Opel Insignia: Repair Instructions

SIR Service Precautions

WARNING: If a service procedure indicates that a module is to be replaced, a new production unit MUST be ordered from the GM Parts Catalog or certified supplier. Using a module that has been reset by a 3rd party company is strictly prohibited. Not using a new production unit may result in improper performance of the safety system in the event of an accident, which may result in bodily injury.

WARNING: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs.

WARNING: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs.

General Service Instructions

NOTE: The Inflatable Restraint Sensing and Diagnostic Module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the SIR air bags. Deployment power may be available for up to 2 minutes after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the SIR air bags from the reserved energy supply.

NOTE: The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity:

• Do not expose air bags to temperatures above 85 ºC (185 ºF)
• Verify the correct replacement part number. Do not substitute a component from a different vehicle.
• Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system.

NOTE: Discard any of the following components if it has been dropped from a height of 80 cm (31.5 in) or greater:

• Inflatable Restraint Sensing and Diagnostic Module
• Passenger Presence System
• Airbag
• Driver steering wheel airbag coil
• Seat belt pretensioner
• Impact sensor

AIRBAG FRONT END DISCRIMINATING SENSOR REPLACEMENT

WARNING: SIR Warning.

WARNING: SIR Inflator Module Handling and Storage Warning.

WARNING:

Following the deployment of a side impact air bag, inspect the following parts for damage. Replace these parts if necessary:

• The seat cushion frame
• The seat recliner, if equipped
• The seat adjuster
• The seat back frame

Failure to do so may cause future personal injury.

Preliminary Procedure Disable the SIR system. Refer to SIR Disabling and Enabling.

1. Airbag Front End Discriminating Sensor[2x]

CAUTION: Refer to Fastener Caution.

Procedure

1. Disconnect the electrical connector.
2. Loosen the fastener and slide the sensor out of the keyhole slot.
3. Enable the SIR System. Refer to SIR Disabling and Enabling

NOTE: Integral sensor assembly bolt uses Left Hand threads. Use counterclockwise rotation to loosen fastener at TORX tip end. If accessing at pan head end of the fastener, use clockwise rotation to loosen bolt.

Tighten 7.5N.m (66 lb in)

AIRBAG FRONT END DISCRIMINATING SENSOR PROTECTOR REPLACEMENT

1. Airbag Front End Discriminating Sensor Protector Nut [2x]

CAUTION: Fastener Caution

Tighten 9N.m (80 lb in)

2. Airbag Front End Discriminating Sensor Protector

AIRBAG SIDE IMPACT SENSOR REPLACEMENT

WARNING: SIR Warning.

WARNING: Following the deployment of a side impact air bag, inspect the following parts for damage. Replace these parts if necessary:

• The seat cushion frame
• The seat recliner, if equipped
• The seat adjuster
• The seat back frame

Failure to do so may cause future personal injury.

Preliminary Procedures

1. SIR Disabling and Enabling.

2. Front Side Door Trim Replacement.

3. Front Side Door Water Deflector Replacement.

1. Airbag Side Impact Sensor Nut
   CAUTION: Fastener Caution
   Tighten 7.5N.m (66 lb in)
2. Airbag Side Impact Sensor

Procedure

1. Disconnect the electrical connector.
2. Loosen the fastener and slide the sensor out of the keyhole slot.

NOTE: The sensor is located on the inside of the front door inner panel.

NOTE: The fastener is integral to the sensor assembly, DO NOT remove separately.

AIRBAG SENSING AND DIAGNOSTIC MODULE REPLACEMENT

WARNING: Do not strike or jolt the inflatable restraint Sensing and Diagnostic Module (SDM). Before applying power to the SDM, make sure that it is securely fastened. Failure to observe the correct installation procedure could cause Supplemental Inflatable Restraint (SIR) deployment, personal injury, or unnecessary SIR system repairs.

WARNING: Refer to SIR Warning.

Preliminary Procedures

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

2. Transmission Control - Remove.

• GF9: Refer to Transmission Control Replacement (Without Base) or Transmission Control Replacement (With Base)
• AF50: Refer to Transmission Control Replacement

1. Airbag Sensing and Diagnostic Module Nut[3x]
   CAUTION: Refer to Fastener Caution.
   Tighten 9 N.m (80 lb in)
2. Airbag Sensing and Diagnostic Module
   Procedure
   1. Disconnect the electrical connectors.
   2. Perform the necessary programming and setup procedure: Refer to Control Module References
   3. Enable the SIR System. Refer to SIR Disabling and Enabling

Steering Wheel Airbag Replacement

Removal Procedure

WARNING: Refer to: Inflatable Restraint Module Handling and Scrapping.

WARNING: Refer to: SIR Inflator Module Handling and Storage Warning.

WARNING: Refer to: SIR Warning.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

2. Steering Column Upper Trim Cover Replacement - Remove.

3. Steering Column Lower Trim Cover Replacement - Remove.

4.

5. Lower the steering column and move to the maximum rear end position.

6. Turn the steering wheel so that the hole is at the top.

7. Insert a screwdriver or equivalent tool (2) through the access opening and push the spring fastener (1) inward to release the steering wheel inflator from the steering wheel.

8. Turn the steering wheel 180 degrees to access the second hole at the top.

9. Insert a screwdriver or equivalent tool through the access opening and push the spring fastener inward to release the steering wheel inflator from the steering wheel.

10.

Open secondary locking (2).

11. Disconnect the electrical connector. (1).

12. Steering Wheel Airbag - Remove.

Installation Procedure

1.

Connect the electrical connector.(2).

2. Close secondary locking.

3. Align the inflatable restraint module fasteners to the steering wheel spring fastener (3).

4. Push the inflatable restraint module (1) firmly into the steering wheel in order to engage the spring fastener.

5. Enable the SIR System - SIR Disabling and Enabling.

6. Steering Column Lower Trim Cover Replacement - Install.

7. Steering Column Upper Trim Cover Replacement - Install.

STEERING WHEEL AIRBAG COIL REPLACEMENT

Preliminary Procedures

1. Steering Wheel Replacement.

2. Steering Column Lower Trim Cover Replacement.

3. Steering Column Upper Trim Cover Replacement.

1. Steering Wheel Airbag Coil
   Procedure
   1. Disconnect the electrical connectors.
   2. Release the retaining tabs and remove the steering wheel airbag coil from the steering column.
   3. Ensure the steering wheel airbag coil is CENTERED during installation. Airbag Steering Wheel Module Coil Centering

AIRBAG STEERING WHEEL MODULE COIL CENTERING

1.

CAUTION: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction.

Inspect the steering wheel airbag coil. If the yellow lock pin (1) is present, the uplead post (2) is at the 12 o'clock position and the loop (u-turn) appears in the centering window (3) then the coil is already in the centered position and no further action is required.

2.

If the steering wheel airbag coil needs to be centered, perform the following preliminary steps:

1. Ensure the wheels on the vehicle are straight ahead.
2. Ensure the block tooth (1) on the steering shaft is in the 6 o'clock position.

3.

To center the steering wheel airbag coil, perform the following steps:

1. Hold the coil with the face up.
2. Slowly rotate the coil hub clockwise until the coil ribbon stops.
3. Slowly rotate the coil hub counterclockwise approximately 2.5 turns until the uplead post (1) is at the 12 o'clock position.
4. View the centering window (2) and ensure the loop (u-turn) is visible. If the loop is visible then the coil is in the center position.
5. While holding the coil hub in the center position, align the coil with the steering column components and slide the coil onto the steering shaft.

Instrument Panel Airbag Replacement

WARNING: Refer to SIR Inflator Module Handling and Storage Warning.

WARNING: Refer to SIR Warning.

Preliminary Procedures

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

2. Refer to Instrument Panel Assembly Replacement.

1. Instrument Panel Airbag

Procedure

1. Refer to Inflatable Restraint Module Handling and Scrapping
2. Insert a wood straight edge, one per side behind all locking tabs, to simultaneously release the instrument panel airbag housing from the instrument panel chute without overextending the airbag locking tabs. Use a wood straight edge that is approximately 50.8 cm (20 in) long and 5 mm (0.20 in) thick with a rounded edge.
3. Enable the SIR System. Refer to SIR Disabling and Enabling

INSTRUMENT PANEL LOWER AIRBAG REPLACEMENT - DRIVER SIDE

WARNING: Refer to SIR Inflator Module Handling and Storage Warning.

WARNING: Refer to SIR Warning.

Preliminary Procedure Disable the SIR system. Refer to SIR Disabling and Enabling

1. Instrument Panel Lower Airbag Nut [2x]
   CAUTION: Refer to Fastener Caution.
   Tighten 9 N.m (80 lb in)
2. Instrument Panel Lower Airbag - Driver Side
   Procedure
   1. Disconnect the electrical connector.
   2. Refer to Inflatable Restraint Module Handling and Scrapping
   3. Enable the SIR System. Refer to SIR Disabling and Enabling

INSTRUMENT PANEL LOWER AIRBAG REPLACEMENT - PASSENGER SIDE

WARNING: Refer to SIR Inflator Module Handling and Storage Warning.

WARNING: Refer to SIR Warning.

Preliminary Procedure Disable the SIR system. Refer to SIR Disabling and Enabling.

1. Instrument Panel Lower Airbag Nut [2x]
   CAUTION: Refer to Fastener Caution.
   Tighten 9 N.m (80 lb in)
2. Instrument Panel Lower Airbag - Passenger Side
   Procedure
   1. Disconnect the electrical connector.
   2. Refer to Inflatable Restraint Module Handling and Scrapping
   3. Enable the SIR System. Refer to SIR Disabling and Enabling

AIRBAG FRONT PASSENGER PRESENCE MODULE REPLACEMENT

WARNING: To avoid personal injury, perform a preload test on the passenger presence system whenever you remove or replace the seat cushion trim. Failure to do so may cause the system to malfunction.

WARNING: Replace the passenger presence system as a complete assembly to prevent possible injury to the occupant. All the components in the service kit are assembled and calibrated as a unit. Using only some of the components in the service kit will cause the passenger presence system to operate improperly.

Preliminary Procedure Front Seat Cushion Cover and Pad Replacement (Except GS) Front Seat Cushion Cover and Pad Replacement (GS).

1. Airbag Front Passenger Presence Module Retainer [2x]
2. Airbag Front Passenger Presence Module
   Procedure
   1. Unhook the module from the bracket on the underside of seat frame and push up through seat pan.
   2. Disconnect the electrical connector and remove the sensor and module from the seat pan.
   3. Rezero the module after installation. Passenger Presence System Re-Zeroing

FRONT AND REAR ROW SEAT ROOF RAIL AIRBAG REPLACEMENT (HATCHBACK)

WARNING: Refer to Inflatable Restraint Module Handling and Scrapping.

WARNING: Refer to SIR Inflator Module Handling and Storage Warning.

WARNING: Refer to SIR Warning.

Preliminary Procedures

1. Refer to SIR Disabling and Enabling.

2. Refer to Headlining Trim Panel Replacement (Hatchback) or Headlining Trim Panel Replacement (Wagon).

1. Roof Side Rail Airbag Bolt [7x]
   CAUTION: Fastener Caution
   1. Use a suitable tool to unlock the connector locking.
   2. Disconnect the electrical connector.

Tighten 9.5N.m (84 lb in)

2. Roof Side Rail Airbag Retainer [7x]
   Procedure
   1. Use a suitable pliers to remove the retainers.
   2. Compress the retainer tabs inward and pull the retainer to disengage from the vehicle
3. Roof Side Rail Airbag Clip
   Procedure
   Use a suitable tool to remove the clip.
4. Roof Side Rail Airbag Bracket
   Procedure
   Use a suitable tool to remove the clip.
5. Roof Side Rail Airbag Electrical Connector
6. Front and Rear Row Seat Roof Rail Airbag

FRONT AND REAR ROW SEAT ROOF RAIL AIRBAG REPLACEMENT (WAGON)

WARNING: Refer to Inflatable Restraint Module Handling and Scrapping.

WARNING: Refer to SIR Inflator Module Handling and Storage Warning.

WARNING: Refer to SIR Warning.

Preliminary Procedures

1. Refer to SIR Disabling and Enabling.

2. Refer to Headlining Trim Panel Replacement (Hatchback) or Headlining Trim Panel Replacement (Wagon).

1. Roof Side Rail Airbag Bolt[7x]
   CAUTION: Fastener Caution
   Tighten 9.5N.m (84 lb in)
2. Roof Side Rail Airbag Retainer [5x]
   Procedure
   1. Use a suitable pliers to remove the retainers.
   2. Compress the retainer tabs inward and pull the retainer to disengage from the vehicle.
3. Roof Side Rail Airbag Clip
   Procedure
   Use a suitable tool to remove the clip.
4. Roof Side Rail Airbag Bracket
   Procedure
   Use a suitable tool to remove the clip.
5. Roof Side Rail Airbag Electrical Connector
   Procedure
   1. Use a suitable tool to unlock the connector locking.
   2. Disconnect the electrical connector.
6. Front and Rear Row Seat Roof Rail Airbag

FRONT SEAT OUTBOARD SEAT BACK AIRBAG REPLACEMENT

WARNING: Refer to Inflatable Restraint Module Handling and Scrapping.

WARNING: Refer to SIR Inflator Module Handling and Storage Warning.

WARNING: Refer to SIR Warning.

WARNING: Following the deployment of a side impact air bag, inspect the following parts for damage. Replace these parts if necessary:

• The seat cushion frame
• The seat recliner, if equipped
• The seat adjuster
• The seat back frame

Failure to do so may cause future personal injury.

Preliminary Procedures

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

2. Refer to Front Seat Back Cover and Pad Replacement (Except GS) or Front Seat Back Cover and Pad Replacement (GS).

1. Front Seat Outboard Seat Back Airbag Nut[2x]
   CAUTION: Fastener Caution
   Tighten 4.25N.m (38 lb in)
2. Front Seat Outboard Seat Back Airbag
   Procedure
   1. Disconnect the electrical connector.
   2. Refer to Inflatable Restraint Module Handling and Scrapping

REAR SEAT BOLSTER AIRBAG REPLACEMENT

WARNING: Following the deployment of a rear seat side air bag, inspect the following parts for damage. Replace these parts if necessary:

• The rear seat side bolster, attachments, brackets and wiring
• The rear seat back frame, cushion and cover
• The rear seat cushion frame, cushion and cover

Failure to do so may cause future personal injury.

Procedure Rear Seat Back Side Cushion Replacement.

1. Rear Seat Bolster Airbag Nut [2x]
   CAUTION: Refer to Fastener Caution.
   Tighten 3.25 N.m (29 lb in)
2. Rear Seat Back Bolster Cover
   Procedure
   Separate the bolster cover and pad assembly from the seat bolster frame.
3. Rear Seat Bolster Airbag
   Procedure
   1. Remove any connector position assurance (CPA) devices or secondary locks.
   2. Disconnect the electrical connector.
   3. Slide the airbag out of the airbag chute.
   4. Install the airbag into the airbag chute with the connector facing down. The airbag mounting studs must fit through the airbag chute holes and then into the module bracket.
   5. Refer to Inflatable Restraint Module Handling and Scrapping

Airbag Side Impact Rear Sensor Replacement

WARNING: SIR Warning.

WARNING: Following the deployment of a side impact air bag, inspect the following parts for damage. Replace these parts if necessary:

• The seat cushion frame
• The seat recliner, if equipped
• The seat adjuster
• The seat back frame

Failure to do so may cause future personal injury.

Preliminary Procedure Rear Seat Back Side Cushion Replacement.

1. Airbag Side Impact Rear Sensor Fastener
   CAUTION: Fastener Caution.
   NOTE: Integral sensor assembly bolt uses Left Hand threads. Use counterclockwise rotation to loosen fastener at TORX tip end.
   Tighten 7.5N.m (66 lb in)
2. Airbag Side Impact Rear Sensor
   Procedure
   1. Disconnect the electrical connector.
   2. Loosen the fastener and slide the sensor out of the keyhole slot.

NOTE: The fastener is integral to the sensor assembly, DO NOT remove separately.

INSTRUMENT PANEL AIRBAG DISABLE SWITCH REPLACEMENT

WARNING: SIR Warning.

Preliminary Procedures

1. Refer to SIR Disabling and Enabling.

2. Refer to Instrument Panel Outer Trim Cover Replacement.

1. Instrument Panel Airbag Disable Switch

WARNING: Verify the proper installation of the airbag disable switch. Ensure the airbag disable switch is functioning properly by activating and deactivating the switch. If the airbag disable switch is not properly installed, and its function is not verified, the airbag may discharge improperly and cause personal injury or death.

Procedure

1. Disconnect the electrical connector.
2. Unlock the retaining tabs.

FRONT SEAT BELT RETRACTOR REPLACEMENT

Removal Procedure

WARNING: Refer to SIR Warning.

WARNING: Refer to SIR Inflator Module Handling and Storage Warning.

WARNING: In order to prevent accidental deployment and the risk of personal injury, do not dispose of an undeployed inflatable restraint seat belt pretensioner as normal shop waste. Undeployed seat belt pretensioners contain substances that could cause severe illness or personal injury if their sealed containers are damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed seat belt pretensioner. Failure to observe the following disposal methods may be a violation of appropriate country, regional or local laws.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

2.

Front Seat Belt Anchor Plate Tensioner Cover(1) - Remove.

3. Front Seat Belt Anchor Bolt (2) - Remove.

4.

Center Pillar Upper Trim Panel(1) - Remove.

5.

Front Seat Belt Retractor D Ring Bolt(1) - Remove.

6. Front Seat Belt Intermediate Guide Bolt (2) - Remove.

7.

Front Seat Belt Retractor Bolt -Upper (1) - Remove.

8. Front Seat Belt Retractor Bolt -Lower (2) - Remove.

9. Front Seat Belt Retractor(3) - Remove.

Installation Procedure

1.

Front Seat Belt Retractor(3) - Install.

CAUTION: Refer to Fastener Caution.

2. Front Seat Belt Retractor Bolt -Lower (2) - Install and tighten45 N.m (33 lb ft).

3. Front Seat Belt Retractor Bolt -Upper (1) - Install and tighten9 N.m (80 lb in).

4.

Front Seat Belt Intermediate Guide Bolt (2) - Install and tighten9 N.m (80 lb in).

5. Front Seat Belt Retractor D Ring Bolt(1) - Install and tighten45 N.m (33 lb ft).

6.

Center Pillar Upper Trim Panel(1) - Install.

7.

Front Seat Belt Anchor Bolt (2) - Install and tighten5 N.m (44 lb in).

8. Front Seat Belt Anchor Plate Tensioner Cover(1) - Install.

9. Enable the SIR System. Refer to SIR Disabling and Enabling.

FRONT SEAT BELT ANCHOR PLATE TENSIONER REPLACEMENT

WARNING: SIR Warning.

WARNING: SIR Inflator Module Handling and Storage Warning.

Preliminary Procedures

1. Refer to SIR Disabling and Enabling.

2. Refer to Front Side Door Sill Garnish Molding Replacement.

1. Front Seat Belt Anchor Plate Tensioner Bolt
   Procedure
   Fold the edge of the rear floor panel carpet down and out of the way to access the bolt.
   Tighten 45N.m (33 lb ft)
2. Front Seat Belt Anchor Plate Tensioner
   Procedure
   Disconnect the electrical connector.

Repairs and Inspections Required After a Collision

Accident With or Without Air Bag Deployment - Component Inspections

WARNING: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended.

After any collision, inspect the following components as indicated. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair the component or replace the hardware as needed.

• The steering column - Inspect the steering column for bending, twisting, buckling or any type of damage.
• The instrument panel knee bolsters and mounting points - Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage.
• The instrument panel brackets, braces, etc. - Inspect for bending, twisting, buckling, or any other type of damage.
• The seat belts - Perform the seat belt operational and functional checks. Refer to Repairs and Inspections Required After a Collision.
• The instrument panel cross car beam - Inspect for bending, twisting, buckling, or any other type of damage.
• The instrument panel mounting points and brackets - Inspect for bending, twisting, buckling, or any other type of damage.
• The seats and seat mounting points - Inspect for bending, twisting, buckling, or any other type of damage.
• The roof and headliner mounting points.
• The brake pedal --Inspect the brake pedal for bending, twisting, buckling or any type of damage.

Accident With Frontal Air Bag Deployment - Component Replacement and Inspections

After a collision involving air bag deployment, replace the following components.

• Driver Steering Wheel Air Bag
• Passenger instrument panel air bag, if deployed
• Inflatable Restraint Sensing and Diagnostic Module (SDM), if the Inflatable Restraint Sensing and Diagnostic Module has set DTC B0052 and will not clear
• Front and/or Side Impact Sensors
• Driver/Passenger Seat Side Air Bag, if deployed
• Seat back cover if Side Seat Air Bag is deployed
• Driver/Passenger Seat Belt Anchor and/or Retractor Pretensioners

Perform additional inspections on the following components.

• Steering wheel air bag coil and the coil wiring connector - Inspect for melting, scorching, or other damage due to excessive heat. If damage is found, replace the component.
• Passenger instrument panel air bag wiring connector - Inspect for melting, scorching, or other damage due to excessive heat. If damage is found, replace the connector. Refer to Wiring Repairs.
• Mounting points or mounting hardware for the passenger instrument panel air bag, steering wheel air bag, Inflatable Restraint Sensing and Diagnostic Module, seat side air bag (if deployed) and seat belt anchor and/or retractor pretensioners - Inspect for any damage and repair or replace each component as needed.

Accident With Side Seat Air Bag Deployment - Component Replacement and Inspections

After a collision involving driver/passenger side seat air bag deployment, replace the following components.

• Left/right side impact sensors on the side of the impact.
• Left/right roof rail air bag on the side of the impact.
• Inflatable Restraint Sensing and Diagnostic Module (SDM), if the Inflatable Restraint Sensing and Diagnostic Module has set DTC B0052 and will not clear.
• Inflatable Restraint Seat Belt Anchor and/or Retractor Pretensioner.
• Driver or passenger seat back cushion cover replacement.

WARNING: Do not repair or replace the seat stitching or seams in the seat back trim cover with an internal mounted seat side airbag module. Replace the complete seat back trim cover from the OEM. Non-OEM seat stitching may cause improper airbag deployment which could result in personal injury.

Perform additional inspections on the following components.

• Mounting points or mounting hardware for the side impact sensors, and driver/passenger side seat air bags on the side of impact - Inspect for any damage and repair or replace each component as needed.
• Mounting points, mounting hardware, headliner and trim pieces for the left/right roof rail air bag on the side of impact - Inspect for any damage and repair or replace each component as needed.
• Mounting points or mounting hardware for the Inflatable Restraint Sensing and Diagnostic Module and seat belt anchor and/or retractor pretensioners - Inspect for any damage and repair or replace each component as needed.
• The seat cushion frame
• The seat recliner and cover, if equipped
• The seat adjuster
• The seat back frame
• Door trim assembly
• Impacted seat cushion side covers and switches

Accident With Seat Belt Pretensioner Deployment Only - Component Replacement and Inspections

After a collision involving driver/passenger Seat Belt Retractor or Anchor Pretensioner deployment, replace the following components.

• Driver and Passenger Inflatable restraint seat belt anchor pretensioner and/or retractor pretensioner
• Inflatable Restraint Sensing and Diagnostic Module (SDM), if the Inflatable Restraint Sensing and Diagnostic Module has set DTC B0052 and will not clear

Perform additional inspections for any damage and repair or replace each component as needed on the following components.

• Mounting points or mounting hardware for the Inflatable Restraint Sensing and Diagnostic Module
• Mounting points or mounting hardware for the Seat Belt Anchor Pretensioners
• Mounting points or mounting hardware for the Seat Belt Retractor Pretensioners

Impact Sensor Replacement Guidelines

The impact sensor replacement policy requires replacing sensors in the area of the accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision.

An example of this would be a moderate collision where the front of the vehicle impacts a object. If the vehicle has an impact sensor mounted forward of the radiator, it must be replaced.

• Replace the impact sensor whether or not the air bags have deployed.
• Replace the impact sensor even if it appears to be undamaged.

Impact sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR system. Do not try to determine whether the impact sensor is undamaged, replace the impact sensor. Also, if you follow a diagnostic trouble code (DTC) procedure and a malfunctioning impact sensor is indicated, replace the impact sensor.

Inflatable Restraint Module Handling and Scrapping

Live and Undeployed Inflator Module

WARNING: A deployed dual stage inflator module will look the same whether one or both stages were used. Always assume a deployed dual stage inflator module has an active stage 2. Improper handling or servicing can activate the inflator module and cause personal injury.

Take special care when handling or storing an undeployed inflator module. An inflator module deployment produces a rapid generation of gas. This may cause the inflator module, or an object in front of the inflator module, to project through the air in the event of an unlikely deployment.

Dual Stage Inflator Module

Dual stage inflator modules have 2 deployment stages. If stage 1 was used to deploy a dual stage inflator module, stage 2 may still be active. Therefore, a deployed dual stage inflator module must be treated as an active module. If disposal of a dual stage module is required, both deployment loops must be energized to deploy the air bag.

Scrapping Procedure

During the course of a vehicles useful life, certain situations may arise which will require the disposal of a live and undeployed inflator module. Do NOT dispose a live and undeployed inflator module through normal disposal channels until the inflator module has been deployed.

Do not deploy the inflator module in the following situations:

• After replacement of an inflator module under warranty - the inflator module may need to be returned undeployed to the manufacturer.
• If the vehicle is the subject of a Product Liability report, GM-1241, related to the SIR system and is subject to a preliminary investigation - do NOT alter the SIR system in any manner.
• If the vehicle is involved in a campaign affecting the inflator modules - follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures.

Deployment Procedures

You can deploy the inflator module either inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation:

Deployment Outside Vehicle - Steering Wheel Module, I/P Module, and Roof Rail Module

Deploy the inflator module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following:

• Using the SIR diagnostics, you determine that the inflator module is malfunctioning.
• The inflator module is cosmetically damaged, scratched, or ripped.
• The inflator module pigtail is damaged.
• The inflator module connector is damaged.
• The inflator module connector terminals are damaged.

Deployment and disposal of a malfunctioning inflator module is subject to any required retention period.

WARNING: In order to prevent accidental deployment and the risk of personal injury, do not dispose of an undeployed inflator module as normal shop waste. Undeployed inflator modules contain substances that could cause severe illness or personal injury if their sealed containers are damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module.

Failure to observe the following disposal methods may be a violation of appropriate country, regional or local laws.

Special Tools

• J 38826 SIR Deployment Harness
• J 39401-B SIR Deployment Fixture
• An appropriate pigtail adapter

1. Turn OFF the ignition.

2. Remove the ignition key.

3. Put on safety glasses.

4. Remove the inflator module. Refer to the relevant airbag replacement procedure.

5.

WARNING: A deployed dual stage inflator module will look the same whether one or both stages were used. Always assume a deployed dual stage inflator module has an active stage 2. Improper handling or servicing can activate the inflator module and cause personal injury.

Place the inflator module on a work bench, with the vinyl trim cover facing up and away from the surface.

6. Clear a space on the ground about 4 m (13.1 ft) in diameter for deployment of the inflator module or deployment fixture. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Ensure you have sufficient ventilation.

7. Clear the area of loose or flammable objects.

NOTE: Dual stage deployments are only used in steering wheel and I/P inflator modules. If stage 1 was used to deploy a dual stage inflator module, stage 2 may still be active. If disposal of a dual stage module is required, both deployment loops must be energized to deploy the air bag.

8. If you are deploying a steering wheel inflator module, place the inflator module in the center of the space.

9.

When deploying an I/P inflator module, perform the following instructions:

1. Place the J 39401-B SIR deployment fixture in the center of the cleared area.
2. Fill the deployment fixture with water or sand.
3. Using the proper nuts and bolts, mount the I/P module (1) to the deployment fixture (2), with the vinyl trim facing up.
4. Securely tighten all fasteners that hold the I/P module (1) to the deployment fixture (2).

10.

When deploying a roof rail module, perform the following instructions:

1. Place the J 39401-B SIR deployment fixture (3) in the center of the cleared area.
2. Fill the deployment fixture with water or sand to provide sufficient stabilization of fixture during deployment.
3. Adjust and secure the fixture arms (4) to the deployment fixture (3), using the proper nuts and bolts.
4. Attach the roof rail module in the deployment fixture and securely tighten all fasteners.

11.

Inspect the SIR deployment harness and the appropriate pigtail adapter (2) for damage. Replace as needed.

12. Short the 2 SIR deployment harness leads (1) together using one banana plug seated into the other.

13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1).

14.

Extend the SIR deployment harness and adapter to the full length from the deployment fixture or area.

15.

NOTE: On a dual stage inflator module, both connectors must be attached to the deployment harness adapter. This will ensure that both stage 1 and stage 2 of the deployment loops are energized, regardless of the deployment state.

Connect the inflator module (1) to the adapter (2) on the SIR deployment harness (3).

NOTE: The rapid expansion of gas involved with deploying an inflator module is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module.

When the inflator module deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of the inflator module due to the force of the rapid expansion of gas inside the inflator module.

If you are deploying a dual stage inflator module with stage 1 already deployed, the fixture may not move and the noise may have been reduced.

16. Clear the area of people.

17.

Separate the 2 banana plugs on the SIR deployment harness that were shorted together earlier in the procedure.

18.

Place a 12-volt minimum/2-amp minimum power source, such as a vehicle battery, near the shorted end of the harness.

19. Connect the SIR deployment harness wires to the power source. Deployment of the inflator module will occur when contact is made.

20.

Disconnect the SIR deployment harness from the power source after the inflator module deploys.

21. If the inflator module did not deploy, disconnect the adapter and discontinue the procedure and contact the Technical Assistance Group.

If deployment was successful, proceed to the following steps.

WARNING: After deployment, the metal surfaces of the SIR component may be very hot. To help avoid a fire or personal injury:

• Allow sufficient time for cooling before touching any metal surface of the SIR component.
• Do not place the deployed SIR component near any flammable objects.

22. Seat one banana plug into the other in order to short the deployment harness leads.

23.

Put on a pair of shop gloves.

24. Disconnect the pigtail adapter from the inflator module as soon as possible.

25. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed.

26. Dispose of the deployed inflator module through normal refuse channels.

27. Wash your hands with a mild soap.

Deployment Inside Vehicle - Vehicle Scrapping Procedure

Deploy the inflator modules inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes, but is not limited to, the following situations:

• The vehicle has completed all useful life.
• Irreparable damage occurred to the vehicle in a non-deployment type accident.
• Irreparable damage occurred to the vehicle during a theft.
• The vehicle is being salvaged for parts to be used on a vehicle with a different VIN, as opposed to rebuilding as the same VIN.

WARNING: When deploying a SIR component for disposal, perform the deployment procedures in the order listed. Failure to observe the procedures in the order listed may result in personal injury.

1. Lower the driver and passenger windows.

2. Turn the ignition switch to the OFF position and remove the ignition key.

3. Check that all inflator modules which will be deployed are mounted securely.

• Driver inflator module is secured to the steering wheel.
• Passenger inflator module is secured to the instrument panel.
• Left roof rail inflator module is secured to the left roof rail.
• Right roof rail inflator module is secured to the right roof rail.

4. Put on safety glasses.

5. Remove all loose objects from the front seats.

WARNING: A deployed dual stage inflator module will look the same whether one or both stages were used. Always assume a deployed dual stage inflator module has an active stage 2. Improper handling or servicing can activate the inflator module and cause personal injury.

6.

Disconnect the steering wheel module yellow connector (1) from vehicle harness yellow connector (2).

7.

NOTE: If the vehicle is equipped with dual stage air bags the steering wheel module and I/P module will each have 4 wires. For determining high and low circuits, refer to Component Connector End View Index.

Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.

8. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.

9.

Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. Use these wires to fabricate the driver deployment harness.

10. Strip 13 mm (0.5 in) of insulation from both ends of the wires.

11. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the inflator module.

12.

Twist together the 2 connector wire leads from the high circuits from both stages of the steering wheel module, to one set of deployment wires. To determine the correct circuits, refer to Component Connector End View Index.

13. Inspect that the 3-wire connection is secure.

14.

Bend flat the twisted connection.

15.

Secure and insulate the 3-wire connection to the deployment harness using electrical tape.

16.

Twist together the 2 connector wire leads from the low circuits from both stages of the steering wheel module, to one set of deployment wires. To determine the correct circuits, refer to Component Connector End View Index.

17. Inspect that the 3-wire connection is secure.

18.

Bend flat the twisted connection.

19.

Secure and insulate the 3-wire connection to the deployment harness using electrical tape.

20. Connect the deployment harness to the connector on the steering wheel module.

21.

Route the deployment harness out of the driver side of the vehicle.

22.

Disconnect the yellow left roof rail harness connector from the vehicle harness connector.

23.

Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.

24. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.

25.

Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. These wires will be used to fabricate the roof rail air bag deployment harness.

26. Strip 13 mm (0.5 in) of insulation from both ends of the wires.

27. Twist together one end from each of the wires in order to short the wires.

28.

Twist together one connector wire lead to one deployment wire.

29.

Bend flat the twisted connection.

30. Secure and insulate the connection using electrical tape.

31.

Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.

32. Connect the deployment harness to the yellow connector of the roof rail module.

33.

Route the deployment harness out of the driver side of the vehicle.

34.

Disconnect the I/P module yellow harness connector (1) from the vehicle harness connector (2).

35.

NOTE: If the vehicle is equipped with dual stage air bags the steering wheel module and I/P module will each have 4 wires. For determining high and low circuits, refer to Component Connector End View Index.

Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.

36. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.

37.

Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. These wires will be used to fabricate the passenger deployment harness.

38. Strip 13 mm (0.5 in) of insulation from both ends of the wires.

39. Twist together one end from each of the wires in order to short the wires.

40.

Twist together the 2 connector wire leads from the high circuits from both stages of the I/P module to one set of deployment wires. To determine the correct circuits, refer to Component Connector End View Index.

41. Inspect that the 3-wire connection is secure.

42.

Bend flat the twisted connection.

43.

Secure and insulate the 3-wire connection to the deployment harness using electrical tape.

44.

Twist together the 2 connector wire leads from the low circuits from both stages of the I/P module to one set of deployment wires. To determine the correct circuits, refer to Component Connector End View Index.

45. Inspect that the 3-wire connection is secure.

46.

Bend flat the twisted connection.

47.

Secure and insulate the 3-wire connection to the deployment harness using electrical tape.

48. Connect the deployment harness to the I/P module in-line connector.

49.

Route the deployment harness out of the passenger side of the vehicle.

50.

Disconnect the yellow harness connector to the right roof rail air bag from the vehicle harness connector.

51.

Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.

52. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.

53.

Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. These wires will be used to fabricate the roof rail module deployment harness.

54. Strip 13 mm (0.5 in) of insulation from both ends of the wires.

55. Twist together one end from each of the wires in order to short the wires.

56.

Twist together one connector wire lead to one deployment wire.

57.

Bend flat the twisted connection.

58. Secure and insulate the connection using electrical tape.

59.

Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.

60.

Connect the deployment harness to the roof rail module yellow connector.

61.

Route the deployment harness out of the passenger side of the vehicle.

62. Completely cover the windshield and the front door window openings with a drop cloth.

63. Stretch to the full length all of the deployment harness wires on the right side of the vehicle.

64. Deploy each deployment loop one at a time.

65. Place a power source, 12 V minimum/2 A minimum, such as a vehicle battery, near the shorted end of the harnesses.

66. Separate one set of wires and touch the wire ends to the power source in order to deploy the selected inflator module.

67. Disconnect the deployment harness from the power source and twist the wire ends together.

68. Continue the same process with the remaining deployment harnesses.

69.

Stretch to the full length all of the deployment harness wires on the left side of the vehicle.

70. Deploy each deployment loop one at a time.

71. Place a power source, 12 V minimum/2 A minimum, such as a vehicle battery, near the shorted end of the harnesses.

72. Separate one set of wires and touch the wires ends to the power source in order to deploy the selected inflator modules.

73. Disconnect the deployment harness from the power source and twist the wire ends together.

74. Continue the same process with the remaining deployment harnesses.

75. Remove the drop cloth from the vehicle.

76. Disconnect all harnesses from the vehicle.

77. Discard the harnesses.

78. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.

79. If one or all of the inflator modules did not deploy, use the relevant airbag replacement procedure to remove the undeployed modules from the vehicle.

Pretensioner Handling and Scrapping

Scrapping Procedure

During the course of a vehicles useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) pretensioner. The following information covers the proper procedures for the disposing of a live (undeployed) pretensioner. Deploy the pretensioner before disposal. Do not dispose of a live (undeployed) pretensioner through normal disposal channels until the pretensioner has been deployed. The following information covers the proper procedures for the disposing of a live (undeployed) pretensioner.

• After replacement of a pretensioner under warranty. The pretensioner may need to be returned undeployed to the original manufacturer of pretensioner.
• If the vehicle is the subject of a Product Liability report related to the SIR system and is subject to a Preliminary Investigation (GM-1241). Do not alter the SIR system in any manner.
• If the vehicle is involved in a campaign affecting the pretensioners. Follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures.

Deployment Procedures

NOTE: Some countries, states or localities may not allow service deployment of air bags without special permission or training. Local laws regarding deploying and scrapping of air bags/devices with pyrotechnics must be followed.

The pretensioner can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation.

Deployment Inside the Vehicle

Refer to Inflatable Restraint Module Handling and Scrapping for deploying the pretensioner inside vehicle under Vehicle Scrapping Procedure.

Deployment Outside Vehicle for Seat Belt Pretensioners

Deploy the seat belt pretensioners outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following:

• Using the SIR diagnostics, you determine that the seat belt pretensioner is malfunctioning.
• The pretensioner pigtail (if equipped) is damaged.
• The pretensioner connector is damaged.
• The pretensioner connector terminal is damaged.

Deployment and disposal of a malfunctioning seat belt pretensioner is subject to any required retention period.

WARNING: In order to prevent accidental deployment of the pretensioner which could cause personal injury, do not dispose of an undeployed pretensioner as normal shop waste. The undeployed pretensioner contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed pretensioner. Failure to dispose of a pretensioner as instructed may be a violation of federal, state, or local laws.

WARNING: When you are deploying a pretensioner for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury.

Special Tools

• EL-39401-B SIR Deployment Fixture
• EL-38826 SIR Deployment Harness

1.

Turn the ignition switch to the OFF position.

2. Remove the ignition key.

3. Put on safety glasses.

4. Remove the seat belt pretensioner from the vehicle.

5. When carrying a pretensioner to the deployment area keep the open end of pretensioner pointed away from the body.

6.

Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the pretensioner. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation.

7. Make sure no loose or flammable objects are in the area.

8. Place the EL-39401-B SIR deployment fixture in the center of the cleared area.

9. Fill the fixture plastic reservoir with water or sand.

10.

Mount the pretensioner (1) in the SIR deployment fixture (3) with the open end facing up using the following mounting method.

1. Adjust and secure the EL-39401-B arms (4) to the deployment fixture (3).
2. To mount, use the proper size bolt (2) and nut (5) with washers in order to secure the pretensioner (1) to the deployment fixture brackets (4).
3. Securely tighten all fasteners prior to deployment.

11.

Inspect the EL-38826 SIR deployment harness and the appropriate pigtail adapter for damage. Replace as needed.

12. Short the 2 SIR deployment harness (1) leads together using one banana plug seated into the other.

13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1).

14.

Extend the SIR deployment harness and adapter to full length from the deployment fixture.

15.

Connect the pretensioner (1) to the adapter (2) on the deployment harness (3).

NOTE: The rapid gas expansion involved with deploying a pretensioner is very loud. Notify all the people in the immediate area that you intend to deploy the seat belt pretensioner.

16. Clear the area of people.

17.

WARNING: When you are deploying a pretensioner for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury.

Separate the 2 banana plugs on the SIR deployment harness.

18.

NOTE: When the seat belt pretensioner deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of the seat belt pretensioner due to the force of the rapid expansion of gas inside the pretensioner.

Place a 12 V minimum/2 A minimum power source (i.e., vehicle battery) near the shorted end of the harness.

19. Connect the SIR deployment harness wires to the power source. Pretensioner deployment will occur when contact is made.

20. Disconnect the SIR deployment harness from the power source after the pretensioner deploys.

21.

Seat one banana plug into the other in order to short the deployment harness leads.

22. If the pretensioner did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps.

23. Put on a pair of shop gloves.

24. Disconnect the pigtail adapter from the pretensioner as soon as possible.

25. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed.

26. Dispose of the deployed pretensioner through normal refuse channels.

27. Wash hands with a mild soap.

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