Service Procedure
Service ProcedureTools Required
J 38778 Door Trim Pad Clip Remover
Important:
Perform this procedure on both the driver and passenger side front side door.
Caution:
When performing service on or near the supplemental inflatable restraint (SIR) components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs.
Caution:
Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is secure fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the airbags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the airbags from the reserved energy supply.
1. Verify that the vehicle is equipped with roof-mounted side impact airbags.
^ If the vehicle does NOT have roof-mounted side impact airbags, no further action is required.
^ If the vehicle does have roof-mounted side impact air bags, proceed to Step 2.
Important:
Perform this procedure on both the driver and passenger side front side door.
2. Disable the SIR system. Refer to SIR Disabling and Enabling in SI.
3. Remove the front side door trim panel. Refer to Front Side Door Trim Panel Replacement in SI.
4. Carefully peel back the water deflector (2) to expose the inner door and window regulator rail (1).
Important:
Determine the routing of the side impact sensor (SIS) harness.
^ If the side impact sensor (SIS) harness is routed on the inboard side of the impact beam and around the inner door flange area, perform Steps 5-13.
^ If the SIS harness is routed along the inboard and outboard side of the side impact beam, no further action is required. Refer to the Claim Information section of this bulletin. Submit a claim for Correct SIS Routing Observed - No Repair Required.
5. Remove the energy absorber block attached to the window regulator rail. Retain the energy absorber block and fasteners for reinstallation in Step 8.
6. Remove the side impact sensor harness from the vehicle.
Important:
Removal of the side impact sensor (3) from the door sensor bracket (2) is required on the passenger's side of the vehicle.
6.1 Remove the connector position assurance connector (1) from the side impact sensor (3).
6.2 Disconnect the side impact sensor (3) from the harness connector.
6.3 Remove the side impact sensor harness fasteners from the door impact beam and inner door flange area.
6.4 Cut the side impact sensor harness (3) at the window regulator (1) location of the door harness (2).
6.5 Tape the remaining end portion of the side impact sensor harness (3) to the door harness (2) with electrical tape.
6.6 Remove the black rubber tubular grommet (1) from A-pillar.
6.7 Disconnect the lever lock connection (3).
6.8 Remove the door panel end of the black rubber tubular grommet (2) from the door.
6.9 Locate the yellow and white pair of terminal wires (driver's side) or twisted tan and green pair of terminal wires (passenger's side).
6.10 Cut the twisted pair of wires (2) at the door harness tape location (1).
6.11 Route the new side impact sensor harness (1) through the tubular grommet (2).
6.12 Remove the terminal positive assurance (TPA) from the connector (2).
6.13 Remove the cut twisted pair of wires from the connector cavities. Note the cavity locations for the yellow and white wires (driver's side) or tan and green wires (passenger's side).
Important:
The new side impact sensor harness can be installed on either front door. The twisted pair of wires at the terminal end of the new harness is the same colour (yellow and white) as the old side impact sensor wire harness on the driver's side door. When installing the new side impact sensor harness on the passenger door, insert the yellow wire in the cavity that the tan wire was removed from (C5). Insert the white wire in the cavity that the green wire was removed from (C4). When installing the new side impact sensor harness on the driver door, insert the yellow and white wires in the same cavities as the old yellow (C5) and white (C4) wire were removed from.
6.14 Install the twisted pair of wires from the new side impact sensor harness into the correct connector cavities.
6.15 Install the connector TPA.
6.16 Route the sensor end of the side impact sensor harness through the door panel grommet hole. Ensure the excess slack from the SIS harness is pulled through the grommet and into the door.
Top View
(1) Tape Location and Door Harness
(2) SIS Wires, Driver's Door Shown;
Passenger Side Similar
Bottom View
(1) Tape Location and Door Harness
(2) SIS Wires
(3) Grommet Tab, Passenger's Side
Shown; Driver's Side Similar
6.17 Completely wrap the SIS (2) wires and door harness (1) together with at least two wraps of electrical tape from the tape location on the door harness (1) to a point 25 mm (1 in) rearward of the tape location. Rearward of the tape location is toward the inside of the door panel. Forward of the tape location is toward the door harness connector. Ensure that the SIS wires and door harness are taped together on the same side of the grommet tab (3). Do not tape the SIS wires over the grommet tab (3).
6.18 Insert the door grommet into the door panel.
6.19 Secure or connect the lever lock connection.
6.20 Install the black rubber tubular grommet into the A-pillar.
6.21 Route and fasten the new side impact sensor harness along the inboard and outboard side of the impact beam (3) using the four SIS harness fasteners. The first fastener (1) on the terminal side of the SIS harness must be installed on the inboard side of the impact beam (3). The remaining three fasteners must be installed on the outboard side of the impact beam (3). Callout (1) in the illustration shows a fastener installed on the inboard side of the impact beam (3). Callout (2) in illustration shows a fastener installed on the outboard side of the impact beam (3).
6.22 Install the connector position assurance connector from the side impact sensor.
6.23 Connect the side impact sensor to the side impact sensor harness connector.
6.24 Install the side impact sensor (3) to the door sensor bracket (2) (passenger's side door only).
Tighten
Tighten the two door sensor bracket bolts to 10Nm (89lb in).
7. Clean the metal on the outboard side of the inner door.
Important:
The point of attachment for the energy absorber block is on the window regulator rail. The fasteners are attached to the energy absorber block. Remove the peel off liner from the adhesive tape before installing the energy foam block.
8. Install the energy absorber block (2) to the window regulator rail (1).
9. Install the water deflector onto the inner door.
10. Cover the two-way locator hole (1) in the door with tape.
11. Install the front side door panel. Refer to Front Side Door Trim Panel Replacement in SI.
12. Enable the SIR system. Refer to Disabling and Enabling in SI.
13. Turn the ignition switch to the ON position. The airbag telltale on the instrument panel will flash several times and then disappear if the SIS harness is installed properly. If the airbag telltale remains illuminated, the SIS harness was not installed properly. Clear the history code stored in the SDM using a Tech 2. Verify that the SIS harness terminals have been inserted into the correct connector cavity. Refer to the "Important" statement before Step 5.14 for the SIS harness and cavity information. Ensure that the SIS harness is installed correctly before submitting a claim for this repair.