Side Air Bag: Service and Repair

SIDE AIR BAG MODULE







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.
- Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment.
- After deployment, the air bag surface 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 air bag module. Doing so can result in air bag deployment, which can result in personal injury.
- Side air bag modules with damaged covers must be replaced.
- Front seat back trim covers installed on seats equipped with side air bags cannot be repaired; they are to be replaced. Cleaning is permissible.
- To reduce the risk of personal injury, do not use any memory saver devices.

NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- If a side air bag deployment took place, the seatback pad, trim cover and side air bag module must be replaced. The seatback frame should be replaced if necessary.
- When replacing the side air bag after deployment, refer to Seats for additional information concerning the installation of a new side air bag.
- Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again.
- RH shown, LH similar.

All vehicles
1. Position the affected seat all the way forward and up.
2. Depower the system.

Police vehicles







3. Remove the zippers from under the material, unzip both the zippers and position the seat backrest trim cover up to access the seat back trim panel.







4. Remove the seat back trim panel.
1 Remove the 2 screws located at the bottom of the seat back trim panel.
2 Pull out at the bottom and slide the seat back trim panel up to disengage the 2 upper retaining hooks.

Non-Police vehicles







5. Release the 3 seat back trim cover J-clips.
- Release the lower J-clip first and then release the 2 side J-clips.

All vehicles







6. Remove the outboard hog rings that attach the foam pad to the seat backrest frame.

7. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module nuts.

Remove the 2 side air bag module nuts.







8. Position the side air bag module and deployment chute away from the mounting bracket and seat back frame.
9. Position the seat back trim cover and seat back pad forward enough to access the side air bag module.







10. Remove the side air bag module from the deployment chute.
- Pull the side air bag module mounting studs back through the deployment chute openings and remove the side air bag module from the deployment chute.

11. Disconnect the electrical connector and remove the side air bag module.

Installation

All vehicles
1. Connect the side air bag module electrical connector.







2. WARNING:
- Inspect the mounting surfaces of the side air bag module for any foreign objects before installing the side air bag module. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment.
- Inspect the side air bag deployment chute and the side air bag cavity in the seat back pad for any foreign objects. If any foreign objects are found, remove them. Failure to do so may result in personal injury in the event of an air bag deployment.
- Before installing the side air bag module into the deployment chute, check it for damage and foreign objects. If the air bag module is damaged, replace it. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment.
- If the air bag cover has separated or the air bag material has been exposed, install a new side air bag module. Do not attempt to repair the air bag module. Failure to do so may result in personal injury in the event of an air bag deployment.
- Check the side air bag deployment chute for damage. The deployment chute must not be repaired. If there is any damage to the deployment chute, the seat back trim cover and deployment chute must be installed new as a unit.
- If the air bag deployment chute is not correctly positioned, the side air bag may not deploy correctly.

NOTE: The alignment pin will only allow the side air bag module to be installed to the seat back mounting bracket one way.

Position the side air bag module into the deployment chute.
- Position the side air bag module into the deployment chute with the alignment pin offset to the top and the electrical connector to the bottom of the seat back. This will position the alignment pin correctly when the side air bag module and deployment chute are mounted to the seat back frame mounting bracket.
- The side air bag module mounting studs and alignment pin must come through the deployment chute stud openings.

3. WARNING:
- Inspect the mounting surfaces of the deployment chute and the seat back frame mounting bracket for any foreign objects, before installing the side air bag module/deployment chute assembly. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment.
- Front seat back trim covers installed on seats equipped with side air bags cannot be repaired; they are to be replaced. Cleaning is permissible.

Install the side air bag module onto the front seat back frame mounting bracket. Install the 2 nuts.
- The deployment chute should not have any wrinkles or folds where it contacts the seat back frame mounting bracket.
- Tighten to 7 Nm (62 lb-in).







4. Make sure the seat backrest trim cover deflector flap is positioned with no wrinkles or folds between the trim cover and seat back pad.
5. Reposition the seat back pad and trim cover to the seat back frame.







6. Install the outboard hog rings that attach the foam pad to the seat backrest frame.
- Make sure the hog rings go around the listing wire in the foam pad as well as the backrest frame wire.

Non-Police vehicles







7. NOTE: Note the alignment of the 2 side J-clips at the top of the seat to avoid bunching.

Attach the 3 seat back trim cover J-clips.
- Attach the 2 side J-clips first and then attach the lower J-clip.

Police vehicles







8. CAUTION: Inspect the seat back trim panel retaining hooks for damage. If damaged, install a new seat back trim panel.

Install the seat back trim panel.
1 Angle the top of the seat back trim panel inward and down to engage the 2 upper retaining hooks to the seat back frame.
2 Push in on the lower seat back trim panel and install the 2 screws.







9. Pull the seat backrest material down, zip both the zippers and tuck the zippers under the material.

All vehicles
10. Repower the system.