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 SRS component is being serviced, the SRS must be depowered.
- If a side air bag deployment took place a new seat back pad, trim cover, and side air bag module must be installed. The seat back frame should be replaced if necessary.
- When replacing the side air bag after deployment, refer to Seats.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- 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.

All seats
1. Depower the system. Service and Repair
2. Remove the front seat.







3. WARNING: Note the position of the wiring harness to aid installation. An incorrectly routed wiring harness could become damaged when the seat is moved. Failure to follow this instruction may result in personal injury.

Detach the side air bag module electrical connector from the seat bulkhead connector.

Three-door







4. Remove the backrest release lever.

All seats







5. Separate the trim cover J-clip.
6. Roll the trim cover and the assembly aid bag up the backrest to access the lower ends of the tensioning rods.







7. Detach the lower ends of the tensioning rods from the foam pad.
8. Roll the trim cover and the assembly aid bag up the backrest to access the upper ends of the tensioning rods.







9. Detach the upper ends of the tensioning rods from the backrest foam pad.
10. Roll the backrest trim cover and the assembly aid bag up the backrest to access the upper end of the backrest frame.







11. Remove the hog rings.







12. WARNING: Do not re-use the plastic retaining rivets. Always install new rivets. Failure to follow this warning could impair the air bag deployment and may result in personal injury.

Remove and discard the side air bag module deployment chute J-clip rivet.







13. WARNING: Do not attempt to separate the plastic retaining strips in any other way than that detailed. Failure to follow this warning could impair the air bag deployment and may result in personal injury.

Slide apart the plastic J-clips securing the side air bag deployment chute.

14. Roll the backrest trim cover and the assembly aid bag up the backrest to access the side air bag module.







15. Remove the nuts, side air bag module and side air bag module protective cover.
- Route the wiring harness out from between the backrest frame and the backrest foam pad.

Installation

All seats







1. Align the holes in the side air bag module protective cover to the mounting holes in the backrest frame.







2. WARNING:
- Before installing the side air bag module, 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.
- Inspect the mounting surfaces of the side air bag module and the seat back frame mounting area 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.

Position the side air bag module studs through the side air bag module protective cover and backrest frame and install the nuts.
- Tighten to 5 Nm (44 lb-in).
- Route the wiring harness back through the backrest frame and the backrest foam pad.

3. Align the backrest trim cover and the assembly aid bag to the backrest frame and backrest foam pad and roll it down into position.







4. WARNING: Check the air bag deployment chute and J-clips for damage. The air bag deployment chute and J-clips must not be repaired. If there is any damage to the deployment chute or J-clips, a new seat back trim cover and deployment chute must be installed as a unit.

Wrap the outboard end of the deployment chute around the outboard end of the side air bag module. Slide together and attach the 2 side air bag module deployment chute J-clips.







5. WARNING: Do not re-use the plastic retaining rivets. Always install new rivets. Failure to follow this warning could impair the air bag deployment and may result in personal injury.

Install the side air bag module deployment chute retainer.
- Assemble the plastic rivet into the deployment chute J-clips.







6. Attach the upper ends of the tensioning rods to the backrest foam pad.







7. Position down the trim cover and install the hog rings.
8. Roll the backrest trim cover and the assembly aid bag down the backrest to the lower end of the spring frame.







9. Attach the lower ends of the tensioning rods to the backrest foam pad.
10. Roll the trim cover and the assembly aid bag down the backrest and attach the trim cover J-clips.

Three-door
11. Install the backrest release lever.

All seats
12. Attach the side air bag module electrical connector back in the seat bulkhead connector.
13. Install the front seat.
14. Repower the system. Service and Repair