Sprinter 2500 L5-2.7L DSL Turbo (2003)
2. Remove the instrument panel top cover tray from over the passenger airbag.
3. Remove the two screws that secure the passenger airbag door upper clips to the instrument panel base trim.
4. Remove the three screws that secure the flange of the passenger airbag housing to the bracket on the instrument panel structural support.
5. Pull the passenger airbag unit rearward to disengage the airbag door from the lower clips and far enough to access the electrical connection on the
right end of the unit.
CAUTION: Do not pull on the wires to disengage the connector from the passenger airbag inflator connector receptacle. Improper removal of the
connector insulator can result in damage to the airbag circuits or the connector insulator.
6. The vehicle wire harness connector is a tight snap-fit into the airbag inflator connector receptacle, which is located on the right end of the
passenger airbag housing. Firmly grasp and pull or gently pry on the connector insulator and pull the connector straight out from the inflator to
disconnect it from the receptacle.
7. Remove the passenger airbag and airbag door from the instrument panel as a unit.
INSTALLATION
The following procedure is for replacement of a faulty or damaged passenger airbag. If the airbag is faulty or damaged, but not deployed, review the
recommended procedures for handling non-deployed supplemental restraints. If the passenger airbag has been deployed, review the recommended
procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle.
WARNING:
-
ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING
ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, 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.
-
WHEN REMOVING A DEPLOYED AIR-BAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD
BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES.
-
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 PASSENGER AIRBAGS ARE SERVICED
WITH DOORS 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. Carefully position the passenger airbag and airbag door unit to the instrument panel.
2. When installing the passenger airbag, reconnect the vehicle wire harness connector to the airbag inflator connector receptacle by pressing straight
in on the connector. You can be certain that the connector is fully engaged by listening carefully for a distinct, audible click as the connector snaps
into place.
3. Push the passenger airbag unit forward far enough to engage the lower edge of the airbag door with the two lower clips in the instrument panel.
4. Install and tighten the two screws that secure the flange of the passenger airbag housing to the bracket on the instrument panel structural support.
Tighten the screws to 10 N.m (89 in. lbs.).
5. Install and tighten the two screws that secure the passenger airbag door upper clips to the instrument panel base trim. Tighten the screws to 2 N.m
(18 in. lbs.).
6. Reinstall the instrument panel top cover tray onto the instrument panel.
7. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed
following service of any supplemental restraint system component.
