Service Procedure Use wiring harness connector kit, P/N 13580234 on 2009 model year vehicles. The 2009 model year kit includes the material required to service a 4-way connector. The service procedure and illustrations below outline the repair required for 2008 model year vehicles equipped with a 2-way connector. The repair procedure for 2009 model year vehicles is the same as 2008 model year vehicles. The illustrations show a 2-way connector. The 4-way connector is similar. USE the procedure below for BOTH 2008 and 2009 model year vehicles. There are other system faults that could cause the SERVICE AIR BAG message in the DIC. This special coverage applies to DTCs B0021 and B0014. All other DTCs are not covered under this special coverage. The seat mounted side impact airbag connection to the body harness is located at the forward edge of the seat, below the plastic trim. The connectors are yellow. The body harness wires are exposed - running forward in vehicle, down through the carpet cutout in the floor.
DO NOT replace the sensing and diagnostic module (SDM), side sensors or air bag modules. Both driver and passenger seats must be repaired when this concern occurs even if only one DTC code is set. The service kit contains sufficient components to repair both seat connectors. Connector Replacement Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool
The service kit shown above includes harness and connector clips, which are not required in this installation. Replace connectors on both driver and passenger seats, and then reposition the connectors following the steps below. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Only use hand tools to remove the seat to floor mounting bolts. If there are any problems with bolt removal, refer to Corporate Bulletin Number 10-08-50-002. 2. Remove the driver's seat to floor mounting bolts. Loosen the seat from the front retainers and tilt it back to expose the underside of the seat. Refer to Front Seat Replacement - Bucket in SI.
3. Disconnect the seat to body harness connector (1). Disconnect the seat airbag connector (2).
the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing into the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Slide the conduit away on the seat airbag harness and remove just enough tape on the body harness to access the wires to install the terminals and seals.
Use caution when stripping insulation. Take care not to cut through the wire strands. 5. Slide the wire seals onto all four leads back enough to enable removal of the insulation. Install the blue seals (1) on the body harness and the white seals (2) on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation.
6. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals on to the bare wire using the J- 38125-7 crimp tool, jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness.
7. Position the wire seal to the terminal and crimp the seal and insulation using the J- 38125-6 crimp tool, jaw 1 (1).
The completed terminal and seal should appear as shown above (body harness connector shown). Avoid getting solder on the terminal end or overheating the terminal. Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. 8. Solder all four terminals at the wire crimp. 9. Slide the two body harness terminals through the opening of the orange connector position assurance (CPA) (1). Ensure that the appropriate wire colors match up (as noted in Step 4) when the connection is made between the seat airbag harness and body harness. 10. Slide all four terminals (2) into the appropriate connector body as shown above. Install the blue terminal position assurance (TPA) devices onto the connector ends. 11. Add NyoGel 760 Lubricant (dielectric lubricant), P/N 12377900 (in Canada, use P/N 10953529) (Saturn retailers, use P/N 12345579) to the terminals on both sides of the connections.
12. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent antiabrasion tape or electrical tape around the two exposed wires on the body harness up to the back of the connector. 13. Reinstall the conduit on the seat airbag harness. 14. Repeat the above procedure on the passenger seat. Reinstall Seats 1. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 2. Reconnect the seat to body harness connector and the seat airbag connector. Reroute Harness and Secure Connector Follow the procedure below to re-route and attach the harness connector to the body harness bundle:
1. The original seat airbag connector was attached with a clip to the bottom of the seat (2) as shown above.
2. Using two wire ties, secure the seat airbag connector to the seat wire bundle as shown. Ensure that there is enough slack for full range of motion of the seat. 3. Inspect the wires through the full range of motion of the seat again as in Step 2. Ensure that the wires have been secured in an orientation that allows full seat motion with adequate clearance to the connectors and sufficient slack in the wires. 4. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 5. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected.