Supplemental Inflatable Restraint System Chevrolet Malibu VI

Fastener Tightening Specifications

Fastener Tightening Specifications

SIR Schematic Icons

SIR Schematic Icons Icon Icon Definition CAUTION: 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 Zones. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. IMPORTANT: In order to prevent accidental deployment, the shorting bars close in order to short the connectors when the connectors are separated. Twisted-pair wires provide an effective shield that helps protect sensitive electronic components from electrical interference. If the wires were covered with shielding, install new shielding. In order to prevent electrical interference from degrading the performance of the connected components, you must maintain the proper specification when making any repairs to the twisted-pair wires shown : The wires must be twisted a minimum of 9 turns per 31 cm (12 in) as measured anywhere along the length of the wires The outside diameter of the twisted wires must not exceed 6.0 mm (0.25 in)

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SIR Zone Identification Views

The SIR Zone Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling Zones for a given service procedure, refer to SIR Disabling and Enabling Zones .

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SIR Connector End Views

Inflatable Restraint Front End Sensor - Left Connector Part Information 15356722 2-Way F GT 150 Series, Sealed (YE) Pin Wire Color Circuit No. Function A TN/OG 5045 Front End Sensor - Left - Signal B YE 354 Front End Sensor - Left - Low Reference

Inflatable Restraint Front End Sensor - Right Connector Part Information 15356722 2-Way F GT 150 Series, Sealed (YE) Pin Wire Color Circuit No. Function A GY 5600 Front End Sensor - Right - Low Reference B D-GN 1409 Front End Sensor - Right - Signal

Inflatable Restraint I/P Module Connector Part Information 15336476 4-Way M Metri-Pack 280 Series, Sealed (YE) Pin Wire Color Circuit No. Function A1 YE 3025 I/P Module Stage 1 - High Control A2 OG 3024 I/P Module Stage 1 - Low Control B1 GY 3027 I/P Module Stage 2 - High Control B2 PU 3026 I/P Module Stage 2 - Low Control

Inflatable Restraint Sensing and Diagnostic Module (SDM) (AK5) Connector Part Information 15456067 60-Way F Micro-Pack 64 Series (BU) With (YE) Case Pin Wire Color Circuit No. Function 1 RD/WT 1340 Battery Positive Voltage 2 D-GN 5060 Low Speed GMLAN Serial Data 3 PK 5057 Low Reference 4 D-GN 5016 Seat Belt Switch - Left - Signal 5-11 - - Not Used 12 PU 3026 I/P Module Stage 2 - Low Control 13 GY 3027 I/P Module Stage 2 - High Control 14 TN 3021 Steering Wheel Module - Stage 1 - High Control 15 BN 3020 Steering Wheel Module - Stage 1 - Low Control 16 PK 3022 Steering Wheel Module Stage 2 - Low Control 17 WH 3023 Steering Wheel Module - Stage 2 - High Control 18 YE 3025 I/P Module Stage 1 - High Control 19 OG 3024 I/P Module Stage 1 - Low Control 20-30 - - Not Used 31 BK 1851 Ground (Sedan) BK/WH 1851 Ground (Extended Sedan) 32 D-GN 5060 Low Speed GMLAN Serial Data 33 PK 1139 Ignition 1 Voltage 34-35 - - Not Used 36 GY 5600 Front End Sensor - Right - Low Reference 37 D-GN 1409 Front End - Sensor - Right Signal 38 YE 354 Front End Sensor - Left - Low Reference 39 TN/OG 5045 Front End Sensor - Left - Signal 40-51 - - Not Used 52 L-GN 2116 Seat Belt Pretensioner - Right - High Control 53 OG 2117 Seat Belt Pretensioner - Right - Low Control 54-55 - - Not Used 56 TN/WH 2118 Seat Belt Pretensioner - Left - High Control 57 OG/BK 2119 Seat Belt Pretensioner - Left - Low Control 58-60 - - Not Used

Inflatable Restraint Sensing and Diagnostic Module (SDM) (AY1) Connector Part Information 15456069 60-Way F Micro-Pack 64 Series (RD) With (YE) Case Pin Wire Color Circuit No. Function 1 RD/WH 1340 Battery Positive Voltage 2 D-GN 5060 Low Speed GMLAN Serial Data 3 PK 5057 Low Reference 4 D-GN 5016 Seat Belt Switch - Left - Signal 5-7 - - Not Used 8 YE/BK 2138 Side Impact Module - LF Low Control 9 BN 2137 Side Impact Module - LF High Control 10 TN/WH 2135 Side Impact Module - RF High Control 11 L-GN 2136 Side Impact Module - RF Low Control 12 PU 3026 I/P Module Stage 2 - Low Control 13 GY 3027 I/P Module Stage 2 - High Control 14 TN 3021 Steering Wheel Module - Stage 1 - High Control 15 BN 3020 Steering Wheel Module - Stage 1 - Low Control 16 PK 3022 Steering Wheel Module - Stage 2 - Low Control 17 WH 3023 Steering Wheel Module - Stage 2 - High Control 18 YE 3025 I/P Module Stage 1 - High Control 19 OG 3024 I/P Module Stage 1 - Low Control 20-30 - - Not Used 31 BK 1851 Ground (Sedan) BK/WH 1851 Ground (Extended Sedan) 32 D-GN 5060 Low Speed GMLAN Serial Data 33 PK 1139 Ignition 1 Voltage 34-35 - - Not Used 36 GY 5600 Front End Sensor - Right - Low Reference 37 D-GN 1409 Front End Sensor - Right - Signal 38 YE 354 Front End Sensor - Left - Low Reference 39 TN/OG 5045 Front End Sensor - Left - Signal 40-45 - - Low Reference 46 YE 2131 Side Impact Sensing Module - Left - Voltage 47 WH 2132 Side Impact Sensing Module - Left - Signal 48 D-GN 2134 Side Impact Sensing Module - Right - Signal 49 TN 2133 Side Impact Sensing Module - Right - Voltage 50-51 - - Not Used 52 L-GN 2116 Seat Belt Pretensioner - Right - High Control 53 OG 2117 Seat Belt Pretensioner - Right - Low Control 54-55 - - Not Used 56 TN/WH 2118 Seat Belt Pretensioner - Left - High Control 57 OG/BK 2119 Seat Belt Pretensioner - Left - Low Control 58-60 - - Not Used

Inflatable Restraint Side Impact Module - Left (AY1) Connector Part Information CA-252-92-5-Q 2-Way F (PU) With (YE) Case Pin Wire Color Circuit No. Function 1 WH 2137 Left Impact Module - LF - High Control (AY1) 2 D-GN 2138 Side Impact Module - LF - Low Control (AY1)

Inflatable Restraint Side Impact Module - Right (AY1) Connector Part Information CA-252-92-5-Q 2-Way F (PU) With (YE) Case Pin Wire Color Circuit No. Function 1 WH 2135 Side Impact Module - RF - High Control 2 D-GN 2138 Side Impact Module - RF - Low Control

Inflatable Restraint Side Impact Sensor - Left (AY1) Connector Part Information 15356724 2-Way F GT 150 Series, Sealed (YE) Pin Wire Color Circuit No. Function A WH 2132 Side Impact Sensing Module - Left - Signal B YE 2131 Side Impact Sensing Module - Left - Voltage

Inflatable Restraint Side Impact Sensor - Right (AY1) Connector Part Information 15356724 2-Way F GT 150 Series, Sealed (YE) Pin Wire Color Circuit No. Function A D-GN 2134 Side Impact Sensing Module - Right - Signal B TN 2133 Side Impact Sensing Module - Right - Voltage

Inflatable Restraint Steering Wheel Module C1 Connector Part Information CA-252-92-4 R 2-Way F AMP (GY) With (YE) Case Pin Wire Color Circuit No. Function 1 TN 3021 Steering Wheel Module - Stage 1 - High Control 2 BN 3020 Steering Wheel Module - Stage 1 - Low Control

Inflatable Restraint Steering Wheel Module C2 Connector Part Information CA-252-92-4 R 2-Way F AMP (PU) With (YE) Case Pin Wire Color Circuit No. Function 1 WH 3023 Steering Wheel Module - Stage 2 - High Control 2 PK 3022 Steering Wheel Module - Stage 2 - Low Control

Inflatable Restraint Steering Wheel Module Coil C1 Connector Part Information 15393421 4-Way F Micro-Pack 064 Series (YE) Pin Wire Color Circuit No. Function 1 BN 3020 Steering Wheel Module - Stage 1 - Low Control 2 TN 3021 Steering Wheel Module - Stage 1 - High Control 3 PK 3022 Steering Wheel Module - Stage 2 - Low Control 4 WH 3023 Steering Wheel Module - Stage 2 - High Control

Inflatable Restraint Steering Wheel Module Coil C2 Connector Part Information 15393433 10-Way F Micro 64 Series (BK) Pin Wire Color Circuit No. Function A-B - - Not Used C PK 339 Ignition 1 Voltage (K34) D GY 1884 Cruise Control Switch Signal (K34) E D-BU 1796 Steering Wheel Controls Signal (UK3) F WH/BK 644 10-Volt Reference (UK3) G GY 8 Instrument Panel Lamp Supply Voltage (K34) H - - Not Used J TN 28 Horn Relay Control K BK/WH 651 Ground

Inflatable Restraint Steering Wheel Module Coil C3 Connector Part Information 15393433 10-Way F Micro 64 Series (BK) Pin Wire Color Circuit No. Function A-B - - Not Used C PK 339 Ignition 1 Voltage (K34) D GY 1884 Cruise Control Switch Signal (K34) E D-BU 1796 Steering Wheel Controls Signal (UK3) F WH/BK 644 10-Volt Reference (UK3) G GY 8 Instrument Panel Lamp Supply Voltage (K34) H - - Not Used J TN 28 Horn Relay Control K BK/WH 651 Ground

Seat Belt Pretensioner - Driver Connector Part Information CA-252-92-5 Q 2-Way F (PU) With (YE) Case Pin Wire Color Circuit No. Function 1 OG/BK 2119 Seat Belt Pretensioner - Left - Low Control 2 TN/WH 2118 Seat Belt Pretensioner - Left - High Control

Seat Belt Pretensioner - Front Passenger Connector Part Information CA-252-92-5 Q 2-Way F (PU) With (YE) Case Pin Wire Color Circuit No. Function 1 OG/BK 2117 Seat Belt Pretensioner - Right - Low Control 2 TN/WH 2116 Seat Belt Pretensioner - Right - High Control

Diagnostic Starting Point - SIR

Begin the system diagnosis with the Diagnostic System Check - Vehicle in Vehicle DTC Information. The Vehicle System Check will provide the following information

1. The identification of the control module(s) which commands the system
2. The ability of the control module(s) to communicate through the serial data circuit
3. The identification of any stored diagnostic trouble codes (DTCs) and their status

The use of Vehicle System Check will identify the correct procedure for diagnosing the system and where the procedure is located.

Scan Tool Data List

The SIR scan tool data list contains all the restraint system related parameters that are available on the scan tool. The parameters in the list are arranged in alphabetical order. The column, Data List, indicates the location of the parameter within the scan tool menu selections.

Use the SIR scan tool data list as directed by a diagnostic table or in order to supplement the diagnostic procedures. Begin all of the diagnostic procedures with the Diagnostic System Check - SIR. Use the SIR Scan Tool Data List after the following is determined

1. There is no published diagnostic trouble code (DTC) procedure nor published symptom procedure for the customer concern.
2. The DTC or symptom diagnostic procedure indicated by the diagnostic system check does not resolve the customer concern.

The typical data values are obtained from a properly operating vehicle under the conditions specified in the second row of the scan tool data list table. Comparison of the parameter values from the suspect vehicle with the typical data values may reveal the source of the customer concern.

SIR Scan Tool Data List

Scan Tool Data Definitions

The SIR scan tool data definitions contain a brief description of all SIR related parameters available on the scan tool. The parameters that are available on the scan tool are listed below in alphabetical order.

Circuit Description

The driver frontal deployment loop consists of the following components

1. A dual stage inflatable restraint steering wheel module.
2. The inflatable restraint steering wheel module coil.
3. The steering wheel module high circuits for both stages 1 and 2.
4. The steering wheel module low circuits for both stages 1 and 2.

There are 2 shorting bars used within the steering wheel module coil connector which will short together both steering wheel module stage 1 high circuit and steering wheel module stage 1 low circuit and both steering wheel module stage 2 high circuit and steering wheel module stage 2 low circuit when the connector is disconnected, this will help to prevent unwanted deployment of the inflator module during servicing. During a frontal crash of sufficient force, the inflatable restraint sensing and diagnostic module (SDM) will allow current to flow through the deployment loop in order to deploy the steering wheel module. The SDM performs continuous diagnostic tests on the deployment loops to check for proper circuit continuity and for shorts to ground or voltage. If a malfunction is detected, a diagnostic trouble code (DTC) will be stored in memory.

DTC Descriptors

1. DTC B0012 Driver Frontal Deployment Loop Stage 1
2. DTC B0013 Driver Frontal Deployment Loop Stage 2

DTC B0012 or B0013

Conditions for Running the DTC

Ignition voltage is within the normal operating voltage range.

B0012 - B0013 01

The steering wheel module high and/or low circuit is short to voltage for 120 milliseconds.

B0012 - B0013 02

The steering wheel module high and/or low circuit is short to ground for 120 milliseconds.

B0012 - B0013 04

The steering wheel module high and/or low circuit is open for 120 milliseconds.

B0012 - B0013 0D

The steering wheel module deployment loop resistance is more than 5.1 ohms for 120 milliseconds.

B0012 - B0013 0E

The steering wheel module deployment loop resistance is less than 1.3 ohms for 120 milliseconds.

Action Taken When the DTC Sets

The SDM commands the AIR BAG indicator ON via GMLAN serial data.

Conditions for Clearing the MIL/DTC

1. The condition responsible for setting the DTC no longer exists and the scan tool Clear DTCs function is used.
2. A history DTC will clear once 255 malfunction free ignition cycles have occurred.

Diagnostic Aids

The following are possible causes of the malfunction

1. A short between the steering wheel module stage 1 or stage 2, high and low circuits.
2. An open or a high resistance in the steering wheel module stage 1 or stage 2, high or low circuits.
3. A short to ground or a short to voltage in the steering wheel module stage 1 or stage 2, high or low circuits.
4. The steering wheel module coil connector.
5. The SDM connector.
6. A malfunctioning steering wheel module.
7. A malfunctioning steering wheel module coil.
8. A malfunctioning SDM.

Thoroughly inspect the wiring and the connectors. An incomplete inspection of the wiring and the connectors may result in a misdiagnosis, causing a part replacement with the reappearance of the malfunction. If an intermittent malfunction exists, refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. 5: Tests to see if the malfunction is caused by the steering wheel module or by the steering wheel module coil.
2. 6: Tests to see if the steering wheel module coil or by the steering wheel module coil in line connector located behind the steering wheel module coil.
3. 7: Tests to see what DTCs are present. If DTC B0012 01 or B0013 01 is present, test the steering wheel module for a short to battery voltage on the high and low circuits in stage 1 or stage 2. If DTC B0012 02 or B0013 02 is present, test the steering wheel module for a short to ground on the high and low circuits in stage 1 or stage 2. If DTC B0012 04, 0D, 0E or B0013 04, 0D, 0E is present, test the high and low circuits for an open circuit and for high or low resistance in stage 1 or stage 2.

DTC B0012 or B0013

The driver seat belt pretensioner deployment loop consists of an seat belt pretensioner-LF, the seat belt pretensioner-LF high and seat belt pretensioner-LF low circuits. A shorting bar used within the seat belt pretensioner connector which will short together both seat belt pretensioner high and low circuits when the connector is disconnected, this will help to prevent unwanted deployment of the pretensioner during servicing. During a frontal crash of sufficient force the inflatable restraint sensing and diagnostic module (SDM) will allow current to flow through the deployment loop in order to deploy the seat belt pretensioner. The SDM performs continuous diagnostic tests on the deployment loops to check for proper circuit continuity and for shorts to ground or voltage. If a malfunction is detected, a diagnostic trouble code (DTC) will be stored in memory.

DTC B0015 Left Front Seat Belt Pretensioner Deployment Loop

DTC B0015

Ignition voltage is within the normal operating voltage range.

B0015 01

The seat belt pretensioner-LF high and/or low circuit is short to voltage for 120 milliseconds.

B0015 02

The seat belt pretensioner-LF high and/or low circuit is short to ground for 120 milliseconds.

B0015 04

The seat belt pretensioner-LF high and/or low circuit is open for 120 milliseconds.

B0015 0D

The seat belt pretensioner-LF deployment loop resistance is more than 3.9 ohms for 120 milliseconds.

B0015 0E

The seat belt pretensioner-LF deployment loop resistance is less than 1.1 ohms for 120 milliseconds.

The SDM commands the AIR BAG indicator ON via GMLAN serial data.

1. The condition responsible for setting the DTC no longer exists and the scan tool Clear DTCs function is used.
2. A history DTC will clear once 255 malfunction free ignition cycles have occurred.

The following are possible causes of the malfunction

1. A short between the seat belt pretensioner-LF high and low circuits.
2. An open or a high resistance in the seat belt pretensioner-LF high or low circuits.
3. A short to ground or a short to voltage in the seat belt pretensioner-LF high or low circuits.
4. The seat belt pretensioner-LF connector
5. The SDM connector
6. A malfunctioning seat belt pretensioner
7. A malfunctioning SDM

Thoroughly inspect the wiring and the connectors. An incomplete inspection of the wiring and the connectors may result in a misdiagnosis, causing a part replacement with the reappearance of the malfunction. If an intermittent malfunction exists, refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

The numbers below refer to the step numbers on the diagnostic table.

1. 4: Tests to see if the malfunction is caused by the seat belt pretensioner-LF.
2. 6: Tests to see what DTCs are present. If DTC B0015 01 is present, test the seat belt pretensioner-LF for a short to battery voltage on the high and low circuits. If DTC B0015 02 is present, test the seat belt pretensioner-LF high and low circuits for a short to ground. If DTC B0015 04, 0D, 0E is present, test the seat belt pretensioner-LF high and low circuits for an open circuit and for high or low resistance.

DTC B0015

The passenger roof rail deployment loop consists of an inflatable restraint roof rail module-left, the roof rail module-left high and roof rail module-left low circuits. A shorting bar used within the roof rail module connector which will short together both roof rail module-left high and low circuits when the connector is disconnected, this will help to prevent unwanted deployment of the inflator module during servicing. During a side or frontal crash of sufficient force the inflatable restraint sensing and diagnostic module (SDM) will allow current to flow through the deployment loop in order to deploy the roof side rail module. The SDM performs continuous diagnostic tests on the deployment loops to check for proper circuit continuity and for shorts to ground or voltage. If a malfunction is detected, a diagnostic trouble code (DTC) will be stored in memory.

DTC B0016 Left Roof Rail Deployment Loop

DTC B0016

Ignition voltage is within the normal operating voltage range.

B0016 01

The roof rail module-left high and/or low circuit is short to voltage for 120 milliseconds.

B0016 02

The roof rail module-left high and/or low circuit is short to ground for 120 milliseconds.

B0016 04

The roof rail module-left high and/or low circuit is open for 120 milliseconds.

B0016 0D

The roof rail module-left deployment loop resistance is more than 3.9 ohms for 120 milliseconds.

B0016 0E

The roof rail module-left deployment loop resistance is less than 1.1 ohms for 120 milliseconds.

The SDM commands the AIR BAG indicator ON via GMLAN serial data.

1. The condition responsible for setting the DTC no longer exists and the scan tool Clear DTCs function is used.
2. A history DTC will clear once 255 malfunction free ignition cycles have occurred.

The following are possible causes of the malfunction

1. A short between the roof rail module-left high and low circuits.
2. An open or a high resistance in the roof rail module-left high or low circuits.
3. A short to ground or a short to voltage in the roof rail module-left high or low circuits.
4. The roof rail module-left connector
5. The SDM connector
6. A malfunctioning roof rail module-left
7. A malfunctioning SDM

Thoroughly inspect the wiring and the connectors. An incomplete inspection of the wiring and the connectors may result in a misdiagnosis, causing a part replacement with the reappearance of the malfunction. If an intermittent malfunction exists, refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

The numbers below refer to the step numbers on the diagnostic table.

1. 4: Tests to see if the malfunction is caused by the roof rail module-left.
2. 6: Tests to see what DTCs are present. If DTC B0016 01 is present, test the roof rail module-left for a short to battery voltage on the high and low circuits. If DTC B0016 02 is present, test the roof rail module-left for a short to ground on the high and low circuits. If DTC B0016 04, 0D, 0E is present, test the roof rail module-left test the high and low circuits for an open circuit and for high or low resistance.

DTC B0016

The passenger frontal deployment loop consists of the following components

1. A dual stage inflatable restraint I/P module
2. The I/P module high circuits for both stages 1 and 2
3. The I/P module low circuits for both stages 1 and 2

There are 2 shorting bar used within the I/P module connector which will short together both I/P module stage 1 high and low circuits and both I/P module stage 2 high and low circuits when the connector is disconnected, this will help to prevent unwanted deployment of the inflator module during servicing. During a frontal crash of sufficient force the inflatable restraint sensing and diagnostic module (SDM) will allow current to flow through the deployment loop in order to deploy the I/P module. The SDM performs continuous diagnostic tests on the deployment loops to check for proper circuit continuity and for shorts to ground or voltage. If a malfunction is detected, a diagnostic trouble code (DTC) will be stored in memory.

1. DTC B0019 Passenger Frontal Deployment Loop Stage 1
2. DTC B0020 Passenger Frontal Deployment Loop Stage 2

DTC B0019 or B0020

Ignition voltage is within the normal operating voltage range.

B0019 01 stage 1 or B0020 01 stage 2

The I/P module high and/or low circuit is short to voltage for 120 milliseconds.

B0019 02 stage 1 or B0020 02 stage 2

The I/P module high and/or low circuit is short to ground for 120 milliseconds.

B0019 04 stage 1 or B0020 04 stage 2

The I/P module high and/or low circuit is open for 120 milliseconds.

B0019 0D stage 1 or B0020 0D stage 2

The I/P module deployment loop resistance is more than 5.1 ohms for 120 milliseconds.

B0019 0E stage 1 or B0020 0E stage 2

The I/P module deployment loop resistance is less than 1.3 ohms for 120 milliseconds.

The SDM commands the AIR BAG indicator ON via GMLAN serial data.

1. The condition responsible for setting the DTC no longer exists and the scan tool Clear DTCs function is used.
2. A history DTC will clear once 255 malfunction free ignition cycles have occurred.

The following are possible causes of the malfunction

1. A short between the I/P module stage 1 or stage 2, high and low circuits.
2. An open or a high resistance in the I/P module stage 1 or stage 2, high or low circuits.
3. A short to ground or a short to voltage in the I/P module stage 1 or stage 2, high or low circuits.
4. The I/P module connector
5. The SDM connector
6. A malfunctioning I/P module
7. A malfunctioning SDM

Thoroughly inspect the wiring and the connectors. An incomplete inspection of the wiring and the connectors may result in a misdiagnosis, causing a part replacement with the reappearance of the malfunction. If an intermittent malfunction exists, refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

The numbers below refer to the step numbers on the diagnostic table.

1. 4: Tests to see if the malfunction is caused by the I/P module.
2. 6: If DTC B0019 01 or B0020 01 is present, test the I/P module for a short to battery voltage on the high and low circuits in stage 1 or stage 2. If DTC B0019 02 or B0020 02 is present, test the I/P module for a short to ground on the high and low circuits in stage 1 or stage 2. If DTC B0019 04, 0D, 0E or B0020 04, 0D, 0E is present, test the high and low circuits for an open circuit and for high or low resistance in stage 1 or stage 2.

DTC B0019 or B0020

The passenger seat belt pretensioner deployment loop consists of an seat belt pretensioner-RF, the seat belt pretensioner-RF high and seat belt pretensioner-RF low circuits. A shorting bar used within the seat belt pretensioner connector which will short together both seat belt pretensioner high and low circuits when the connector is disconnected, this will help to prevent unwanted deployment of the pretensioner during servicing. During a frontal crash of sufficient force the inflatable restraint sensing and diagnostic module (SDM) will allow current to flow through the deployment loop in order to deploy the seat belt pretensioner. The SDM performs continuous diagnostic tests on the deployment loops to check for proper circuit continuity and for shorts to ground or voltage. If a malfunction is detected, a diagnostic trouble code (DTC) will be stored in memory.

DTC B0022 Right Front Seat Belt Pretensioner Deployment Loop

DTC B0022

Ignition voltage is within the normal operating voltage range.

B0022 01

The seat belt pretensioner-RF high and/or low circuit is short to voltage for 120 milliseconds.

B0022 02

The seat belt pretensioner-RF high and/or low circuit is short to ground for 120 milliseconds.

B0022 04

The seat belt pretensioner-RF high and/or low circuit is open for 120 milliseconds.

B0022 0D

The seat belt pretensioner-RF deployment loop resistance is more than 3.9 ohms for 120 milliseconds.

B0022 0E

The seat belt pretensioner-RF deployment loop resistance is less than 1.1 ohms for 120 milliseconds.

The SDM commands the AIR BAG indicator ON via GMLAN serial data.

1. The condition responsible for setting the DTC no longer exists and the scan tool Clear DTCs function is used.
2. A history DTC will clear once 255 malfunction free ignition cycles have occurred.

The following are possible causes of the malfunction

1. A short between the seat belt pretensioner-RF high and low circuits.
2. An open or a high resistance in the seat belt pretensioner-RF high or low circuits.
3. A short to ground or a short to voltage in the seat belt pretensioner-RF high or low circuits.
4. The seat belt pretensioner-RF connector
5. The SDM connector
6. A malfunctioning seat belt pretensioner
7. A malfunctioning SDM

Thoroughly inspect the wiring and the connectors. An incomplete inspection of the wiring and the connectors may result in a misdiagnosis, causing a part replacement with the reappearance of the malfunction. If an intermittent malfunction exists, refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

The numbers below refer to the step numbers on the diagnostic table.

1. 4: Tests to see if the malfunction is caused by the seat belt pretensioner-RF.
2. 6: Tests to see what DTCs are present. If DTC B0022 01 is present, test the seat belt pretensioner-RF for a short to battery voltage on the high and low circuits. If DTC B0022 02 is present, test the seat belt pretensioner-RF high and low circuits for a short to ground. If DTC B0022 04, 0D, 0E is present, test the seat belt pretensioner-RF high and low circuits for an open circuit and for high or low resistance.

DTC B0022

The passenger roof rail deployment loop consists of an inflatable restraint roof rail module-right, the roof rail module-right high and roof rail module-right low circuits. A shorting bar used within the roof rail module connector which will short together both roof rail module-right high and low circuits when the connector is disconnected, this will help to prevent unwanted deployment of the inflator module during servicing. During a side or frontal crash of sufficient force the inflatable restraint sensing and diagnostic module (SDM) will allow current to flow through the deployment loop in order to deploy the roof side rail module. The SDM performs continuous diagnostic tests on the deployment loops to check for proper circuit continuity and for shorts to ground or voltage. If a malfunction is detected, a diagnostic trouble code (DTC) will be stored in memory.

DTC B0023 Right Roof Rail Deployment Loop

DTC B0023

Ignition voltage is within the normal operating voltage range.

B0023 01

The roof rail module-right high and/or low circuit is short to voltage for 120 milliseconds.

B0023 02

The roof rail module-right high and/or low circuit is short to ground for 120 milliseconds.

B0023 04

The roof rail module-right high and/or low circuit is open for 120 milliseconds.

B0023 0D

The roof rail module-right deployment loop resistance is more than 3.9 ohms for 120 milliseconds.

B0023 0E

The roof rail module-right deployment loop resistance is less than 1.1 ohms for 120 milliseconds.

The SDM commands the AIR BAG indicator ON via GMLAN serial data.

1. The condition responsible for setting the DTC no longer exists and the scan tool Clear DTCs function is used.
2. A history DTC will clear once 255 malfunction free ignition cycles have occurred.

The following are possible causes of the malfunction

1. A short between the roof rail module-right high and low circuits.
2. An open or a high resistance in the roof rail module-right high or low circuits.
3. A short to ground or a short to voltage in the roof rail module-right high or low circuits.
4. The roof rail module-right connector
5. The SDM connector
6. A malfunctioning roof rail module-right
7. A malfunctioning SDM

Thoroughly inspect the wiring and the connectors. An incomplete inspection of the wiring and the connectors may result in a misdiagnosis, causing a part replacement with the reappearance of the malfunction. If an intermittent malfunction exists, refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

The numbers below refer to the step numbers on the diagnostic table.

1. 4: Tests to see if the malfunction is caused by the roof rail module-right.
2. 6: Tests to see what DTCs are present. If DTC B0023 01 is present, test the roof rail module-right for a short to battery voltage on the high and low circuits. If DTC B0023 02 is present, test the roof rail module-right for a short to ground on the high and low circuits. If DTC B0023 04, 0D, 0E is present, test the roof rail module-right test the high and low circuits for an open circuit and for high or low resistance.

DTC B0023

The inflatable restraint sensing and diagnostic module (SDM) contains a sensing device that converts vehicle velocity changes into an electrical signal. The SDM compares this electrical signal to a value stored in memory. When the generated signal exceeds the stored value, the SDM performs additional signal processing and compares the generated signals to values stored in memory. When two of the generated signals exceed the stored values, the SDM will cause current to flow through the deployment loops, deploying the air bags and/or pretensioners causing DTC B0052 to set.

Ignition 1 voltage must be within the normal operating range.

Conditions for Setting the DTC

The DTC will set if one of the following conditions occurs.

1. The SDM detects a frontal impact of sufficient force to warrant deployment of the frontal inflator modules.
2. The SDM detects a side impact of sufficient force to warrant deployment of a roof rail inflator module.
3. The SDM has deployed the seatbelt pretensioner for 3 separate deployments.

1. The SDM commands the AIR BAG warning lamp ON via GMLAN serial data.
2. The SDM records crash data.

Conditions for Clearing the DTC

DTC B0052 becomes a latched code after 3 consecutive pretensioner deployments or 1 frontal or side air bag deployment. You cannot clear a latched code. Replace the SDM after following the instructions in the diagnostic table.

The seat belt pretensioners may deploy for impacts that are not severe enough to warrant frontal or side air bag deployment. The SDM is capable of sustaining 3 pretensioner deployment events, or 1 frontal or side deployment event. After the maximum number of deployments has occurred, DTC B0052 sets and becomes a latched code, which cannot be cleared.

DTC B0052

The inflatable restraint sensing and diagnostic module (SDM) contains a sensing device that converts vehicle velocity and convert this to a electrical signal. The SDM processes the generated electrical signal and compares the signal to a value stored in memory. If the generated signal exceeds the stored value, the SDM performs additional signal processing and compares the generated signals to signals stored in memory. When two of the generated signals exceed the stored values, the SDM will cause current to flow through the inflator modules, deploying the air bags. DTC B0053 will set along with DTC B0052 when a deployment occurs while an inflator circuit fault is present that may result in a non-deployment situation in one or more inflator modules.

Ignition 1 voltage must be present.

SDM commands inflators deployment with loop faults present.

1. The SDM sets DTC B0052.
2. The SDM sets DTC B0053.
3. The SDM commands the AIR BAG warning lamp ON via GMLAN serial data.
4. The SDM records crash data.

DTC B0053 is a latched code. You cannot clear a latched code. Replace the SDM after following the instructions in the diagnostic table.

When DTC B0053 is accompanied by additional DTCs, other than B0052, repair the malfunction causing the other DTCs before replacing SDM.

DTC B0053

The inflatable restraint front end sensor also known as the electronic frontal sensor (EFS) utilizes a unidirectional 2-wire circuit. The front end sensor modulates current on the interface to send ID, State of Health, and deployment commands to the inflatable restraint sensing and diagnostic module (SDM). The SDM serves as a power source and a ground for the front end sensor. When the ignition is turned on and input power from the SDM is first detected, the front end sensor responds by performing internal diagnostics and sending an ID to the SDM. The SDM considers the ID to be valid if the response time is less than 5 seconds. The front end sensor continually communicates status messages to the SDM, which determines if a fault is present in the front end sensor circuit. When a fault is detected, the SDM may reset the front end sensor up to two times by removing and reapplying power to it. If the fault is still present, the SDM will set a diagnostic trouble code (DTC).

This diagnostic procedure supports the following DTCs

1. DTC B0083 Front End Sensor 1 (Left)
2. DTC B0084 Front End Sensor 2 (Right)

This vehicle has DTCs which include DTC Symptoms. For more information on DTC Symptoms, refer to DTC Symptom Description in Vehicle DTC Information.

DTC B0083 or B0084

Ignition 1 voltage is within the normal operating voltage range of 9-16 volts.

All of the following conditions exist for 2.5 seconds

B0083 01 or B0084 01

1. The front end sensor has been shorted to voltage.
2. The SDM has not received a message from the front end sensor for more than 375 milliseconds.

B0083 02 or B0084 02

1. The front end sensor has been shorted to ground.
2. The front end sensor current has been above 23 mA for longer than 5 milliseconds.

B0083 04 or B0084 04

The front end sensor circuit is open.

B0083 39 or B0084 39

1. The SDM has received a NOK message from the front end sensor.
2. The SDM has not received a message.

B0083 71 or B0084 71

The SDM has received invalid serial data from the front end sensor.

B0083 0F or B0084 0F

The SDM has received erratic messages from the front end sensor.

B0083 3A or B0084 3A

1. The SDM has received an ID message from the front end sensor which does not match the ID stored in the SDM memory.
2. The SDM has reset the front end sensor twice without detecting the correct ID message.

The SDM commands ON the AIR BAG warning lamp via GMLAN serial data.

1. The DTC will clear when the condition responsible for setting the DTC no longer exists and the scan tool Clear DTCs function is used.
2. A history DTC will clear once 255 malfunction free ignition cycles have occurred.

The following are conditions that may cause the malfunction

1. An open in the front end sensor circuit
2. A short to ground or voltage in the front end sensor circuit
3. High or low resistance in the front end sensor circuit
4. Improper front end sensor installed on vehicle
5. An internal failure in the front end sensor

Thoroughly inspect the wiring and the connectors. An incomplete inspection of the wiring and connectors may result in misdiagnosis, causing a part replacement with the reappearance of the malfunction. If an intermittent malfunction exists, refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

The numbers below refer to the step numbers on the diagnostic table.

1. 7: Tests the front end sensor signal and front end sensor voltage circuits for high or low resistance or open
2. 8: Tests between the front end sensor signal and front end sensor voltage circuits for continuity
3. 9: Tests the front end sensor signal and front end sensor voltage circuits for a short to voltage or ground.

DTC B0083 or B0084

The inflatable restraint side impact sensor (SIS) utilizes a unidirectional 2-wire circuit. The SIS modulates current on the interface to send ID, State of Health, and deployment commands to the inflatable restraint sensing and diagnostic module (SDM). The SDM serves as a power source and a ground for the SIS. When the ignition is turned on and input power from the SDM is first detected, the SIS responds by performing internal diagnostics and sending an ID to the SDM. The SDM considers the ID to be valid if the response time is less than 5 seconds. The SIS continually communicates status messages to the SDM, which determines if a fault is present in the SIS circuit. When a fault is detected, the SDM resets the SIS twice by removing and reapplying power to it. If the fault is still present, the SDM will set a diagnostic trouble code (DTC).

DTC B0085 LF Side Impact Sensor

DTC B0085

Ignition 1 Voltage is within the normal operating voltage range of 9-16 volts.

All of the following conditions exist for 2.5 seconds

B0085 01

1. The SIS has been shorted to voltage.
2. The SDM has not received a message from the SIS for more than 375 milliseconds.

B0085 02

1. The SIS has been shorted to ground.
2. The SIS current has been above 23 mA for longer than 5 milliseconds.

B0085 04

The SIS circuit is open

B0085 39

1. The SIS circuit is open.
2. The SDM has received a NOK message from the SIS.
3. The SDM has not received a message.

B0085 71

The SDM has received invalid serial data from the SIS.

B0085 0F

The SDM has received erratic messages from the SIS.

B0085 3A

1. The SDM has received an ID message from the SIS which does not match the ID stored in the SDM memory.
2. The SDM has reset the SIS twice without detecting the correct ID message.

The SDM commands ON the AIR BAG warning lamp via GMLAN serial data.

1. The DTC will clear when the condition responsible for setting the DTC no longer exists and the scan tool Clear DTCs function is used.
2. A history DTC will clear once 255 malfunction free ignition cycles have occurred.

The following are conditions that may cause the malfunction

1. An open in the SIS circuit
2. A short to ground or voltage in the SIS circuit
3. A short between the SIS voltage and signal circuits
4. High or low resistance in the SIS circuit
5. Improper SIS installed on vehicle
6. An internal failure in the SIS

Thoroughly inspect the wiring and the connectors. An incomplete inspection of the wiring and connectors may result in misdiagnosis, causing a part replacement with the reappearance of the malfunction. If an intermittent malfunction exists, refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

The numbers below refer to the step numbers on the diagnostic table.

1. 7: This step tests the SIS signal and SIS voltage circuits for an open or high resistance.
2. 8: This step tests between the SIS signal and SIS voltage circuits for continuity.
3. 9: This step tests the SIS signal and SIS voltage circuits for a short to voltage.

DTC B0085

The inflatable restraint side impact sensor (SIS) utilizes a unidirectional 2-wire circuit. The SIS modulates current on the interface to send ID, State of Health, and deployment commands to the inflatable restraint sensing and diagnostic module (SDM). The SDM serves as a power source and a ground for the SIS. When the ignition is turned on and input power from the SDM is first detected, the SIS responds by performing internal diagnostics and sending an ID to the SDM. The SDM considers the ID to be valid if the response time is less than 5 seconds. The SIS continually communicates status messages to the SDM, which determines if a fault is present in the SIS circuit. When a fault is detected, the SDM resets the SIS twice by removing and reapplying power to it. If the fault is still present, the SDM will set a diagnostic trouble code (DTC).

DTC B0086 RF Side Impact Sensor

DTC B0086

Ignition 1 Voltage is within the normal operating voltage range of 9-16 volts.

All of the following conditions exist for 2.5 seconds

B0086 01

1. The SIS has been shorted to voltage.
2. The SDM has not received a message from the SIS for more than 375 milliseconds.

B0086 02

1. The SIS has been shorted to ground.
2. The SIS current has been above 23 mA for longer than 5 milliseconds.

B0086 04

The SIS circuit is open

B0086 39

1. The SIS circuit is open
2. The SDM has received a NOK message from the SIS.
3. The SDM has not received a message

B0086 71

The SDM has received invalid serial data from the SIS.

B0086 0F

The SDM has received erratic messages from the SIS.

B0086 3A

1. The SDM has received an ID message from the SIS which does not match the ID stored in the SDM memory.
2. The SDM has reset the SIS twice without detecting the correct ID message.

The SDM commands ON the AIR BAG warning lamp via GMLAN serial data.

1. The DTC will clear when the condition responsible for setting the DTC no longer exists and the scan tool Clear DTCs function is used.
2. A history DTC will clear once 255 malfunction free ignition cycles have occurred.

The following are conditions that may cause the malfunction

1. An open in the SIS circuit
2. A short to ground or voltage in the SIS circuit
3. A short between the SIS voltage and signal circuits
4. High or low resistance in the SIS circuit
5. Improper SIS installed on vehicle
6. An internal failure in the SIS

Thoroughly inspect the wiring and the connectors. An incomplete inspection of the wiring and connectors may result in misdiagnosis, causing a part replacement with the reappearance of the malfunction. If an intermittent malfunction exists, refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

The numbers below refer to the step numbers on the diagnostic table.

1. 7: This step tests the SIS signal and SIS voltage circuits for an open or high resistance.
2. 8: This step tests between the SIS signal and SIS voltage circuits for continuity.
3. 9: This step tests the SIS signal and SIS voltage circuits for a short to voltage.

DTC B0086

The inflatable restraint sensing and diagnostic module (SDM) stores the vehicles restraint ID from the vehicle identification number (VIN) and the last 4 digits of the SDMs part number. When the ignition is turned ON, the SDM compares this information to the information stored in the body control module (BCM) over the GMLAN communication circuit. If there is a mismatch between the information stored in the SDM and BCM, DTC B1001 will set.

DTC Descriptor

This diagnostic procedure supports the following DTC

DTC B1001 SDM Option Configuration Error

This vehicle has DTCs which include DTC Symptoms. For more information on DTC Symptoms, refer to DTC Symptom Description in Vehicle DTC Information.

DTC B1001

Ignition voltage is within the normal operating voltage range.

B1001 00

1. The last 4 digits of the SDM part number does not match the last 4 digits stored in the BCM.
2. The VIN stored in the BCM does not match that of the vehicle.

1. The SDM commands ON the AIR BAG warning lamp via GMLAN serial data.
2. The SDM disables all deployments.

1. The last 4 digits of the SDM part number match the last 4 digits stored in the BCM.
2. The restraints ID that is stored in the SDM matches the restraints ID that is stored in the BCM.

This DTC is an indication that an incorrect SDM is installed in the vehicle, or that the SDM and/or the BCM was replaced without reprogramming the BCM with the new information.

The numbers below refer to the step numbers on the diagnostic table.

1. 2: This test checks for current SDM DTCs.
2. 3: This test checks to see if the correct VIN is programmed in the BCM.
3. 4: This step explains that the BCM must have the correct VIN.
4. 6: This test checks to see if after clearing the DTCs, if this DTC is current.

DTC B1001

The inflatable restraint sensing and diagnostic module (SDM) runs continuous diagnostic tests on the system. When the ignition is turned on, the SDM will check to see if the correct components are installed for the vehicle configuration. If the SDM detects that there are too few or too many components on the system, DTC B1019 will set. If the SDM has been replaced, make sure that the correct part number was installed for this vehicle.

This diagnostic procedure supports the following DTC

DTC B1019 System Configuration Error

This vehicle has DTCs that include DTC Symptoms. For more information on DTC Symptoms, refer to DTC Symptom Description in Vehicle DTC Information.

DTC B1019

Ignition voltage is within the normal operating voltage range.

1. The SDM was programmed with the wrong options for the vehicle.
2. The wrong SDM was installed for the content of the vehicle.

1. The SDM commands ON the AIR BAG warning lamp via GMLAN serial data.
2. The SDM disables all deployments.

The correct SDM must be installed.

The correct components must be installed.

This DTC is an indication that an incorrect SDM is installed in the vehicle.

The following numbers refer to the step numbers in the diagnostic table

1. 2: This test checks for current inflatable restraint SDM DTCs.
2. 3: This test checks to see if the correct vehicle information numbers (VIN) is programmed in the body control module (BCM).
3. 4: This step explains that the BCM must be programmed.
4. 6: This test checks to see if after clearing the DTCs, if this DTC is current then its possible that the wrong SDM has been installed.

DTC B1019

The inflatable restraint sensing and diagnostic module (SDM) monitors the battery positive voltage input from the battery. If the SDM detects this battery positive voltage circuit is above or below the threshold, then DTC B1325 will set.

A type information accompanies the DTC. Refer to DTC Symptom Description in Vehicle DTC Information.

This diagnostic procedure supports the following DTC

DTC B1325 Device Power 1 Circuit

This vehicle has DTCs which include DTC Symptoms. For more information on DTC Symptoms refer to DTC Symptom Description in Vehicle DTC Information.

DTC B1325

The voltage supplied to the BCM is in the range of 9-16 volts.

1. B1325 03: The SDM detects a system voltage below 9.0 volts. The above condition is present at least 10 seconds.
2. B1325 07: The SDM detects a system voltage above 16.0 volts. The above condition is present at least 10 seconds.

1. The SDM commands the AIR BAG indicator ON via GMLAN serial data.
2. The SDM stores DTC to memory.

1. A current DTC clears when the malfunction is no longer present.
2. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction.

DTC B1325

The inflatable restraint sensing and diagnostic module (SDM) monitors the Ignition 1 signal from the ignition switch. When the vehicle ignition switch is placed in the RUN or CRANK position the switch supplies voltage to the SDM Ignition 1 input terminal. If an open, short to voltage, or short to ground in this SDM ignition 1 circuit is detected then DTC B1370 will set.

This diagnostic procedure supports the following DTC

DTC B1370 Device Ignition 1 Circuit

This vehicle has DTCs which include DTC Symptoms. For more information on DTC Symptoms refer to DTC Symptom Description in Vehicle DTC Information.

DTC B1370

Ignition 1 voltage is within the normal operating range of 9-16 volts.

B1370 01

The SDM detects a short to ground or an open in the Ignition 1 voltage circuit when the ignition switch is in RUN or CRANK.

B1370 06

1. The SDM detects a short to battery in the ignition 1 voltage circuit when the switch is in the OFF position.
2. Any of the condition above must be present for more than 10 seconds.

1. The SDM commands the AIR BAG indicator ON via GMLAN serial data.
2. The SDM stores DTC to memory.
3. The SDM determines its power mode only from the GMLAN power mode messages and discards the ignition 1 input for the remainder of the ignition cycle.

1. A current DTC clears when the malfunction is no longer present.
2. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction.

A history DTC maybe caused by an intermittent short or open in the Ignition 1 circuit. Refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

The numbers below refer to the step numbers on the diagnostic table.

1. 6: This tests the Air Bag ignition 1 voltage circuit for a short or open.
2. 7: This tests the Run/Crank voltage circuit between the relay and fuse.
3. 9: This tests the Run/Crank voltage circuit for an short or open.

DTC B1370

Symptoms - SIR

1. Perform the «Diagnostic System Check - Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/oem-general-information/#vehicle-dtc-information) in Vehicle DTC Information before using the symptom tables in order to verify that all of the following are true: There are no DTCs set. The inflatable restraint sensing and diagnostic module (SDM) can communicate via the serial data link.
2. Review the SIR system description and operation in order to familiarize yourself with the system functions. Refer to «SIR System Description and Operation»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the SIR system. Refer to «Checking Aftermarket Accessories»(/chevrolet/malibu/vi-2003-2006/remont/body-electrical/#wiring-systems-specifications-component-views-and-connector-end-views__checking-aftermarket-accessories) in Wiring Systems.
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.

Intermittent

Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

Symptom List

Refer to Air Bag Indicator Circuit Malfunction in order to diagnose the symptom.

The ignition switch supplies ignition voltage to the inflatable restraint sensing and diagnostic module (SDM) using the SIR Fuse. The ignition switch also supplies ignition 1 voltage to the instrument panel cluster (I/P). The AIR BAG warning indicator is controlled by the SDM via GMLAN serial data. When the ignition switch is first turned ON, the SDM responds by performing tests on the SIR system and then commanding the AIR BAG warning indicator OFF after it has flashed seven times if no trouble codes, DTCs, are found.

If battery voltage is outside of the normal operating voltage range, 9-16 volts, the AIR BAG warning indicator will come ON solid with no DTCs set.

Air Bag Indicator Circuit Malfunction

SIR Disabling and Enabling Zones

The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views . Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones.

Scheme 18

SIR Disabling and Enabling Zones

SIR Service Precautions

The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the air bags from the reserved energy supply.

General Service Instructions

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

1. Do not expose inflator modules to temperatures above 65°C (150°F).
2. Verify the correct replacement part number. Do not substitute a component from a different vehicle.
3. Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system.

Discard any of the following components if it has been dropped from a height of 91 cm (3 ft) or greater

1. Inflatable restraint sensing and diagnostic module (SDM)
2. Inflatable restraint I/P module
3. Inflatable restraint steering wheel module
4. Inflatable restraint steering wheel module coil
5. Inflatable restraint roof side rail modules
6. Inflatable restraint side impact sensors (SIS)
7. Inflatable restraint seat belt retractor pretensioners
8. Inflatable restraint front end sensors

Disabling Procedure

1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead.
2. Place the ignition switch to the OFF position.
3. Remove the key from the ignition switch.
4. Locate the body control module (BCM) fuse center then remove fuse center cover.
5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center.
6. Open front hood and locate the front end sensor (1), also known as the electronic front sensor (EFS).
7. Remove both connector position assurance (CPA) from the right and left front end sensor connector.
8. Remove both front end sensors connector from the front end sensor (1).

Enabling Procedure

1. Remove the key from the ignition switch.
2. Connect both front end sensors connector to the front end sensor (1).
3. Connect both CPA's to each front end sensor connector.
4. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center (1).
5. Use caution while reaching in and turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF.
6. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to «Diagnostic System Check - Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/oem-general-information/#vehicle-dtc-information) in Vehicle DTC Information.

1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead.
2. Turn the ignition switch to the OFF position.
3. Remove the key from the ignition switch.
4. Locate the body control module (BCM) fuse center then remove fuse center cover.
5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center.
6. To disable the seat belt pretensioner-LF go to step 7. To disable the roof rail module-left go to step 10 and for the side impact sensor (SIS)-Left go to step 13.
7. Remove the lower center pillar trim. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
8. Remove the connector position assurance (CPA) from the seat belt pretensioner-LF connector.
9. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector.
10. Remove the garnish molding from the upper lock pillar. Refer to «Garnish Molding Replacement - Rear Corner Upper»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
11. Remove the CPA from the roof rail module-left connector.
12. Disconnect the roof rail module-left connector from the vehicle harness connector.
13. Remove the LH door trim panel (2). Refer to «Trim Panel Replacement - Side Front Door»(/chevrolet/malibu/vi-2003-2006/remont/door-locks-anti-theft-systems/#door-system-mirror-system-window-system) in Doors.
14. Remove the connector position assurance (CPA) (3) from the SIS-Left connector (4).
15. Remove the SIS-Left connector (4) from the SIS (2).

1. Remove the key from the ignition switch.
2. To enable the SIS-Left go to step 3. To enable the roof rail module-left go to step 7, and to enable the seat belt pretensioner-LF go to step 9.
3. Install the SIS-Left connector (4) to the SIS (2).
4. Install the CPA (3) to the SIS-Left connector (4).
5. Install the LH door trim panel (2). Refer to «Trim Panel Replacement - Side Front Door»(/chevrolet/malibu/vi-2003-2006/remont/door-locks-anti-theft-systems/#door-system-mirror-system-window-system) in Doors.
6. Connect the roof rail module-left connector to the vehicle harness connector.
7. Install the CPA to the roof rail module-left connector.
8. Install the garnish molding to the upper lock pillar. Refer to «Garnish Molding Replacement - Rear Corner Upper»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
9. Connect the seat belt pretensioner-LF and install the CPA.
10. Install the lower center pillar. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
11. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center.
12. Install the BCM fuse center cover.
13. Use caution while reaching in and turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF.
14. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to «Diagnostic System Check - Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/oem-general-information/#vehicle-dtc-information) in Vehicle DTC Information.

1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead.
2. Turn the ignition switch to the OFF position.
3. Remove the key from the ignition switch.
4. Locate the body control module (BCM) fuse center then remove the fuse center cover.
5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center.
6. Remove the left/driver outer trim cover from the I/P. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Left»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
7. Remove the connector position assurance (CPA) from the steering wheel module coil connector.
8. Disconnect the steering wheel module coil connector from the vehicle harness connector.

1. Remove the key from the ignition switch.
2. Connect the steering wheel module coil connector to the vehicle harness connector.
3. Install the CPA to the steering wheel module coil connector.
4. Install the left outer trim cover to the I/P. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Left»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center.
6. Install the body control module fuse center cover.
7. Use caution while reaching in and turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF.
8. Perform the Diagnostic System Check if the AIR BAG warning indicator does not operate as described. Refer to «Diagnostic System Check - Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/oem-general-information/#vehicle-dtc-information) .

1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead.
2. Turn the ignition switch to the OFF position.
3. Remove the key from the ignition switch.
4. Locate the body control module (BCM) fuse center, then remove the fuse center cover.
5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center.
6. Remove the right/passenger outer trim cover from the I/P (3). Refer to «Instrument Panel (I/P) Trim Panel Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
7. Remove the connector position assurance (CPA) from the I/P module connector (2).
8. Disconnect the I/P module connector (1) from the vehicle harness connector (2).

1. Remove the key from the ignition switch.
2. Connect the I/P module connector (1) to the vehicle harness connector (2).
3. Install the CPA to the I/P module connector (2).
4. Install the right outer trim cover to the I/P (3). Refer to «Instrument Panel (I/P) Trim Panel Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
5. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center.
6. Install the body control module fuse center cover.
7. Use caution while reaching in and turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF.
8. Perform the Diagnostic System Check if the AIR BAG warning indicator does not operate as described. Refer to «Diagnostic System Check - Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/oem-general-information/#vehicle-dtc-information) .

1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead.
2. Turn the ignition switch to the OFF position.
3. Remove the key from the ignition switch.
4. Locate the body control module (BCM) fuse center then remove fuse center cover.
5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center.
6. To disable the seat belt pretensioner-RF go to step 7. To disable the roof rail module-right go to step 10 and for the side impact sensor (SIS)-Right go to step 13.
7. Remove the lower center pillar trim. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
8. Remove the connector position assurance (CPA) from the seat belt pretensioner-RF connector.
9. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector.
10. Remove the garnish molding from the upper lock pillar. Refer to «Garnish Molding Replacement - Rear Corner Upper»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
11. Remove the CPA from the roof rail module-right connector.
12. Disconnect the roof rail module-right connector from the vehicle harness connector.
13. Remove the RH door trim panel (2). Refer to «Trim Panel Replacement - Side Front Door»(/chevrolet/malibu/vi-2003-2006/remont/door-locks-anti-theft-systems/#door-system-mirror-system-window-system) in Doors.
14. Remove the CPA (3) from the SIS-Right connector (4).
15. Remove the SIS-Right connector (4) from the SIS (2).

1. Remove the key from the ignition switch.
2. To enable the SIS-Right go to step 3. To enable the roof rail module-right go to step 7, and to enable the seat belt pretensioner-RF go to step 9.
3. Install the SIS-Right connector (4) to the SIS (2).
4. Install the CPA (3) to the SIS-Right connector (4).
5. Install the RH door trim panel (2). Refer to «Trim Panel Replacement - Side Front Door»(/chevrolet/malibu/vi-2003-2006/remont/door-locks-anti-theft-systems/#door-system-mirror-system-window-system) in Doors.
6. Connect the roof rail module-right connector to the vehicle harness connector.
7. Install the CPA to the roof rail module-right connector.
8. Install the garnish molding to the upper lock pillar. Refer to «Garnish Molding Replacement - Rear Corner Upper»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
9. Connect the seat belt pretensioner-LF and install the CPA.
10. Install the lower center pillar. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
11. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center.
12. Install the BCM fuse center cover.
13. Use caution while reaching in and turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF.
14. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to «Diagnostic System Check - Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/oem-general-information/#vehicle-dtc-information) in Vehicle DTC Information.

1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead.
2. Turn the ignition switch to the OFF position.
3. Remove the key from the ignition switch.
4. Locate the body control module (BCM) fuse center then remove the fuse center cover.
5. Locate and remove the AIR BAG (IGN) and AIR BAG (BATT) fuses from the BCM fuse center.
6. Remove the garnish molding from the right upper lock pillar. Refer to «Garnish Molding Replacement - Rear Corner Upper»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
7. Remove the connector position assurance (CPA) from the roof rail module-right connector.
8. Disconnect the roof rail module-right connector from the vehicle harness connector.
9. Remove the passenger/right outer trim cover from the I/P (3). Refer to «Instrument Panel (I/P) Trim Panel Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
10. Remove the CPA from the I/P module connector (1).
11. Disconnect the I/P module connector (1) from the vehicle harness connector (2).
12. Remove the lower right center pillar trim. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
13. Remove the CPA from seat belt pretensioner-RF connector.
14. Disconnect the seat belt pretensioner-RF connector from the vehicle harness connector.
15. Remove the driver/left outer trim cover from the instrument Panel (I/P). Refer to «Instrument Panel (I/P) Trim Panel Replacement - Left»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
16. Remove the CPA from the steering wheel module coil connector.
17. Disconnect the steering wheel module coil connector from the vehicle harness connector.
18. Remove the lower left center pillar trim. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
19. Remove the CPA from seat belt pretensioner-LF connector.
20. Disconnect the seat belt pretensioner-LF connector from the vehicle harness connector.
21. Remove the garnish molding from the left upper lock pillar. Refer to «Garnish Molding Replacement - Rear Corner Upper»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
22. Remove the CPA from the roof rail module-left connector.
23. Disconnect the roof rail module-left connector from the vehicle harness connector.

1. Remove the key from the ignition switch.
2. Connect the steering wheel module coil connector to the vehicle harness connector.
3. Install the CPA to the steering wheel module coil connector.
4. Install the driver/left outer trim cover to the instrument Panel (I/P). Refer to «Instrument Panel (I/P) Trim Panel Replacement - Left»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
5. Connect the seat belt pretensioner-LF connector.
6. Install the CPA to the seat belt pretensioner-LF connector.
7. Install the left/driver lower center pillar trim. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
8. Connect the roof rail module-left connector to the vehicle harness connector.
9. Install the CPA to the roof rail module-left connector.
10. Install the garnish molding to the left upper lock pillar. Refer to «Garnish Molding Replacement - Rear Corner Upper»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
11. Connect the I/P module connector (1) to the vehicle harness connector (2).
12. Install the CPA to the I/P module connector (1).
13. Install the passenger/right outer trim cover to the instrument Panel (I/P) (3). Refer to «Instrument Panel (I/P) Trim Panel Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
14. Connect the seat belt pretensioner-RF connector.
15. Install the CPA to the seat belt pretensioner-RF connector.
16. Install the right lower center pillar trim. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
17. Connect the roof rail module-right connector to the vehicle harness connector.
18. Install the CPA to the roof rail module-right connector.
19. Install the garnish molding to the right upper lock pillar. Refer to «Garnish Molding Replacement - Rear Corner Upper»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
20. Install the AIR BAG (IGN) and AIR BAG (BATT) fuses into the BCM fuse center.
21. Install the BCM fuse center cover.
22. Use caution while reaching in and turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF.
23. Perform the Diagnostic System Check if the AIR BAG warning indicator does not operate as described. Refer to «Diagnostic System Check - Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/oem-general-information/#vehicle-dtc-information) in Vehicle DTC Information.

Removal Procedure

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zone 1»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
2. Remove the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) .
3. Remove the connector position assurance (CPA) from the electrical connector on the front end sensor.
4. Disconnect the front end sensor electrical connector from the front end sensor.
5. Remove the 2 integral bolts that retain the front end sensor to the frame front crossmember.
6. Remove the front end sensor from the vehicle.

Installation Procedure

1. Install the front end sensor to the vehicle.
2. Install the 2 integral bolts that retain the front end sensor to the frame front crossmember. Tighten: Tighten the bolts to 8 N.m (71 lb in).
3. Connect the sensor electrical connector to the front end sensor.
4. Install the CPA to the sensor electrical connector.
5. Install the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) .
6. Enable the SIR system. Refer to «SIR Disabling and Enabling Zone 1»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .

1. Disable the roof rail SIR system. Refer to «SIR Disabling and Enabling Zone 8»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
2. Remove the door trim panel. Refer to «Trim Panel Replacement - Side Front Door»(/chevrolet/malibu/vi-2003-2006/remont/door-locks-anti-theft-systems/#door-system-mirror-system-window-system) in Doors.
3. Remove the fasteners securing the sensor to the vehicle and remove the sensor from the vehicle.
4. Disconnect the electrical connector.

1. Connect the electrical connector.
2. Position the sensor to the vehicle and install the sensor fasteners. Tighten: Tighten the fasteners to 9 N.m (80 lb in).
3. Install the door trim panel. Refer to «Trim Panel Replacement - Side Front Door»(/chevrolet/malibu/vi-2003-2006/remont/door-locks-anti-theft-systems/#door-system-mirror-system-window-system) in Doors.
4. Enable the roof rail SIR system. Refer to «SIR Disabling and Enabling Zone 8»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .

Inflatable Restraint Sensing and Diagnostic Module Replacement

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zone 8»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) in SIR.
2. Remove the console. Refer to «Console Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
3. Remove the inflatable restraint sensing and diagnostic module nuts.
4. Remove the inflatable restraint sensing and diagnostic module wire harness connector.
5. Remove the inflatable restraint sensing and diagnostic module.

1. Point the arrow on the SDM toward the front of the vehicle.
2. Install the inflatable restraint sensing and diagnostic module.
3. Install the inflatable restraint sensing and diagnostic module wire harness connector.
4. Install the inflatable restraint sensing and diagnostic module nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
5. Install the console. Refer to «Console Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
6. Enable the SIR system. Refer to «SIR Disabling and Enabling Zone 8»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) in SIR.

Inflatable Restraint Steering Wheel Module Replacement

Tools Required

J 44298 Driver Air Bag Removal Tool. See Special Tools and Equipment .

1. Remove the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(/chevrolet/malibu/vi-2003-2006/remont/steering-column-switches/#steering-wheel-steering-column) .
2. Disable the SIR system. Refer to «SIR Disabling and Enabling Zone 3»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
3. On the back side of the steering wheel are 4 openings for removing the driver inflator module. Place the steering wheel so that 2 of the openings are on top.
4. Adjust and install J 44298 into 2 of the holes. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
5. Pull the handle towards the back of the steering wheel, releasing the 2 spring-loaded fasteners at the same time.
6. Turn the steering wheel and open J 44298 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
7. Place J 44298 and insert into place and repeat the same steps for the other 2 openings. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
8. Pull the driver inflator module gently away from the steering wheel.
9. Remove the connector position assurance (CPA) and the electrical connector for the driver inflator module.
10. Remove the horn grounded lead from the steering wheel.
11. Remove the inflatable restraint module.
12. Fully deploy the module before disposal. If the module was replaced under warranty, fully deploy and dispose of the module after the required retention period. Refer to «Inflator Module Handling and Scrapping»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .

1. Connect the horn ground lead onto the steering wheel.
2. Connect the inflator module electrical connector and the CPA. IMPORTANT: This vehicle is equipped with dual stage frontal air bags. Match the right color connector to the right color opening in the module. Route the driver inflator wires, the redundant control wires, and the horn wires correctly.
3. Align the driver inflator module fasteners to the steering column fastener holes.
4. Push the driver inflator module firmly into the steering column in order to engage the fasteners.
5. Enable the SIR system. Refer to «SIR Disabling and Enabling Zone 3»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
6. Install the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(/chevrolet/malibu/vi-2003-2006/remont/steering-column-switches/#steering-wheel-steering-column) .

Scheme 19

Scheme 20

1. Disable the SIR System. Refer to «SIR Disabling and Enabling Zone 3»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
2. Remove the inflatable restraint steering wheel module. Refer to «Inflatable Restraint Steering Wheel Module Replacement»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__inflatable-restraint-steering-wheel-module-replacement) .
3. Remove the steering wheel. Refer to «Steering Wheel Replacement»(/chevrolet/malibu/vi-2003-2006/remont/steering-column-switches/#steering-wheel-steering-column__steering-wheel-replacement) in Steering Wheel and Column.
4. Remove the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(/chevrolet/malibu/vi-2003-2006/remont/steering-column-switches/#steering-wheel-steering-column) .
5. Disconnect the SIR harness.
6. Remove the SIR coil (2) from the steering shaft.
7. If replacing, discard the SIR coil.

1. To install the SIR coil, perform the following procedure: Aim the wheels straight ahead. Align the block tooth and the centering mark on the race and upper shaft assembly at the 12 o'clock position.
2. If centering is required, refer to «Inflatable Restraint Steering Wheel Module Coil Centering»(/chevrolet/malibu/vi-2003-2006/remont/steering-column-switches/#steering-wheel-steering-column__inflatable-restraint-steering-wheel-module-coil) in Steering Wheel and Column.
3. Slide the new SIR coil (2) onto the steering shaft assembly (1).
4. Connect the SIR harness.
5. Remove and discard the centering tab from the new SIR coil.
6. Install the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(/chevrolet/malibu/vi-2003-2006/remont/steering-column-switches/#steering-wheel-steering-column) .
7. Install the steering wheel. Refer to «Steering Wheel Replacement»(/chevrolet/malibu/vi-2003-2006/remont/steering-column-switches/#steering-wheel-steering-column__steering-wheel-replacement) .
8. Install the inflatable restraint steering wheel module. Refer to «Inflatable Restraint Steering Wheel Module Replacement»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__inflatable-restraint-steering-wheel-module-replacement) .
9. Enable the SIR system. Refer to «SIR Disabling and Enabling Zone 3»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .

Inflatable Restraint Instrument Panel Module Replacement

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zone 5»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) in SIR.
2. Remove the I/P trim pad. Refer to «Trim Pad Replacement - Instrument Panel (I/P)»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
3. Remove the wire harness connector from the inflatable restraint I/P module.
4. Remove the bolts from the inflatable restraint I/P module and discard the bolts.
5. Remove the inflatable restraint I/P module.

1. Install the inflatable restraint I/P module.
2. Install new bolts to the inflatable restraint I/P module. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the wire harness connector to the inflatable restraint I/P module.
4. Install the I/P trim pad. Refer to «Trim Pad Replacement - Instrument Panel (I/P)»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
5. Enable the SIR system. Refer to «SIR Disabling and Enabling Zone 5»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) in SIR.
6. Deploy the old module before disposal. If the module was replaced under warranty, fully deploy and dispose of the module after the required retention period. Refer to «Pretensioner Handling and Scrapping»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__pretensioner-handling-and-scrapping) .

Inflatable Restraint Roof Rail Module Replacement

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zone 2»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) or to «SIR Disabling and Enabling Zone 6»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
2. Remove the headliner and the garnish moldings from the vehicle. Refer to «Headliner Replacement (Sedan)»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) and «Headliner Replacement (Extended Sedan)»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
3. Unsnap the SIR tether retainer and remove the tether from the windshield pillar.
4. Remove the fasteners and the clips from the SIR module.
5. Remove the SIR module from the vehicle.

1. Unpack the new inflator assembly. Start at the rear of the vehicle and install the inflator module to the structure.
2. Working from the rear of the vehicle, install the retaining tabs to the structure to hold the inflator module in place.
3. Install the remaining side SIR module fasteners. Tighten: Tighten the fasteners to 5 N.m (44 lb in).
4. Install the hook on the curtain tether to the windshield pillar. Snap the hook retainer into place.
5. Install the headliner and the garnish moldings to the vehicle. Refer to «Headliner Replacement (Sedan)»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) and «Headliner Replacement (Extended Sedan)»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
6. Enable the SIR system. Refer to «SIR Disabling and Enabling Zone 2»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) or to «SIR Disabling and Enabling Zone 6»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
7. After replacing the module, deploy the old module before disposal. If the module was replaced under warranty, fully deploy and dispose of the module after the required retention period. Refer to «Inflator Module Handling and Scrapping»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .

Seat Belt Retractor Pretensioner Replacement - Front

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zone 2»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) or to «SIR Disabling and Enabling Zone 6»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
2. Remove the lower garnish molding from the center pillar. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
3. Remove the side trim cover from the front seat. Refer to «Seat Cushion Outer Trim Panel Replacement - Front Seat»(/chevrolet/malibu/vi-2003-2006/remont/seats/#seat-system) in Seats.
4. Remove the seat belt anchor from the front seat.
5. Remove the cover from the pretentioner retractor mounting nut.
6. Remove the mounting nut.
7. Remove the pretentioner retractor assembly from the vehicle.

1. Install the pretentioner retractor assembly to the vehicle.
2. Install the retractor mounting nut. Tighten: Tighten the nut to 35 N.m (25 lb ft).
3. Install the cover over the mounting nut.
4. Install the seat belt anchor to the front seat.
5. Install the side trim cover to the front seat. Refer to «Seat Cushion Outer Trim Panel Replacement - Front Seat»(/chevrolet/malibu/vi-2003-2006/remont/seats/#seat-system) in Seats.
6. Install the lower garnish molding to the center pillar. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
7. Enable the SIR system. Refer to «SIR Disabling and Enabling Zone 2»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) or to «SIR Disabling and Enabling Zone 6»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .

Repairs and Inspections Required After a Collision

Accident With or Without Air Bag Deployment - Component Inspections

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

1. Steering column - Perform the steering column accident damage checking procedures. Refer to «Steering Column Accident Damage Inspection»(/chevrolet/malibu/vi-2003-2006/remont/steering-column-switches/#steering-wheel-steering-column__steering-column-accident-damage-inspection) in Steering Wheel and Column.
2. I/P knee bolsters and mounting points - Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage.
3. I/P brackets, braces, etc. - Inspect for bending, twisting, buckling, or any other type of damage.
4. Seat belts - Perform the seat belt operational and functional checks. Refer to «Operational and Functional Checks»(/chevrolet/malibu/vi-2003-2006/remont/restraints-control-systems/#seat-belt-system__operational-and-functional-checks) in Seat Belts.
5. Seats and seat mounting points - Inspect for bending, twisting, buckling, or any other type of damage.
6. The roof and headliner mounting points.

Frontal Inflator Module Deployment

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

1. Inflatable restraint I/P module
2. Inflatable restraint steering wheel module
3. Inflatable restraint sensing and diagnostic module (SDM)
4. Inflatable restraint front end sensor
5. Inflatable restraint seat belt retractor pretensioners

Perform additional inspections on the following components.

1. Steering wheel module coil and the coil wiring pigtail - Inspect for melting, scorching, or other damage due to excessive heat.
2. Mounting points or mounting hardware for the I/P module, steering wheel module, SDM, and pretensioners - Inspect for any damage and repair or replace each component as needed.

Accident With Side Air Bag Deployment - Component Replacement and Inspections

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

1. Inflatable restraint side impact sensors (SIS), Left/Right, on the side of the impact.
2. Inflatable restraint roof rail module, Left/Right, on the side of the impact.
3. Inflatable restraint side impact module, Left/Right, on the side of impact.
4. Inflatable restraint sensing and diagnostic module (SDM).
5. Inflatable restraint seat belt retractor pretensioner.

Perform additional inspections on the following components.

1. Mounting points or mounting hardware for the SIS - Inspect for any damage and repair or replace each component as needed.
2. Mounting points or mounting hardware for the roof rail module (left/right) on the side of impact - Inspect for any damage and repair or replace each component as needed.
3. Mounting points or mounting hardware for the SDM and seat belt pretensioners - Inspect for any damage and repair or replace each component as needed.

Live (Undeployed) Inflator Module

Scheme 21

Use caution when handling or storing a live (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 two 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 deployed or undeployed 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, you may need to dispose of a live (undeployed) inflator module. Do not dispose of a live (undeployed) inflator module through normal disposal channels until the inflator module has been deployed. The following information covers the proper procedures for the disposing of a live (undeployed) inflator module.

Do not deploy the inflator module in the following situations

1. After replacement of an inflator module under warranty. The inflator module may need to be returned undeployed to the manufacturer.
2. 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.
3. 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

The inflator module 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 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, for seat belt pretensioner deployment outside the vehicle refer to Pretensioner Handling and Scrapping . Situations that require deployment outside of the vehicle include the following

1. Using the SIR diagnostics, determine that the inflator module is malfunctioning.
2. The inflator module is cosmetically damaged, scratched or ripped.
3. The inflator module pigtail (if equipped) is damaged.
4. The inflator module connector is damaged.
5. The inflator module connector terminals are damaged.

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

Tools Required

1. J 38826 SIR Deployment Harness. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
2. J 39401-B SIR Deployment Fixture. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
3. J 38826-25 Roof rail module adapter
4. J 38826-75 Steering wheel module adapter (dual stage air bags)
5. J 38826-80 I/P module adapter (dual stage air bags)

1. Turn OFF the ignition.
2. Remove the ignition key.
3. Put on safety glasses.
4. Remove the inflator module. Refer to the following: If you are removing the steering wheel module, refer to «Inflatable Restraint Steering Wheel Module Replacement»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__inflatable-restraint-steering-wheel-module-replacement) . If you are removing the I/P module, refer to «Inflatable Restraint Instrument Panel Module Replacement»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__inflatable-restraint-instrument-panel-module-replacement) . If you are removing a roof rail module, refer to «Inflatable Restraint Roof Rail Module Replacement»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__inflatable-restraint-roof-rail-module-replacement) .
5. Place the inflator module with the vinyl trim cover facing up and away from the surface on a work bench.
6. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the inflator module. 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. When deploying the steering wheel module, place the steering wheel module in the center of the space.
9. When deploying the I/P module, refer to the following instructions: Place J 39401-B (2) in the center of the cleared area. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) . Fill the deployment fixture with water or sand. Using the proper nuts and bolts, mount the I/P module (1) to the deployment fixture (2), with the vinyl trim facing up. Securely tighten all fasteners that hold the I/P module (1) to the deployment fixture (2) prior to deployment.
10. If you have a roof rail module, refer to the following instructions: Place the SIR deployment fixture (3) in the center of the cleared area. Fill the deployment fixture with water or sand. Using the proper nuts (2) and mount the roof rail module (1) to the deployment fixture (3), with the vinyl face up. Adjust and secure the fixture arms (4) to the deployment fixture (3). Securely tighten all fasteners that hold the side impact module (1) to the deployment fixture (3) prior to deployment.
11. Inspect J 38826 and the appropriate pigtail adapter for damage. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) . Replace as needed.
12. Short the two 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 inflator module (1) to the adapter (2) on the SIR deployment harness (3).
16. Clear the area of people.
17. Place a 12 V minimum/2 A minimum power source, such as a vehicle battery, near the shorted end of the SIR deployment harness.
18. Separate the 2 banana plugs on the SIR deployment harness.
19. Connect the SIR deployment harness wires to the power source. Inflator module deployment will occur when contact is made.
20. Disconnect the SIR deployment harness from the power source.
21. Seat one banana plug into the other in order to short the deployment harness leads.
22. If the inflator module 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 inflator module as soon as possible.
25. Dispose of the deployed inflator module through normal refuse channels.
26. Wash 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

1. The vehicle has completed a useful life.
2. Irreparable damage occurs to the vehicle in a non-deployment type accident.
3. Irreparable damage occurs to the vehicle during a theft.
4. 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.

1. Turn OFF the ignition.
2. Remove the ignition key.
3. Put on safety glasses.
4. Remove all loose objects from the front seats.
5. Disable the SIR system. Refer to «SIR Disabling and Enabling Zones»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling-zones) .
6. Disconnect the steering wheel module yellow connector (1) from vehicle harness yellow connector (3).
7. 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 gage) 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 cut in the previous step.
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 two connector wire leads (the high circuits from both stages of the steering wheel module) to one sets of deployment wires. Refer to «SIR Connector End Views»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__sir-connector-end-views) in order to determine the correct circuits.
13. Inspect that the 3 wire connection is secure.
14. Bend flat the twisted connection.
15. Secure and insulate the 3 wire connection to deployment harness using electrical tape.
16. Twist together two connector wire leads (the low circuits from both stages of the steering wheel module) to one sets of deployment wires. Refer to «SIR Connector End Views»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__sir-connector-end-views) in order to determine the correct circuits.
17. Inspect that the 3 wire connection is secure.
18. Bend flat the twisted connection.
19. Secure and insulate the 3 wire connection to deployment harness using electrical tape.
20. Connect the deployment harness to the steering wheel module in-line connector.
21. Route the deployment harness out of the driver side of the vehicle.
22. Disconnect the driver/left seat belt pretensioner yellow connector (1) from the vehicle wiring harness located under the rear of driver seat.
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 gage) or thicker multi-strand wire. These wires will be used to fabricate the left seat belt pretensioner deployment harness.
26. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
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 left seat belt pretensioner yellow connector.
33. Route the deployment harness out of the driver side of the vehicle.
34. Disconnect the left/driver roof rail module yellow harness connector (2).
35. Cut the 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 gage) or thicker multi-strand wire. These wires will be used to fabricate the roof rail module deployment harness.
38. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
39. Twist together one end from each of the wires in order to short the wires.
40. Twist together one connector wire lead to one deployment wire.
41. Bend flat the twisted connection.
42. Secure and insulate the connection using electrical tape.
43. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
44. Connect the deployment harness to the roof rail module.
45. Route the deployment harness out of the driver side of the vehicle.
46. Disconnect the I/P module yellow harness connector (1) from the vehicle harness connector (2).
47. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
48. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
49. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used to fabricate the IP module deployment harness.
50. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
51. Twist together one end from each of the wires in order to short the wires.
52. Twist together two connector wire leads (the high circuits from both stages of the steering wheel module) to one sets of deployment wires. Refer to «SIR Connector End Views»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__sir-connector-end-views) in order to determine the correct circuits.
53. Inspect that the 3 wire connection is secure.
54. Bend flat the twisted connection.
55. Secure and insulate the 3 wire connection to deployment harness using electrical tape.
56. Twist together 2 connector wire leads (the low circuits from both stages of the steering wheel module) to one sets of deployment wires. Refer to «SIR Connector End Views»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__sir-connector-end-views) in order to determine the correct circuits.
57. Inspect that the 3 wire connection is secure.
58. Bend flat the twisted connection.
59. Secure and insulate the 3 wire connection to deployment harness using electrical tape.
60. Connect the deployment harness to the I/P module in-line connector.
61. Route the deployment harness out of the passenger side of the vehicle.
62. Disconnect the passenger/right seat belt pretensioner yellow connector (1) from the vehicle wiring harness located under the rear of passenger seat.
63. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
64. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
65. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used to fabricate the right seat belt pretensioner deployment harness.
66. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
67. Twist together one end from each of the wires in order to short the wires.
68. Twist together one connector wire lead to one deployment wire.
69. Bend flat the twisted connection.
70. Secure and insulate the connection using electrical tape.
71. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
72. Connect the deployment harness to the right seat belt pretensioner yellow connector.
73. Route the deployment harness out of the passenger side of the vehicle.
74. Disconnect the right/passenger roof rail module yellow harness connector (2).
75. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
76. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
77. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used to fabricate the roof rail module deployment harness.
78. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
79. Twist together one end from each of the wires in order to short the wires.
80. Twist together one connector wire lead to one deployment wire.
81. Bend flat the twisted connection.
82. Secure and insulate the connection using electrical tape.
83. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
84. Connect the deployment harness to the roof rail module.
85. Route the deployment harness out of the passenger side of the vehicle.
86. Completely cover the windshield and front door window openings with a drop cloth.
87. Stretch out all of the deployment harness wires on the right side of the vehicle to their full length.
88. Deploy each deployment loop one at a time.
89. Place a power source, 12 V minimum/2 A minimum (i.e., a vehicle battery) near the shorted end of the harnesses.
90. Separate the one set of wires and touch the wires ends to the power source in order to deploy the inflator modules, doing one module at a time.
91. Disconnect the deployment harness from the power source and twist the wire ends together.
92. Continue the same process with the remaining deployment harnesses that are available.
93. Stretch out all of the deployment harness wires on the left side of the vehicle to their full length.
94. Deploy each deployment loop one at a time.
95. Place a power source, 12 V minimum/2 A minimum (i.e., a vehicle battery) near the shorted end of the harnesses.
96. Separate the one set of wires and touch the wires ends to the power source in order to deploy the inflator modules, doing one module at a time.
97. Disconnect the deployment harness from the power source and twist the wire ends together.
98. Continue the same process with the remaining deployment harnesses that are available.
99. Remove the drop cloth from the vehicle.
100. Disconnect all harnesses from the vehicle.
101. Discard the harnesses.
102. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
103. If one or all of the inflator modules did not deploy, perform the following steps to remove the undeployed module(s) from the vehicle: «Inflatable Restraint Steering Wheel Module Replacement»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__inflatable-restraint-steering-wheel-module-replacement) «Inflatable Restraint Instrument Panel Module Replacement»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__inflatable-restraint-instrument-panel-module-replacement) «Inflatable Restraint Roof Rail Module Replacement»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__inflatable-restraint-roof-rail-module-replacement) «Seat Belt Retractor Pretensioner Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__seat-belt-retractor-pretensioner-replacement)

Pretensioner Handling and Scrapping

During the course of a vehicles useful life, certain situations may arise which will require the disposal of a live and undeployed seat belt retractor pretensioner. Do not dispose of a live and undeployed seat belt pretensioner through normal disposal channels until the seat belt pretensioner has been deployed. The following information covers the proper procedures for disposing of a live and undeployed seat belt pretensioner. Do not deploy the seat belt retractor pretensioner in the following situations

1. After replacement of a seat belt retractor pretensioner under warranty. The seat belt retractor pretensioner may need to be returned undeployed to the manufacturer.
2. If the vehicle is the subject of a Product Liability report, GM1241, related to the SIR system or the seat belt system. If the vehicle is subject to the Product Liability report, do not alter the SIR or seat belt system in any manner.
3. If the vehicle is involved in a campaign affecting the seat belt retractor pretensioners. Follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures.

The seat belt 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 Inflator 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

1. Using the SIR diagnostics, it is determined that the seat belt pretensioner is malfunctioning.
2. The seat belt pretensioner pigtail, if equipped, is damaged.
3. The seat belt retractor pretensioner connector is damaged.
4. The seat belt retractor pretensioner connector terminals are damaged.

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

Tools Required

1. J 38826 SIR Deployment Harness. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
2. J 38826 -25 for seat belt pretensioner module adapter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
3. J 39401-B SIR Deployment Fixture. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
4. An appropriate pigtail adaptor

1. Turn OFF the ignition.
2. Remove the ignition key.
3. Put on safety glasses.
4. Remove the seat belt retractor pretensioner from the vehicle. Refer to «Seat Belt Retractor Pretensioner Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system__seat-belt-retractor-pretensioner-replacement) .
5. When carrying a seat belt retractor pretensioner to the deployment area, keep fingers clear of the seat belt webbing.
6. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the seat belt 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 J 39401-B in the center of the cleared area. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) .
9. Fill the fixture plastic reservoir with water or sand.
10. Mount the seat belt pretensioner in the SIR deployment fixture with the seat belt webbing exiting through the top of the pretensioner. Use the following mounting method. Adjust and secure two of the J 39401-B arms to the deployment fixture, with the short slotted portions of the arms standing vertically and facing toward the center of the deployment fixture. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) . To mount, use the proper size bolt and nut with washers in order to secure the seat belt pretensioner mounting hole between the two deployment fixture brackets. Securely tighten all fasteners prior to deployment.
11. Inspect the J 38826 and the appropriate pigtail adapter for damage. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/airbag/#supplemental-inflatable-restraint-system) . Replace as needed.
12. Short the 2 SIR deployment harness (1) leads together using 1 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 seat belt pretensioner connector to the adapter on the deployment harness.
16. Clear the area of people.
17. Separate the 2 banana plugs on the SIR deployment harness.
18. Place a 12 V minimum/2 A 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. Seat belt pretensioner deployment will occur when contact is made.
20. Disconnect the SIR deployment harness from the power source after the seat belt retractor pretensioner deploys.
21. Seat one banana plug into the other in order to short the deployment harness leads.
22. If the seat belt retractor 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 seat belt retractor pretensioner as soon as possible.
25. Dispose of the deployed seat belt retractor pretensioner through normal refuse channels.
26. Wash hands with a mild soap.

Scheme 22

The Supplemental Inflatable Restraint (SIR) System supplements the protection offered by the occupant seat belt system (2). The SIR system contains various inflator modules located throughout the vehicle, i.e. inflatable restraint steering wheel module (1) and the inflatable restraint I/P module (1). Each inflator module has a deployment loop that is controlled by the inflatable restraint sensing and diagnostic module (SDM), which is mounted inside of the vehicle. The SDM determines the severity of a collision and commands deployment of each inflator module. The SDM performs continuous diagnostic monitoring of the SIR system electrical components. Upon detection of a circuit malfunction, the SDM will set a diagnostic trouble (DTC) and inform the driver by commanding the instrument panel cluster (IPC) to turn the AIR BAG indicator ON. The steering column and knee bolsters (3) are designed to absorb energy and compress during frontal collisions in order to limit leg movement and decrease the chance on injury to the driver and front passenger.

Frontal SIR System Description

The frontal Supplemental Inflatable Restraint (SIR) System consists of the following components

1. AIR BAG indicator located in the instrument panel cluster (IPC)
2. Inflatable restraint I/P module.
3. Inflatable restraint sensing and diagnostic module (SDM)
4. Inflatable restraint steering wheel module
5. Inflatable restraint steering wheel module coil
6. Steering wheel and column
7. Inflatable restraint front end sensor (left/right)
8. Inflatable restraint seat belt retractor pretensioners
9. Inflatable restraint wiring harnesses
10. Driver and passenger knee bolsters

A frontal collision of sufficient force will deploy the frontal air bags. The SDM contains a sensing device that converts vehicle velocity changes to an electrical signal. In the event of a frontal collision, the SDM receives a signal from the electronic frontal sensor which assists the SDM in determining the severity of the collision. The SDM compares these signals to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the frontal deployment loops simultaneously deploying the frontal air bags. The SDM, I/P module, steering wheel module, steering wheel module coil, seat belt pretensioner and the connecting wires makeup the frontal deployment loops. The SDM continuously monitors the deployment loops for malfunctions and turns the AIR BAG indicator ON if a fault is detected.

Inflatable Restraint Sensing and Diagnostic Module (SDM)

The sensing and diagnostic module (SDM) is a microprocessor and the control center for the Supplemental Inflatable Restraint (SIR) System. This SDM has two fused power inputs; one fuse is for the battery voltage and the other fuse is for the ignition voltage. The SDM uses vehicle battery voltage as its main power input. The SDM then uses the vehicles GMLAN Serial Data Communication line and the ignition voltage logic input for enabling or disabling the SIR deployment loops. The SDM contains internal sensors along with several external sensors, if equipped, mounted at strategic locations on the vehicle. In the event of a collision, the SDM compares the signals from the internal and external sensors to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags or seat belt pretensioners.

If the force of the impact is not sufficient to warrant inflator module deployment, the SDM may still deploy the seat belt pretensioners. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator located in the IPC ON. As soon as three distinct deployment commands (representing different events) have been issued to any belt pretensioner, or the SDM commands any front and side air bag to deploy once, the SDM shall be considered to not be reusable. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON, notifying the driver that a malfunction exist. In the event that ignition positive voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute.

AIR BAG Indicator

The AIR BAG indicator, located in the instrument panel cluster (IPC), is used to notify the driver of Supplemental Inflatable Restraint (SIR) System malfunctions and to verify that the sensing and diagnostic module (SDM) is communicating with the IPC. When the ignition is turned ON, the SDM is supplied with ignition positive voltage. The SDM requests the IPC to flash the AIR BAG indicator seven times. While flashing the indicator, the SDM conducts tests on all SIR system components and circuits. If no malfunctions are detected, the SDM will communicate with the IPC through the GMLAN serial data circuit and command the AIR BAG indicator OFF. The SDM provides continuous monitoring of the air bag circuits by conducting a sequence of checks. If a malfunction is detected the SDM will store a diagnostic trouble code (DTC) and command the IPC to turn the AIR BAG indicator ON via GMLAN serial data. The presence of a SIR system malfunction could result in non-deployment of the air bags or deployment in conditions less severe than intended. The AIR BAG indicator will remain ON until the malfunction has been repaired.

Dual Stage Inflator Modules

Dual stage inflator modules contain a housing, inflatable air bag, two initiating devices, canister of gas generating material and, in some cases, stored compressed gas. The two initiators are part of the frontal deployment loop. The function of the frontal deployment loops are to supply current through the steering wheel and instrument panel (I/P) inflator modules to deploy the air bags. The inflator modules have two stages of deployment, which varies the amount of restraint to the occupant according to the collision severity. For moderate frontal collisions the inflator modules deploy at less than full deployment (low deployment) which consists of stage 1 of the inflator module. For more severe frontal collisions, a full deployment is initiated which consists of stage 1 and stage 2 of the inflator module. The current passing through the initiators ignites the material in the canister producing a rapid generation of gas and is some cases, the release of compressed gas. The gas produced from this reaction rapidly inflates the air bag. Once the air bag is inflated, it quickly deflates through the air bag vent holes and/or the bag fabric.

Each dual stage inflator module is equipped with a shorting bar located in the connectors of the module. The shorting bar shorts the inflator module deployment loop circuitry to prevent unwanted deployment of the air bag when it is disconnected.

Inflatable Restraint Steering Wheel Module Coil

The steering wheel module coil is attached to the steering column and is located under the steering wheel. The steering wheel module coil consists of two or more current-carrying coils. The coils allow the rotation of the steering wheel while maintaining continuous electrical contact between the steering wheel module deployment loop and the steering wheel module. Two coil wires are used for the steering wheel module deployment loop. Additional coil wires are used for accessories that are attached to the steering wheel, depending on the vehicle model. The steering wheel module coil connector is located near the base of the steering column. The connector contains a shorting bar that shorts the steering wheel module coil deployment loop circuitry to prevent unwanted deployment of the steering wheel module when the connector is disconnected.

Steering Wheel and Column

The steering wheel and column are designed to absorb energy when driver contact is made with steering wheel or inflated module. In a collision, the driver may contact the steering wheel directly or load the steering wheel and column through the inflated module. When the driver applies load to the inflator module or the steering wheel, the column will compress downward, absorbing some of the impact and helping to reduce bodily injuries to the driver. The steering wheel and column must be inspected for damages after a collision.

Inflatable Restraint Front End Sensors

The front end sensor, also known as the electronic frontal sensor (EFS), is equipped on vehicles to supplement the Supplemental Inflatable Restraint (SIR) System performance. The front end sensor is an electronic sensor and is not part of the deployment loops, but instead provides an input to the sensing and diagnostic module (SDM). The front end sensor can assist in determining the severity of some frontal collisions. The SDM contains a microprocessor which performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the frontal deployment loops deploying the frontal air bags.

Inflatable Restraint Seat Belt Pretensioner

The seat belt pretensioner modules contain a housing, a seat belt retractor, the seat belt webbing, an initiating device, and a canister of gas generating material. The initiator is part of the seat belt pretensioner deployment loop. When the vehicle is involved in a collision of sufficient force, the sensing and diagnostic module (SDM) will cause current to flow through the deployment loops to the initiator. Current passing through the initiator ignites the material in the canister producing a rapid generation of gas and the release of compressed gas, if present. The gas produced from this reaction deploys the seat belt pretensioner and retracts the seat belt webbing, which removes slack in the seat belt.

Depending on the severity of the collision, the seat belt pretension may deploy without the frontal inflator modules deploying, or they will deploy immediately before the frontal inflator modules deploy. As soon as three distinct deployment commands (representing different events) have been issued to any belt pretensioner the SDM shall be considered to not be reusable.

Each seat belt pretensioner is equipped with a shorting bar located on the connector of the pretensioner. The shorting bar shorts the seat belt pretensioner deployment loop circuitry to prevent unwanted deployment of the pretensioner when servicing the seat belt pretensioner.

Inflatable Restraint Wiring Harness

The inflatable restraint wiring harness connects the inflator modules, the sensing and diagnostic module (SDM), the deployment loops, and the serial data circuit together using weather - packed connectors. Supplemental Inflatable Restraint (SIR) System connectors are yellow for easy identification. When repairing SIR wiring harnesses, follow the proper testing and repair procedures listed in the service manual.

Knee Bolster

The knee bolsters are designed to help restrain the lower torso of front seat occupants by absorbing the energy through the front seat occupants upper legs. In a collision, the front seat occupants legs may come in contact with the knee bolsters. The knee bolsters are designed to crush and deform, absorbing some of the impact and helping to reduce bodily injuries. The driver and passenger knee bolsters are located in the lower part of the instrument panel and must be inspected for damages after a collision.

Side SIR System Description

The side SIR system consists of the following components

1. AIR BAG indicator located in the instrument panel cluster (IPC)
2. Inflatable restraint sensing and diagnostic module (SDM)
3. Inflatable restraint seat belt retractor pretensioners (left/right)
4. Inflatable restraint side impact sensors (SIS) (left/right)
5. Inflatable restraint roof rail modules (left/right)
6. Inflatable restraint wiring harnesses

Inflatable Restraint Roof Rail Modules

The roof rail modules are located under the headliner extending from the front windshield pillar to the rear window pillar. The roof rail modules contain a housing, inflatable air bag, initiating device, and a canister of gas generating material. The initiator is part of the roof rail module deployment loop. When a side impact of sufficient force occurs the side impact sensor (SIS) detects the impact and sends a signal to the sensing and diagnostic module (SDM). The SDM compares the signal received from the SIS to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the side deployment loop deploying the roof rail air bags. The SDM, roof rail modules and the connecting wires makeup the side deployment loops. The SDM continuously monitors the deployment loops for malfunctions and turns the AIR BAG indicator ON if a fault is present.

Each roof rail module is equipped with a shorting bar located on the connector of the module. The shorting bar shorts the roof rail modules deployment loop circuitry to prevent unwanted deployment of the air bag when servicing the inflator module.

Inflatable Restraint Side Impact Sensor (SIS)

The side impact sensor (SIS) contains a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The SIS is not part of the deployment loop, but instead provides an input to the sensing and diagnostic module (SDM). The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops deploying the side air bags.

Special Tools

Special Tools Illustration Tool Number/Description J 38715-A Driver/Passenger SIR Load Tool J 38826 SIR Deployment Harness J 39401-B SIR Deployment Fixture J 44298 Driver Air Bag Removal Tool J 45289 CANdi Module

Scheme 23

See also:
• Diagnostic System Check - Vehicle
• Testing for Intermittent Conditions and Poor Connections
• Connector Repairs
• Steering Column Trim Covers Replacement
• Circuit Testing
• Wiring Repairs
• Diagnostic Trouble Code (DTC) List - Vehicle
• DTC Symptom Description
• Control Module References
• Body Control Module (BCM) Programming/RPO Configuration
• Body Control Module Replacement
• Charging System Test
• Power Distribution Schematics
• Checking Aftermarket Accessories
• Instrument Panel Cluster (IPC) Replacement
• Garnish Molding Replacement - Center Pillar Lower
• Trim Panel Replacement - Side Front Door
• Air Cleaner Intake Duct Replacement
• Fastener Notice
• SIR Inflator Module Handling and Storage Caution
• SIR Caution
• Steering Wheel Replacement
• Inflatable Restraint Steering Wheel Module Coil Centering
• Seat Cushion Outer Trim Panel Replacement - Front Seat
• Steering Column Accident Damage Inspection
• Operational and Functional Checks
• SIR Inflator Module Disposal Caution
• SIR Deployed Inflator Modules Are Hot Caution
• SIR Inflatable Module Deployment Outside Vehicle Caution
• SIR Disabling and Enabling Zones
• SIR Schematics
• SIR Connector End Views
• Inflatable Restraint Steering Wheel Module Replacement
• Inflatable Restraint Sensing and Diagnostic Module Replacement
• Seat Belt Retractor Pretensioner Replacement - Front
• Inflatable Restraint Roof Rail Module Replacement
• Inflatable Restraint Instrument Panel Module Replacement
• Repairs and Inspections Required After a Collision
• SIR Service Precautions
• SIR Zone Identification Views
• Pretensioner Handling and Scrapping