Service Procedure
Service ProcedureAir Bag Connector Inspection
1. Move the driver's seat to the maximum forward position and raise the seat to its maximum height.
2. Using a flash light, locate the air bag and body wire harnesses.
Note
Vehicles that have new air bag connectors will have a tie strap securing the two (2) wires exiting the air bag connector to the main body wiring harness. In addition, the new air bag connectors will have an orange connector position assurance (CPA) clip that is tethered to the connector. Ensure both the orange CPA clip and tie strap are located. Air bag and body wire harnesses without the tie strap and/or CPA clip must have the air bag connectors replaced.
3. Determine if the new air bag connectors have been installed.
- If the vehicle is equipped with the new air bag connectors, no further action is required. Refer to Warranty Transaction Information in this bulletin.
- If the vehicle is NOT equipped with the new air bag connectors, replace the air bag connectors. Refer to Replace Wire Harness Connector in this bulletin.
Replace Wire Harness Connector
Tools Required
- J-38125-7, Crimp Tool
- J-38125-6, Crimp Tool
Note
The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit.
1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI.
(Seat shown out-of-vehicles for illustration purposes)
2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2).
Note
Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002.
3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI.
Note
Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing 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.
Note
The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6.
5. Slide the conduit away and remove the tape (1).
Caution
Use caution when stripping insulation. Take care not to cut through the wire strands.
6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation.
7. 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 onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness.
8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1).
Warning
DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the SIR 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.
Note
Avoid getting solder on the terminal end or overheating the terminal.
9. Solder all four terminals at the wire crimp.
10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1).
Note
Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness.
11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends.
12. Install the gray connector clip onto the appropriate connector body.
13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections.
14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector.
15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in).
16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector.
17. Repeat the above procedure on the passenger seat.
Attach Driver's Side Harness to Seat
1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration.
2. Ensure that the service loop (2) faces towards the front of the seat.
3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration.
4. Attach the existing black clip to the new seat suspension location (4).
Attach Passenger Side Harness to Seat
1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration.
2. Ensure that the service loop (2) faces towards the front of the seat.
3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration.
4. Attach the existing black clip to the new seat suspension location (4).
Reinstall Seats
1. Make the connections between the seat airbag harness and the body harness.
Note
Apply medium strength Loctite (blue) to bolts before installing.
2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI.
3. Move the seat to the maximum forward position and raise the seat to its maximum height.
4. Using a flash light, locate the air bag and body wire harnesses.
5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1).
6. Remove excess tie strap with wire cutters.
7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI.
8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI.