Air Bag Deployment Door: Service and Repair

PASSENGER AIRBAG DOOR

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

REMOVAL
1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service.
2. Remove the passenger airbag from the instrument panel.

Fig. 33 Passenger Airbag Door Upper Flange Remove/Install:

3. Remove the five screws that secure the upper flange of the passenger airbag door to the top of the instrument panel structural support.
4. Remove the grab handle bezel from the instrument panel.
5. Remove the five screws that secure the lower flange of the passenger airbag door to the upper glove box opening reinforcement.

Fig. 34 Passenger Airbag Door Remove/Install:

6. Remove the two screws that secure the ends of the passenger airbag door bracket to the instrument panel structural support.
7. Remove and discard the two passenger airbag door bracket J-nuts from the instrument panel structural support. These J-nuts must be replaced with new parts whenever the passenger airbag door bracket screws are removed.
8. Remove the passenger airbag door from the instrument panel.

INSTALLATION

WARNING:
- USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE PASSENGER AIRBAG CUSHION AND THE PASSENGER AIRBAG DOOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.

- THE PASSENGER AIRBAG DOOR MUST NEVER BE PAINTED. REPLACEMENT AIRBAG DOORS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE AIRBAG DOOR RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.

1. Install two new passenger airbag door bracket J-nuts onto the instrument panel structural support. These J-nuts must be replaced with new parts whenever the passenger airbag door bracket screws are removed.
2. Position the passenger airbag door onto the instrument panel and align the mounting holes in each end of the airbag door bracket with the J-nuts on the instrument panel structural support.
3. Install and tighten the two screws that secure the passenger airbag door bracket to the instrument panel structural support. Tighten the screws to 12 N.m (105 in. lbs.).
4. Install and tighten the five screws that secure the lower flange of the passenger airbag door to the upper glove box opening reinforcement. Tighten the screws to 2 N.m (20 in. lbs.).
5. Reinstall the grab handle bezel onto the instrument panel.
6. Install and tighten the five screws that secure the upper flange of the passenger airbag door to the top of the instrument panel structural support. Tighten the screws to 2 N.m (20 in. lbs.).
7. Reinstall the passenger airbag onto the instrument panel.