FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Home >> Ford Truck >> 2002 >> Explorer AWD V6-4.0L VIN K Flex Fuel >> Repair and Diagnosis >> Restraints and Safety Systems >> Air Bag Systems >> Side Air Bag >> Service and Repair >> Side Air Curtain Module

Side Air Curtain Module

Special Tool(s):






SPECIAL TOOL(S)

REMOVAL

WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ TO REDUCE THE RISK OF PERSONAL INJURY FROM AN ACCIDENTAL DEPLOYMENT, ALWAYS CARRY OR PLACE A LIVE SIDE AIR CURTAIN MODULE WITH THE CURTAIN AND TEAR SEAM POINTED AWAY FROM YOUR BODY.
^ AFTER DEPLOYMENT, THE SURFACE OF THE CURTAIN CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE SIDE AIR CURTAIN MODULE. DOING SO CAN RESULT IN SIDE AIR CURTAIN DEPLOYMENT.
^ BEFORE INSTALLING THE SIDE AIR CURTAIN MODULE, INSPECT THE ROOFLINE FOR ANY DAMAGE. IF NECESSARY, THE SHEET METAL MUST BE REWORKED TO ITS ORIGINAL CONDITION AND STRUCTURAL INTEGRITY. ALL DAMAGED FASTENERS MUST BE REPLACED AND ANY FOREIGN OBJECTS REMOVED. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF A SIDE AIR CURTAIN DEPLOYMENT.

NOTE:
^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again.
^ The left-hand drive driver side is shown, all others are similar.

All vehicles
1. Prepare the vehicle for side air curtain module removal.
1 Disconnect the battery ground cable and wait at least one minute.

WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.

PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS.

THE SIDE IMPACT SENSORS (IF EQUIPPED) ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLARS AND C-PILLARS.

TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED).

2 Deactivate the supplemental restraint system (SRS).

WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming

2. Remove the headliner.

WARNING: ANYTIME THE SIDE AIR CURTAIN HAS DEPLOYED, THE HEADLINER, AND ALL A, B, AND C PILLAR UPPER TRIM PANELS AND ATTACHING HARDWARE MUST BE REPLACED ALONG WITH ANY OTHER DAMAGED COMPONENTS AND HARDWARE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF A SIDE AIR CURTAIN DEPLOYMENT.

Vehicles with a moonroof







3. Release the moonroof drain tube pin-type retainers.

All vehicles







4. Remove the bolt and bracket for the tether cord from the A-pillar.

CAUTION: Inspect the rivet nut and A-pillar sheet metal for damage. Install a new rivet nut if necessary.







5. Remove the tether cord and pin-type retainer from the A-pillar.







6. Remove the side air curtain wire harness and electrical connector pin-type retainers at the C-pillar.







7. Remove the bolts.







8. Remove the bolts.







9. Remove the bolts.







10. Push the retainers together and separate the rear ramp from the sheet metal.







11. Remove the side air curtain.
1 Release the side air curtain from the front ramp lower retainers.
2 Rotate the side air curtain up, releasing the side air curtain from the front ramp upper retainers.
3 Remove the side air curtain.







12. Push the retainers together and separate the front ramp from the roof.

INSTALLATION

WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE.

All vehicles
1. Disconnect the battery ground cable and wait at least one minute.







2. Install the side air curtain front ramp.
^ Completely engage the front ramp retainers to the sheet metal.

WARNING: BEFORE INSTALLING THE SIDE AIR CURTAIN MODULE, INSPECT THE ROOFLINE FOR ANY DAMAGE. IF NECESSARY, THE SHEET METAL MUST BE REWORKED TO ITS ORIGINAL CONDITION AND STRUCTURAL INTEGRITY. ALL DAMAGED FASTENERS MUST BE REPLACED AND ANY FOREIGN OBJECTS REMOVED. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF A SIDE AIR CURTAIN DEPLOYMENT.







3. Position the side air curtain into the front ramp.
1 Position the top of the side air curtain into the front ramp upper retaining clips.
2 Rotate the side air curtain down, engaging the front ramp lower retainers.

WARNING:
^ BEFORE INSTALLING THE SIDE AIR CURTAIN MODULE, INSPECT THE ROOFLINE FOR ANY DAMAGE. IF NECESSARY, THE SHEET METAL MUST BE REWORKED TO ITS ORIGINAL CONDITION AND STRUCTURAL INTEGRITY. ALL DAMAGED FASTENERS MUST BE REPLACED AND ANY FOREIGN OBJECTS REMOVED. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF A SIDE AIR CURTAIN DEPLOYMENT.
^ BEFORE INSTALLING THE SIDE AIR CURTAIN MODULE, IF THE MODULE IS DAMAGED OR THE COVER HAS SEPARATED OR AIR CURTAIN MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR CURTAIN MODULE. DO NOT ATTEMPT TO REPAIR THE CURTAIN. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN PERSONAL INJURY IN THE EVENT OF A SIDE AIR CURTAIN DEPLOYMENT.







4. Install the side air curtain rear ramp.
^ Completely engage the rear ramp retainers to the sheet metal.







5. Install the bolts.







6. Install the bolts.







7. Install the bolts.







8. Install the side air curtain wire harness and electrical connector pin-type retainers at the C-pillar.







9. Install the pin-type retainer and tether cord to the A-pillar.







10. Position the A-pillar tether cord. Install the bolt.

CAUTION: Inspect the rivet nut and A-pillar sheet metal for damage. Install a new rivet nut if necessary.

Vehicles with a moonroof







11. Position the moonroof drain tube. Install the pin-type retainers.

All vehicles







12. Remove the restraint system diagnostic tool from the side air curtain electrical connector.







13. Connect the side air curtain electrical connector.
14. Connect the battery ground cable.
15. With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the supplemental restraint system (SRS). Prove Out Procedure
16. Disconnect the battery ground cable and wait at least one minute.

WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.

PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS.

THE SIDE IMPACT SENSORS (IF EQUIPPED) ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLARS AND C-PILLARS.

TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED).

17. Install the headliner.

WARNING: ANYTIME THE SIDE AIR CURTAIN HAS DEPLOYED, THE HEADLINER, AND ALL A, B, AND C PILLAR UPPER TRIM PANELS AND ATTACHING HARDWARE MUST BE REPLACED ALONG WITH ANY OTHER DAMAGED COMPONENTS AND HARDWARE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF A SIDE AIR CURTAIN DEPLOYMENT.

18. Restore the vehicle to operating condition.
1 Reactivate the supplemental restraint system (SRS).

WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming

2 With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). Prove Out Procedure

WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
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