Service Procedure
Tools RequiredJ 38778 Door Trim Pad Clip Remover
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.
Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely 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.
Skip Steps 17.0-17.24 if the vehicle is NOT equipped with roof-mounted side impact air bags. Vehicles without roof-mounted side impact airbags will NOT have the side impact sensor (SIS) harness. Review and complete the door trim panel and door energy absorber block service procedure in this bulletin.
Perform this procedure on both the driver and passenger side front side door.
Disable the SIR system. Refer to SIR Disabling and Enabling in SI.
Remove the front side door trim panel. Refer to Front Side Door Trim Panel Replacement in SI.
Inspect the water deflector to determine if two of the three foam blocks (1) have been removed from the water deflector.
If the two foam blocks have been removed from the water deflector, the door trim modifications and the energy absorber blocks have been installed. Proceed to Step 16.
If the two foam blocks have NOT been removed from the water deflector, proceed to Step 4.
Funnel
Slots
Sonic Weld
Doghouse # 1
Doghouse # 2
2-Way Locator
Panel Bridge Area
Pull Cup Screw
Map Pocket Area
Place the door trim panel on a work bench.
After separating the funnel from the beltline flange, break off the funnel from the base of the door trim panel. Ensure that the base of the trim panel is smooth after removing the funnel.
Remove the tunnel (1) from the beltline flange.
The first slot is to the left of the funnel location. Refer to (1) in illustration.
Cut out the first three slots from the beltline flange.
Do not drill a hole through the door trim panel. Only drill through the sonic weld to avoid damaging the door trim panel.
Drill out the sonic weld (2).
Cut two notches into the front base of the doghouse # 1 (1). Make the cuts 3.1 mm (1/8 in) in diameter.
Cut two notches into the backside of doghouse # 2 (2). Make the cuts 3.1 mm (1/8 in) in diameter.
Remove the two-way locator (1) from the base of the door trim panel. Ensure that the base of the trim panel is smooth after removing the two-way locator from the base of the door trim panel.
Refer to the illustration before Step 4 for location reference. Callout (7) is the bridge area of the door trim panel. Cut a notch (1) in the bridge area of the door trim panel. Cut the notch 2 mm (5/64 in) deep and 10 mm (25/64 in) long.
Remove the screw and boss (1) from the pull cup.
Clean the map pocket area of the door trim panel.
Remove the peel-off liner from the adhesive tape before installing the energy absorber plastic cone. Insert the energy absorber plastic cone (1) below the map pocket area as shown in the illustration.
Remove the two foam blocks (1) from the water deflector.
Carefully peel back the water deflector (2) to expose the inner door and window regulator rail (1). If the energy absorber block is attached to the window regulator rail, remove it. Retain the energy absorber block and fasteners for reinstallation in Step 19.
Determine if there is a side impact sensor and side impact sensor harness. Note the routing of the side impact sensor 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
17-24.
If the vehicle is not equipped with the side impact sensor and SIS harness, or 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 Door Inspection - No Repair Required.
Remove the side impact sensor harness from the vehicle.
Removal of the side impact sensor (3) from the door sensor bracket (2) is required on the passenger's side of the vehicle.
Remove the connector position assurance connector (1) from the side impact sensor (3).
Disconnect the side impact sensor (3) from the harness connector.
Remove the side impact sensor harness fasteners from the door impact beam and inner door flange area.
Cut the side impact sensor harness (3) at the window regulator (1) location of the door harness (2).
Tape the remaining end portion of the side impact sensor harness (3) to the door harness (2) with electrical tape.
Remove the black rubber tubular grommet (1) from A-pillar.
Disconnect the lever lock connection (3).
Remove the door panel end of the black rubber tubular grommet (2) from the door.
Locate the yellow and white pair of terminal wires (driver's side) or twisted tan and green pair of terminal wires (passenger's side).
Cut the twisted pair of wires (2) at the door harness tape location (1)
Route the new side impact sensor harness (1) through the tubular grommet (2).
Remove the terminal positive assurance (TPA) from the connector (2).
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).
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 color (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.
Install the twisted pair of wires from the new side impact sensor harness into the correct connector cavities.
Install the connector TPA.
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
Tape Location and Door Harness
SIS Wires, Driver's Side Shown; Passenger's Side Similar
Bottom View
Tape Location and Door Harness
SIS Wires
Grommet Tab, Passenger's Side Shown, Driver's Side Similar
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).
Insert the door grommet into the door panel.
Secure or connect the lever lock connection.
Install the black rubber tubular grommet into the A-pillar.
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).
Install the connector position assurance connector from the side impact sensor.
Connect the side impact sensor to the side impact sensor harness connector.
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 10 N.m (89 lb in).
Clean the metal on the outboard side of the inner door.
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.
Install the energy absorber block (2) to the window regulator rail (1).
Install the water deflector onto the inner door.
Cover the two-way locator hole (1) in the door with tape.
Install the front side door panel. Refer to Front Side Door Trim Panel Replacement in SI.
Enable the SIR system. Refer to Disabling and Enabling in SI.
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 17.14 for the SIS harness and cavity information. Ensure that the SIS harness is installed correctly before submitting a claim for this repair.