 N.m).
c. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender. Tighten the nuts to 60 in. lbs. (7 N.m).
d. Install and tighten the two vertical screws that secure the front fascia to the front fenders.
e. Install the two screws that secure the right and left wheelhouse shield to the front fascia.
f. Using new push pins if necessary, securing the air dam to the lower radiator crossmember.
g. For vehicles with fog lamps, connect the electrical harness connectors to the right and left fog lamps.
16. Lower the vehicle.
17. Connect the negative battery cable to the battery.
18. 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 "ON" position. Wait 10 seconds:
> If the airbag warning light is not illuminated, the repair has been completed. 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 19 to clear the sensor DTC.
19. 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.
20. Turn the ignition key to the "ON" position.
21. Press the "YES" button when the DRBIII powers up.
22. Select "DRBIII STANDALONE" and press "ENTER".
23. Select "1997-2007 DIAGNOSTICS" and press "ENTER".
24. Select "ALL" and press "ENTER".
25. Select "PASSIVE RESTRAINT" and press "ENTER".
26. Select "CLEAR DTCS".
27. Disconnect and remove the DRBIII from the vehicle.