A. Supplemental Front Airbag Sensor Replacement
1. Lower the driver��s window completely.2. Open the hood.
3. Disconnect 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 harness connector to the right and left supplemental front airbag sensor (Figure 1).
6. Remove the right and left supplemental front airbag sensors and discard the bolts and sensors.
NOTE:
There are two types of bolts used to fasten the sensors to the radiator crossmember; an M7 self tapping bolt or an M6 bolt used with a riv-nut. If the bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensors, continue with Step 8.
7. Replaced a spun riv-nut as follows:
NOTE:
The following procedure is applicable for vehicle built at the Windsor Assembly Plant after May 24, 2004 or the St. Louis Assembly Plant after June 28, 2004. Very few vehicles are expected to require riv-nut replacement.
a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps.
b. Remove the two screws that secure the left and right wheelhouse splash shield to the front fascia.
c Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember.
d. Partially lower the vehicle.
e. Remove the right and left fascia upper bolts from the upper radiator crossmember (Figure 2).
f. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Figure 3)
g. Remove the two vertical screws holding the front fascia to the front fender.
h. Carefully remove the front fascia and set it aside.
CAUTION:
Be careful not to scratch the painted surfaces of the front fascia and the 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, cut off 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 M6 nut and the riv-nut onto the M6 bolt as shown in Figure 4.
o. Insert the riv-nut-bolt/nut assembly into the body sheet metal hole.
p. Using a 10 mm 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).
s. Clean the supplemental front airbag sensor mounting surface for both sensors.
t. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091:
> For sensors fastened with self tapping bolts:
a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6.
b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts.
c. Tightening the self tapping bolts to 60 in.lbs. (7 N.m).
> For sensors fastened with M6 bolts and riv-nuts:
a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts.
b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m).
u. 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 Harness Connector Replacement.
v. Position the front fascia onto the vehicle.
w. Install the right and left upper bolts fascia bolts and tighten to 50 in. lbs. (5 N.m).
x. Install the right and left horizontal nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m).
y. Install and tighten the two vertical screws that secure the front fascia to the front fenders.
z. Install the two screws that secure the right and left wheelhouse shield to the front fascia.
aa. Using new push pins if necessary, install the air dam to the lower radiator crossmember.
ab. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps.
ac. Continue with Step 10.
8. Clean the supplemental front airbag sensor mounting surface for both sensors.
9. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091:
> For sensors fastened with self tapping bolts:
a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6.
b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts.
c. Tightening the self tapping bolts to 60 in. lbs. (7 N.m).
> For sensors fastened with M6 bolts and riv-nuts:
a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts.
b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m).
10. 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 - Harness Connector Replacement.
11. 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.
12. Connect harness connectors to the right and left supplemental front airbag sensors.
13. Lower the vehicle.
14. Connect the negative battery cable to the battery.
15. 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 16 to clear the sensor DTC.
16. 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.
17. Turn the ignition key to the "ON" position.
18. Press the "YES" button when the DRBIII powers up.
19. Select "DRBIII STANDALONE" and press "ENTER".
20. Select "1997-2007 DIAGNOSTICS" and press "ENTER".
21. Select "ALL" and press "ENTER"
22. Select "PASSIVE RESTRAINT" and press "ENTER".
23. Select "CLEAR DTCS".
24. Disconnect and remove the DRBIII from the vehicle.