G E N E R A L M O T O R S INTERNATIONAL SOUTH AFRICA

Model Introduction Training For Approved Motor Body Repairers

Opel Mokka

Contents Mokka

Overview

Technical

Body

Restraint System

This introduction manual highlights the design and function of new vehicle models.

The introduction manual is not a repair manual! All values given are intended as a guideline only. Some vehicle pictures may be overseas specification.

For body repair work, always refer to the current body repair manual.

3 Overview

Introduction

Opel’s Mokka takes on the sub-compact SUV segment, which is hotly contested in South Africa. Think of products like the Nissan Juke, Nissan Qashqai and Hyundai iX35. Initially, thought of as a rival to the Duster and Ford EcoSport, but in reality feels and is priced like a more premium product.

It comes in at a starting price of R288 500, which will get you the 1.4T Enjoy manual gearbox. The top of the range is the 1.4T Cosmo with an automatic . At launch there are four models in the range with two trim levels, two gearboxes to choose from, and all are powered by the same 1.4-litre turbo engine.

Apart from front-wheel drive (FWD), the Mokka can be fitted with an all-wheel drive (AWD) technology for better traction and handling. The AWD technology is efficient, clever and affordable for a wider segment of customers and is only activated on demand. The AWD system combines the advantages of improved vehicle handling, especially in bends and ensures that there is enough traction for example in the case of wheel slip. However, it also recognizes when AWD is no longer required. For example, when the vehicle is moving in a straight line on a highway, it is driving in high grip conditions with all the torque on the front wheels. This is when the vehicle is in FWD mode and good fuel economy is provided.

Not only is it generously specced, it also offers good performance from a tried-and-tested engine. The Intellilink infotainment system is just superb and shows you don’t need to fork out huge amounts of money for a decent system.

4 Overview

COLOURS

Blaze Red Boracay Blue

Carbon Flash Summit White

Orange Rock Satin Steel Grey

Snowflake White Switchblade Silver

Velvet Red Deep Espresso Brown

5 Overview

SPECIFICATIONS

Mokka Enjoy Mokka Cosmo 1.4L Turbo - 103kW / 200Nm 1.4L Turbo - 103kW / 200Nm 6 Speed Manual / 6 Speed Auto 6 Speed Manual / 6 Speed Auto

• Start/ Stop Engine Control (MT only) Key standard features over Enjoy: • Eco-Drive Assistance Display (MT only) • Anti-Lock Braking System (ABS) • Individual Tyre Pressure Monitoring • Electronic Stability Program (ESP) • Rain Sensing Wipers • Pedal Release System • Auto Dimming Rear View Mirror • Disc Brakes, Front and Rear • Auto Headlights • Tyre Deflation Detection System • Active Beam Assist • Front/Rear Foglamps • Front and Rear Park Assist • Daytime Running Lights • Power Folding Mirrors • Headlamp Levelling • 230V Inverter • Dual Tone Hone • Sunglasses Holder • 6 Airbags • Intellilink with BT,USB,AUZ • Front Seatbelt Pre-tensioners • Reverse Camera • Seatbelt Reminders • Heated Steering Wheel • Passenger Airbag Deactivation Switch • Heated Front Seats • ISOFIX Child seat Anchors • Interior Ambient Lighting • Manual Anti-Dazzle Rear View Mirror • 18” Alloys • Cruise Control With Speed Limiter • JASMIN Leather Seat Trim • Speed Sensitive Power Steering • AGR Certified Ergonomic Seats • Steering Wheel Audio Controls • 4-Way Adjustable Passenger Seat • Radio/CD with BT,USB,AUX • Rear Split Folding Seats with Armrest • 6 Speakers • Visible Chrome Exhaust Tip • 12V Power Outlet • Tilt/ Telescopic Steering Adjustment • Driver Armrest • Electronic Climate Control and Pollution Filter • On Board Computer • Solar Absorbing Windshield • Body Colour Door Handles • Electric and Heated Side Mirrors • Power Windows – Express Up/Down • Foldable Key • Visible Chrome Exhaust Tip • 17” Alloys • Steel Spare Wheel • LINE DRIVE Black Cloth seat Trim • 4-Way Adjustable Driver Seat • 2-Way adjustable Passenger Seat • Rear Split Folding Seats • Cargo Compartment Cover • Premium Floor Mats • Turbo Badge

6 Technical

Suspension

Front

Design features

• MacPherson struts • Dual path Strut mount • Side load compensation spring • Camber adjusting bolt concept • Double bonded handling bushing • High rate Gripper type Stabilizer bushing • Six solid mounting points Crossmember

Benefit

• Strong and dynamic ride and handling behaviour • Solid and safe driving in different road conditions

Back

Design features

• U-section tubular torsion beam • Rear shock behind rear wheel • Urethane inserted Shear

7 Technical

Chassis Protection Kit

1) Front Strut and Spring 2) Rear Shock 3) Rear Spring 4) Protection Shield-Engine Compartment

Mokka can be equipped with a Chassis Protection Kit (option XL4) to prevent vehicle damage under bad road conditions. The Chassis Protection kit consists of an additional protection shield for the engine oil pan and modified spring rates/damping characteristics.

Electric Power Steering (EPS)

The EPS utilizes an to provide steering assist to the driver. Major advantage of this system is the speed sensitive power steering assist as well as active steering features for precise and predictable steering feel. The EPS system is environmentally-friendly because it does not require an energy consuming hydraulic pump, hence it saves fuel and fluids that require special handling. The rake & telescope function of the EPS column allows the driver to find the individually ideal driving and seating position.

8 Technical

Engine

1) Structured Aluminium Oil Pan Improves NVH behaviour / PT bending stiffness and guarantees high heat transfer 2) Torsional Vibration Damper Reduced torsional vibration improved NVH 3) Chain Drive 4) Hollow Camshaft 5) Dual-CV Cam Phaser Reduced fuel consumption, increased performance (low end torque) 6) Intake Manifold 7) 16-valve Cylinder Head Gen 2 intake ports improves performance due to increased air motion and burn rate (swirl & neutral port) 8) Oil water cooler 9) Turbo charger Intergrated design 10) Map controlled thermostat 11) Close-coupled Pre-Catalyst (Achieve Euro 4/5 emissions)

9 Technical

Heating / Ventilation and Air Conditioning

The new Mokka will be the first Opel vehicle which operates with the new refrigerant liquid HFO-1234 yf and it will use the Internal heat exchanger (IHX) feature.(Also known as R1234yf)

1 Condenser 2 Refrigerant lines 3 High and low side charge ports 4 Evaporator core 5 Thermostatic expansion valve 6 Fixed displacement, cycling clutch compressor 7 Receiver / dehydrator 8 Internal heat exchanger (IHX)

10 Technical

Refrigerant Service Port Locations

Positive-coupled, quick-connect type service ports are for AC service. The refrigerant service ports are located on the right side of the engine compartment. The service fittings are located on the refrigerant lines. The service fittings are unique to the R-1234yf system so that R-134a service equipment cannot be used. The service caps for the R-1234yf system are grey, whereas R-134a caps are black.

1 - High pressure service port 2 - Low pressure service port

FAQ’s concerning R134a and R1234yf

Are there differences in the service couplings for R1234yf and R134a? The vehicle-side filling valves of a R1234yf air conditioning system are geometrically different from those of a R134a system. A R1234yf air conditioning service unit therefore has different service couplings than the R134a unit.

Can you fill a R1234yf air conditioning system with R134a? No, this is not permitted by law. Mixing of the refrigerant must be avoided. In addition, the components of a R1234yf air conditioning unit are specifically designed and released for this new refrigerant. Should however, R1234yf and R134a be mixed in the workshop, the resulting refrigerant mixture must be professionally removed from the vehicle air conditioning unit and disposed of. The disposal shall be performed by the gas supplier or a suitable disposal facility.

11 Technical

When Handling refrigerants, which occupational health and safety aspects have to be observed? The key measure for ensuring occupational health and safety during handling of both R134a and R1234yf is the use of personal protective equipment as specified in the risk assessment, that is, for instance, long sleeved work clothes, leather gloves and safety goggles.

Common characteristics of R134a and R1234yf: R134a and R1234yf are gases liquefiable in vehicle air conditioning systems. The vapours are heavier than air and will settle under atmospheric conditions. The thermodynamic properties of R134a and R1234yf are similar. Both materials are fluorocarbons (FC). Both materials are toxicologically safe.

As the Opel Mokka is the first GM vehicle introduced in South Africa which uses the new R1234yf refrigerant, and can only be serviced with all new Air conditioning equipment, GM South Africa has funded and placed 6 of these new Air conditioning Recovery Recycling Recharging units at selected Dealer Service centres across South Africa (R1234yf Air Conditioning Repair Centres)

This equipment may be purchased by any dealers/repairers, and therefore we expect that more R1234yf Air Conditioning Repair centres will become available in due course.

Below is a list of the 6 initial repair/recharge centres:

R1234yf Air Conditioning Location Contact Details Repair Centre VCDC Aloes Industrial Park Main 041 4073537 Road R335 PE Williams Hunt The Glen C/O Comaro & Boundary Road 011 2106000 Oakdene Williams Hunt Durban 60 Old Fort Road Durban CBD 031 3196224 Williams Hunt Pretoria 23 Visagie Str. Pretoria West 012 3286580 Reeds N1 City Giel Basson Drive N1 City 021 5962600 Goodwood Imperial GM Bloemfontein Cnr Church & St George Str 051 4039200 Bloemfontein

12 Technical

Power Distribution Centres

Four power distribution centres route battery voltage throughout the vehicle: the battery fuse block, underhood fuse block, rear fuse block and interior fuse block.

Interior Fuse Block Rear Fuse Block Underhood Fuse Block

13 Technical

High Voltage Power Outlet

230 - Volt power outlet location

12V DC / 230V AC Converter Location

14 Technical

Windshield Moisture And Temperature Sensor

• Measures the relative humidity on the inner side of the windshield • HVAC control module can proactively engage the A/C and send drier air to prevent fog from forming • Sensor is located at the base of the inside rearview mirror • Sensor includes the relative humidity sensor, humidity sensing element, temperature sensor and windshield temperature sensor • The HVAC module uses the sensor information to determine if fog is likely to form on the windshield.

Ambient Light / Sunload Sensor

• Sensor uses a photovoltaic diode that connects to ground and to the 5 V stabilized voltage • As the Solar load, or sunload, increases, the sensor signal voltage also increases • The signal to the HVAC control module varies between 1.4 V and 4.5 V.

15 Technical

Tire Pressure Monitor System (TPMS)

The tire pressure monitoring system warns the driver when a significant loss, or gain, of tire pressure occurs in any of the four tires. The driver can choose to display individual tire pressures and their locations on the driver information centre.

The system uses the Body Control Module (4) (BCM), driver information centre (3), instrument panel cluster (2), a radio frequency (RF) transmitting pressure sensor (1) in each wheel / tire assembly, and the serial data circuit (7) to perform the system functions. The remote control door lock receiver (6) with the incorporated keyless entry antenna (5) is hard wired (8) to the BCM.

Benefits: • Warns of change of tire pressure • Displays individual tire pressure on DIC

16 Technical

Tire Pressure Sensor

Each sensor has an internal power supply with an approximate 10-year service life.

Sensor Learning Procedure

Sensors need to be learned (relearned) in case of following events:

• Tire rotation • BCM replacement • Sensor replacement

Once enabled, each sensors’ unique ID codes may be learned into BCM memory. When sensor ID has been learned, BCM sounds horn chirp. BCM must learn sensor IDs in proper sequence to determine correct

Special tools

Tire Pressure Monitor Sensor Activating Tool To learn the Tire pressure sensor to be BCM a special tool is necessary to activate the transmitter in the tire pressure sensor this can be either done with the...

17 Body

Body Structure

Number Part Material 1 Front Wheelhouse Front Wheelhouse Front Panel - Mild Steel Panel Front Wheelhouse Panel Brace - Dual Phase Steel 2 Roof Outer Panel Mild Steel 3 Rear Wheelhouse Outer Mild Steel Panel 4 Quarter Outer Panel Mild Steel 5 Center Pillar - Outer Mild Steel 6 Rocker Outer Panel Mild Steel 7 Front Compartment Front Compartment Upper Outer Rail - Dual Phase Upper Side Rail Steel Hood Hinge Reinforcement - High Strength Low Alloy Steel 8 Center Pillar Center Pillar Upper Reinforcement - Ultra High Reinforcement Strength Steel Center Pillar Lower Reinforcement - High Strength Low Alloy Steel

9 Body Hinge Pillar Outer Mild Steel Panel 10 Front Compartment Front Compartment Outer Side Rail - High Strength Side Rail Low Alloy Steel Front Compartment Inner Side Rail - Dual Phase Steel

18 Body

Number Part Material 1 Body Tail Lamp Filler Mild Steel Panel 2 Rear Side Door Mild Steel Outer Panel 3 Front Side Door Mild Steel Outer Panel 4 Rear End Panel Mild Steel

19 Body

Front Bumper Upper & Lower Impact Bar Replacement

Number Component Name 1 Front Bumper Upper Impact Bar Bolt (Qty: 8) 2 Front Bumper Upper Impact Bar

Number Component Name 1 Front Bumper Lower Impact Bar Bolt (Qty: 4) 2 Front Bumper Lower Impact Bar Bolt Outer (Qty 2) 3 Front Bumper Lower Impact Bar

20 Body

Front Compartment Side Rail Sectioning

Position where sectioning to take place:

• (a) 235mm - on left rail • (a) 160mm - on right rail • (b) 195mm - on left rail • (b) 200mm - on right rail • (1) Outer • (2) Inner

21 Body

Body Hinge Pillar Outer Panel Sectioning

(1) Hinge Pillar Outer Panel (1) Structural Adhesive

Spot weld the body hinge pillar outer Braze the body hinge pillar outer panel (1) panel (1) accordingly: accordingly:

• (2) 18 spot welds •(2) - 430 mm • (3) 7 spot welds •(3) - 260 mm • (4) 12 spot welds

22 Body

Center Pillar Sectioning - Outer

Center pillar outer panel (1). Structural adhesive (1).

Spot weld the center pillar outer panel (1). Braze the center pillar outer panel (1).

• Flange (2) - 32 spot welds •(2) - 170 mm • Flange (3) - 33 spot welds •(3) - 280 mm • Flange (4) - 15 spot weld •(4) - 280 mm

23 Body

Rear Wheelhouse Outer Panel Replacement

Cut line (1) on the rear wheelhouse outer Structural adhesive (1). panel.

Rear wheelhouse panel (1).

•63 spot welds (2) • 3 spot welds (1) •5 plug welds (3) • MAG-weld seams (2)

24 Body

Rocker Outer Panel Sectioning

Braze the rocker outer panel (1).

• front side door hinge pillar (1) - 355 mm • front side door opening (2) - 265 mm • front side door opening (3) - 265 mm • center pillar outer panel (4) - 343 mm • center pillar (5) - 278 mm • quarter outer panel (6 - 247 mm

Body Side Frame Rocker Reinforcement Replacement

•9 8 mm holes (1) for plug welding •Form-Baffle (2). Install the 2 fasteners (3).

25 Body

Body Side Frame Rocker Reinforcement Replacement

Structural adhesive (1).

Body side frame rocker reinforcement (1).

•9 plug welds (2) •55 spot welds (3)

26 Body

Roof Outer Panel Replacement

Drill out all factory welds. To remove the roof panel(1) cut the adhesive(2) with an appropriate tool.

Drill 26x holes 13x on left and right side for waterproof rivets B1 along the attaching flanges(2) of the roof panel(1) .

Note: The maximum space between the rivet holes is 150 mm and the minimum space to the roof rail holes is 20 mm.

27 Body

Structural adhesive(1,3). One-part urethane adhesive(2).

Spot welding on roof panel(1):

• Roof panel rear flange(3) - 19 spot welds • Roof panel flange front side(4) - 22 spot welds

28 Body

Roof Front Header Panel Replacement

Locate and mark all factory welds on panel(1). Drill out all factory welds.

Remove the roof front header panel(1).

29 Body

Apply structural adhesive(1).

Install the roof front header panel(1) accordingly with 18 spot welds.

30 Body

Rear End Panel Replacement

Locate and mark all the necessary factory welds of Drill out four factory welds(2) of the rear end lower the rear end lower panel(1). panel(1). Drill all factory welds. Note the number and location of welds for installation of the service assembly.

Note: Flange from right and left quarter outer Cut out the rear end panel edge(1) on the left and panel stay on vehicle. right side. Do not damage any inner panels or Detach and drill away rear end panel. reinforcements.

31 Body

Cut out the rear end panel edge(1) Prepare new rear end panel. Remove the rear end panel. Cut shaded connecting piece(1) from rear end inner panel extension left and right side. Cut rear end panel(2) left and right side.

Drill 8mm plug weld holes on service part, four on Drill 8 holes 4 on each side for waterproof rivets B1 each side on the rear end lower panel inner(1). along the attaching flanges(2, 3) of the rear end Note: Install the NEW rear end panel from out- panel(1). side to flange on quarter outer panel left and right side.

32 Body

Apply structural adhesive(1) to the attaching surfaces on the body. In MAG-welding areas 50mm must be kept clear of structural adhesive. Note: Install the NEW rear end panel from outside to quarter outer panel on left and right side.

Rivet the rear end lower panel(2) on each side(1, 3). Spot weld the rear end lower panel with 69 spot welds(4, 5, 6). Note: Areas 1,3,4,6 of the new rear end panel has to be located outside. Spot weld the rear end lower panel / liftgate opening with four spot welds(3) on each side. Plug weld at each 8mm(5/16 in) plug weld hole location(2) body side inner panel. Weld the rear end panel inner edges(1). Apply the sealers and anti-corrosion materials to the repair area as necessary.

33 Body Front Bumper Fascia Replacement

Number Component Name 1 Headlamp Screw (Qty: 2) 2 Front Bumper Fascia Grille Bolt (Qty: 4) 3 Front Bumper Fascia Carefully push a small nylon wedge between the fascia and the front fascia guide. Insert a small flat-bladed tool into the fascia slot and depress the snaps one at a time and pull on the fascia at the same time to gradually remove the fascia from the front fascia guide.

34 Body

Front Grille Replacement

Number Component Name 1 Radiator Grille Upper Screws (Qty: 2) 2 Radiator Grille Upper Release the 8 locking tabs while pulling the radiator grille upper from the front fascia.

35 Body

Front Fog Lamp Replacement

Number Component Name 1 Front Fog Lamp Screw (Qty: 2) Remove the three fog lamp mounting screws from the front bumper fascia. 2 Front Fog Lamp Aim the front fog lamps after replacement.

36 Body

Headlamp Replacement

Number Component Name 1 Headlamp Assembly Screw (Qty: 4) 2 Headlamp Assembly Disconnect the electrical connector and remove the headlamp assembly. Aim the headlamps after replacement.

37 Body

Rear Bumper Fascia Replacement

Number Component Name 1 Rear Bumper Fascia Retainer (4x) 2 Rear Bumper Fascia Carefully push a small nylon wedge between the fascia and the rear fascia guide. Insert a small flat-bladed tool into the fascia slot and depress the snaps one at a time and pull on the fascia at the same time to gradually remove the fascia from the rear fascia guide.

38 Body

Tail Lamp Replacement

Number Component Name 1 Tail Lamp Screw Cap 2 Tail Lamp Bolt 3 Tail Lamp Nut (Qty 4) 4 Tail Lamp Assembly Hold both sides of the tail lamp assembly and carefully pull the tail lamp reward in order to disengage the two locator pins from the bodyside outer panel.

39 Body

Rear Fog Lamp Replacement

Number Component Name 1 Rear Fog Lamp Screw (Qty: 3) 2 Rear Fog Lamp

40 Body

Outside Rearview Mirror Replacement

1 Outside Rearview Mirror Locator Note: When install the outside rearview mirror align the locator pin to the door hole. 2 Outside Rearview Mirror Nuts (Qty: 3) 3 Outside Rearview Mirror

Number Component Name 1 Outside Rearview Mirror Bracket Cover Screw (Qty: 2) 2 Outside Rearview Mirror Bracket Cover

41 Body

Outside Rearview Mirror Housing Bezel Replacement

Number Component Name 1 Outside Rearview Mirror Housing Cover Bezel Screws (Qty: 4) 2 Outside Rearview Mirror Housing Bezel

Inside Rearview Mirror Replacement

Number Component Name 1 Inside Rearview Mirror Screw 2 Inside Rearview Mirror

42 Body

Front Side Door Outside Handle Replacement

Number Component Name

1 Front Side Door Lock Cylinder Screw No. Component Name Access Plug 1 1. Pull the outside door handle outward 2 Front Side Door Lock Cylinder Clamp and hold it in the open position. Screw 2. Sliding the outside door handle rearwards and then out in a 1.Pull and hold the door handle in the swinging motion releasing it from it open position. from the door. 2.Do Not remove the cylinder clamp 3.Install the rear side door outside screw completely from the housing, handle into the handle guide. unscrew the screw to a hard stop, 4.While screwing in the screw for the releasing the cylinder from the lock cylinder hold the handle in the housing. open position, this will avoid the door 3.Release the handle, at this point the handle from snapping once the handle should stay in the open spring pressure is relieved and the position. door handle returns to the close 4.Remove the lock cylinder assembly. position. 5.While screwing in the screw for the lock 5.Turn fastener to the right and to the cylinder hold the handle in the open mechanical stop. position, this will avoid the door handle from snapping once the spring pressure is relieved and the door handle returns to the closed position.

3 Front Side Door Lock Cylinder Bezel 4 Front Side Door Lock Cylinder

43 Body

Liftgate Outside Handle Replacement

Number Component Name 1 Liftgate Outside Handle Bolt (Qty: 4) 2 Liftgate Outside Handle Seal 3 Liftgate Outside Handle

44 Restraint System

Supplemental Inflatable Restraint System

SIR System Overview

The supplemental inflatable restraint (SIR) system supplements the protection offered by the seat belts. The SIR system contains an inflatable restraint sensing and diagnostic module (SDM), air bags, seat belt pretensioners (anchor and retractor), and impact sensors. The SDM determines the severity of a collision with the assistance of side impact sensors located at strategic points on the vehicle. When the SDM detects a collision, the SDM will process the information provided by the sensors to further support air bag or pretensioner deployment. The SDM will deploy the air bags and pretensioners if it detects a collision of sufficient force. If the force of the impact is not sufficient to warrant air bag deployment, the SDM may still deploy the seat belt pretensioners. The SDM contains a sensing device that converts vehicle velocity changes to an electrical signal. The SDM compares these signals to values stored in memory. If the signals exceed a stored value, the SDM will determine the severity of the impact and either cause current to flow through the frontal deployment loops deploying the frontal air bags and pretensioners, or it will deploy the pretensioners only. The SDM continuously monitors the deployment loops for malfunctions and illuminates the AIR BAG indicator if a fault is detected. The SDM performs continuous diagnostic monitoring of the SIR system electrical components. Upon detection of a circuit malfunction, the SDM will set a DTC and inform the driver by illuminating the AIR BAG indicator. The steering column and knee bolsters are designed to absorb energy and compress during frontal collisions in order to limit leg movement and decrease the chance of injury to the driver and passenger.

Air Bags

This vehicle contains 6 air bags. The 6 air bags are located in the steering wheel, instrument panel (passenger side), driver side (B-pillar), passenger side (B-pillar), left roof rail, and right roof rail. To view the locations of the air bags refer to Master Electrical Component List . Air bags contain a housing, inflatable air bag, two initiating devices (if dual inflator), canister of gas gener- ating material and, in some cases, stored compressed gas. The deployment loops supply cur- rent through the inflator modules to deploy the air bags. The steering wheel and instrument panel passenger side air bags have two stages of deployment, which varies the amount of restraint to the occupant according to the collision severity. The current passing through the air bag, 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 air bag is equipped with a shorting bar located in the connectors of the module. The shorting bar shorts the air bag deployment loop circuitry to prevent unwanted deployment of the air bag when it is disconnected.

45 Restraint System

Seat Belt Pretensioners (Anchor and Retractor)

The seat belt pretensioners (driver and passenger) consist of a housing, seat belt retractor (located in the B-pillar), seat belt anchor (located on the floor), seat belt webbing, an initiator, and a canister of gas generating materials. To view the locations of the seat belt pretentioners refer to Master Electrical Component List . The initiator is part of the seat belt pretensioner deployment loop. When the vehicle is involved in a collision of sufficient force, the SDM causes current to flow through the seat belt deployment loops to the initiator. Current passing through the initiator ignites the material in the canister producing a rapid generation of gas. The gas produced from this reaction deploys the seat belt pretensioners which removes all of the slack in the seat belts. Depending on the severity of the collision, the seat belt pretensioners may deploy without the frontal air bags deploying, or they will deploy immediately before the frontal air bags deploy. Each seat belt pretensioner is equipped with a shorting bar that is located in the connector of the seat belt pretensioner. The shorting bar shorts the seat belt pretensioner circuitry to prevent unwanted deployment of the seat belt pretensioner when the connector is disconnected.

Impact Sensors

This vehicle contains 3 impact sensors. The 3 impact sensors are located in the front of the vehicle 1 and 2 in the B-pillars (left and right). To view the locations of the impact sensors refer to Master Electrical Component List . The impact sensors contain a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The impact sensors are not part of the deployment loop, but instead provide input to the 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 appropriate impact module air bags.

Passenger Air Bag Disable Switch

The passenger air bag disable switch is used to turn the passenger frontal air bag on or off. The customer can decide to disable the passenger air bag by turning this switch on. When the inflatable restraint sensing and diagnostic module sees a ground circuit from this switch the passenger air bag is turned off. The vehicle has a PASSENGER AIR BAG ON/OFF indicator to tell the customer when the passenger air bag is on or off based on the disable switch position.

Seat Belt Indicators

The seat belt indicators are controlled through the inflatable restraint sensing and diagnostic module (SDM). For further information on seat belt indicators refer to Seat Belt System Description and Operation .

46 Restraint System

Airbag Front End Discriminating Sensor

1) Front Crash Sensor

Airbag Side Impact Sensor

1) Side Crash Sensor (X2, Left and Right)

47 Restraint System

Airbag Sensing and Diagnostic Module

1) Fastener x(3)

2) Sensing And Diagnostic Module (SDM)

Steering Wheel Airbag Replacement

Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling.

1) Lower the steering column and move to the maximum rear end position. 2) Turn the steering wheel from straight ahead to 180 degree position. 3) Insert a small screwdriver, or equivalent tool, through the service openings on the rear left and right side of the steering wheel. 4) Push the spring fastener in the direction of the steering column to release the steering wheel inflator from the steering wheel. 5) Disconnect the electrical connectors.

48 Restraint System

Steering Wheel Airbag Coil Replacement

1) Steering Wheel Airbag Coil Bolt (4x) 2) Steering Wheel Airbag Coil • Disconnect the electrical connectors • Transfer components as necessary. • Ensure the steering wheel airbag coil is CENTERED during installation. (See Airbag Steering Wheel Module Centering)

Airbag Instrument Panel Module

1) Instrument Panel Inflatable Restraint Module

49 Restraint System

Roof Side Rail Airbag

1) Roof Side Rail Airbag Fastener (3x) 2) Roof Side Rail Airbag Clip (2x) 3) Roof Side Rail Airbag

50