DAEWOO NUBIRA 2004 Service Repair Manual

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 87
DAEWOO V–121 BL4
DTC 87
Passenger Side Airbag Sensor Failure
CAUTION : The sensing and diagnostic module(SDM)
can maintain sufficient voltage to deploy the airbags
and pretensioners for 1 minute after the ignition is
OFF and the fuse has been removed. If the airbags
and pretensioners are not disconnected, do not be-
gin service until one minute has passed after discon-
necting power to SDM. Otherwise, injury could result.
CAUTION : During service procedure, be very careful
when handling the SDM. Never strike or jar the SDM.Never power the supplemental inflatable re-
straints(SIR) when the SDM is not rigidly attached to
the vehicle. All SDM mounting bolts must be carefully
tightened , and the arrow on the SDM must be point
toward the front of the vehicle to ensure proper op-
eration of the SIR. The SDM could be activated if it is
powered when it is not rigidly attached to the vehicle,
resulting in unexpected deployment and possible in-
jury.
Step
ActionValue(s)YesNo
11. Confirm the ignition switch ”OFF”.
2. Wait for a minute the SDM charger to be dis-
charged.
3. Visually check any damage for the passenger
side airbag sensor wiring and the connector.
Are the airbag wiring and connector OK?–Go to Step 3Go to Step 2
2Replace the airbag wiring and connect the connec-
tor.–––
3Replace the passenger side airbag sensor.–––

8B – 88ISUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
SERVICE PRECAUTION
CAUTION : The sensing and diagnostic mod-
ule(SDM) can maintain sufficient voltage to
deploy the airbags and pretensioners for 1 min-
ute after the ignition is OFF and the fuse has been
removed. If the airbags and pretensioners are not
disconnected, do not begin service until one
minute has passed after disconnecting power to
SDM. If the airbags are disconnected, service can
be excuted immediately without waiting for one–
minute time period to expire. Failure to tempo-
rarily disable the SIR during service can result in
unexpected deployment, personal injury and un-
necessary SIR repairs.
DISABLING THE SUPPLEMENTAL
INFLATABLE RESTRAINTS(SIR)
1. Turn the steering wheel to the straight–ahead posi-
tion.
2. Turn the ignition switch to LOCK and remove the
key.
3. Remove the airbag fuse F1 in the I/P fuse block
and wait more than one minute for SIR capacitor to
discharge.
ENABLING THE SUPPLEMENTAL
INFLATABLE RESTRAINTS(SIR)
1. Insert the airbag fuse F8 in the I/P fuse block.
2. Turn the ignition switch to ON and verify that the
airbag indicator flashes seven times and turns OFF.
If it does not operate as described, perform the”
SIR Diagnostic System Check” referring in this sec-
tion.
CAUTION : While turning the ignition switch,
staying well away from the inflator modules, or
personal injury can be occurred.

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 89
DAEWOO V–121 BL4
HANDLING, INSTALLATION AND
DIAGNOSIS
S Airbag modules should not be subjected to temper-
ature above 65 degrees Celsius(149 degrees Fahr-
enheit).
S An airbag and SDM should not be used if it has
been dropped from height of 0.9 meters(3 feet) or
greater.
S When an SDM is replaced, it must be oriented with
the arrow on the SDM pointing toward the front of
the vehicle.
S It is very important for the SDM to be installed flat
on the mounting surface, parallel to the vehicle’s
longitudinal axis.
S To avoid setting diagnostic trouble codes(DTCs), do
not apply power to the SIR unless all components
are connected or a diagnostic chart request it.
S The SIR Diagnostic System Check must be the
starting point of any SIR diagnostics. The SIR Diag-
nostic System Check will verify proper airbag indi-
cator operation and will lead you to correct chart to
diagnose any SIR malfunctions. Bypassing these
procedures may result in extended diagnostic time
incorrect parts replacement.
REPAIRS AND INSPECTIONS
REQUIRED AFTER AN ACCIDENT
CAUTION : Any repairs to the vehicle’s structure
must return it to the original production configu-
ration. Deployment requires replacement of
SDM, the inflator modules and a dimensional in-
spection of the steering column.
S If any SIR components are damaged, they must be
replaced. If SIR components mounting points are
damaged, they must be repaired or replaced.
S Never use SIR parts from another vehicle. This
does not include remanufactured parts purchased
from an authorized source.
S Do not attempt to service the SDM, the clock spring
or other airbag modules, these items must be re-
placed if they are defective.
S Verify the part number of replaced airbag modules.
Some inflator modules look identical but contain
different internal components.

8B – 90ISUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO V–121 BL4
ACCIDENT WITH DEPLOYMENT
COMPONENTS REPLACEMENTS
All SIR components must be replaced after frontal
crash involving airbag deployment. After deployment,
a powdery residue may be on the surface of the air-
bag. The powder consists primarily of corn-
starch(used to lubricate the bag as it inflates) and by–
products of the chemical reaction. The sodium
hydroxide then quickly reacts with atmospheric mois-
ture and is converted to sodium bicarbonate(also
known as baking soda). Therefore, it is unlikely that
sodium hydroxide will be present after deployment.
Replace the following SIR components.
CAUTION : Wear gloves and safely glasses dur-
ing the disposal procedure. Refer to ”Deployed
airbag module disposal procedure” in this sec-
tion.
S The SDM
S Airbag modules and pretensioners
S SIR wiring
S Clock spring
ACCIDENT WITHOUT DEPLOYMENT
COMPONENT INSPECTION
Certain inspection must be performed after any
crash, whether the airbag has deployed or not. :
S The steering column must be dimensionally in-
spected.
S Inspect the knee bolsters and mounting points for
distortion, bending and cracking or other damages.
S Inspect the instrument panel(I/P) and steering col-
umn reinforcement plate for distorsion, bending and
cracking or other damage.
S Inspect the I/P braces for distortion, bending and
cracking or other damage.
S Inspect the seat belt and mounting points. Refer to
Section 8A, Seat Belts.
SENSING AND DIAGNOSTIC
MODULE (SDM)
CAUTION : During service procedure, be very
careful when handling the SDM. Never strike or
jar the SDM. Never power the supplemental inflat-
able restraints(SIR) when the SDM is not rigidly
attached to the vehicle. All SDM mounting bolts
must be carefully tightened , and the arrow on the
SDM must be point toward the front of the vehicle
to ensure proper operation of the SIR. The SDM
could be activated if it is powered when it is not
rigidly attached to the vehicle, resulting in unex-
pected deployment and possible injury.

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 91
DAEWOO V–121 BL4
Important : If the vehicle interior has been exposed to ex-
tensive water intrusion such as water leaks, driving
through high water, flooding or other causes, then the
SDM and SDM connector may need to be replaced. With
the ignition OFF, inspect the area of SDM, including the
carpet. If any significant soaking or evidence of previous
soaking is detected, the water must be removed, the water
damage repaired and the SDM and SDM connector must
be replaced. Before attempting any of these repairs, the
SRS must be disabled. Refer to ”Disabling the SIR” in this
section.
Removal and Installation Procedure
1. Disable the supplemental inflatable restraints(SIR).
Refer to ”Disabling the SIR” in this section.
2. Remove the floor console. Refer to section 9G, In-
terior Trim.
3. Remove the connector position assurance lock,
which is tethered to SDM connector.
4. Disconnect the SDM electrical connector.
5. Remove the SDM mounting bolts.
6. Remove the SDM.
7. Install the removed parts in the reverse order.
Installation Notice
Tightening torque of SDM mounting bolts is 10 NSm
(89 lb–in).
Enable the SIR. Refer to”Enabling the SIR”
in this section.
CAUTION : All SDM mounting bolts must be care-
fully tightened and the arrow on the SDM must be
pointing toward the front of the vehicle to ensure
proper operation of the SIR. The SDM could be
activated if it is powered while not rigidly at-
tached to the vehicle, resulting in unexpected de-
ployment and possible injury.
0
DRIVER AIRBAG MODULE
Removal and Installation Procedure
1. Disconnect the negative battery cable.
CAUTION : The sensing and diagnostic mod-
ule(SDM) can maintain sufficient voltage to
deploy the airbags and pretensioners for 1 min-
ute after the ignition is OFF and the fuse has been
removed. If the airbags and pretensioners are not
disconnected, do not begin service until one
minute has passed after disconnecting power to
SDM. If the airbags are disconnected, service can
be excuted immediately without waiting for one–
minute time period to expire. Failure to tempo-
rarily disable the SIR during service can result in
unexpected deployment, personal injury and un-
necessary SIR repairs.
2. Remove two driver airbag module mounting bolts
and discard them.

8B – 92ISUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO V–121 BL4
3. Remove the connector from the driver airbag mod-
ule.
4. Remove the driver airbag module.
CAUTION : When handling an airbag module, al-
ways keep the top the unit facing upward. This
leaves room for the airbag to expand if the mod-
ule unexpectedly deploys. Without room for ex-
pansion, a module suddenly propelled toward a
person or object can cause injury or vehicle dam-
age.
5. Installation should follow the removal procedure in
the reverse order.
Installation Notice
Tightening torque of the driver airbag module mount-
ing bolt is 8 NSm (71 lb–in).
CLOCK SPRING
Removal and Installation Procedure
CAUTION : The sensing and diagnostic mod-
ule(SDM) can maintain sufficient voltage to
deploy the airbags and pretensioners for 1 min-
ute after the ignition is OFF and the fuse has been
removed. If the airbags and pretensioners are not
disconnected, do not begin service until one
minute has passed after disconnecting power to
SDM. If the airbags are disconnected, service can
be excuted immediately without waiting for one–
minute time period to expire. Failure to tempo-
rarily disable the SIR during service can result in
unexpected deployment, personal injury and un-
necessary SIR repairs.
1. Disconnect the negative battery cable.
2. Remove the driver airbag module. Refer to ”Driver
airbag module” in this section.
3. Remove the steering wheel. Refer to Section 6E,
Steering Wheel and Column.
4. Remove the screws from the upper and lower
steering column covers. And remove the covers.

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 93
DAEWOO V–121 BL4
5. Remove the driver side knee bolster or instrument
panel lower cover.
6. Disconnect the driver airbag, horn and connectors
from the lower steering column.
7. Remove the screws and discard them.
8. Remove the clock spring from the steering shaft.
9. Installation should follow the removal procedure in
the reverse order. Refer to ”Clock Spring Align-
ment” in this section for alignment.
Tightening torque of the clock spring screw is 3 NSm
(27 lb–in).
CAUTION : If the clock spring is not properly
aligned, the steering wheel may not be able to ro-
tate completely during a turn. Restricted turning
ability can cause the vehicle to crash. Improper
alignment of the clock spring also may make the
SIR inoperative, preventing the airbag from de-
ploying during crash. Both of the out comes can
result in injury.
CLOCK SPRING ALIGNMENT
Notice : Turning the clock spring more than three turns
clockwise or counterclockwise can damage the spring.
1. Turn the front wheels straight ahead.
2. Turn the lobe of clock spring clockwise to lock (Do
not force).
3. Then turn the lobe of clock spring counterclockwise
approximately three turns to the neutral position,
with the front of the wheels straight ahead.
4. Properly align the pointed marks on the compo-
nents of the clock spring.

8B – 94ISUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO V–121 BL4
PASSENGER AIRBAG MODULE
Removal and Installation Procedure
CAUTION : The sensing and diagnostic mod-
ule(SDM) can maintain sufficient voltage to
deploy the airbags and pretensioners for 1minute
after the ignition is OFF and the fuse has been re-
moved. If the airbags and pretensioners are not
disconnected, do not begin service until one
minute has passed after disconnecting power to
SDM. If the airbags are disconnected, service can
be excuted immediately without waiting for one–
minute time period to expire. Failure to tempo-
rarily disable the SIR during service can result in
unexpected deployment, personal injury and un-
necessary SIR repairs.
1. Disconnect the negative battery cable.
2. Remove the glove box. Refer to 9E, Instrumenta-
tion/Driver Information.
3. Disconnect the passenger airbag yellow electrical
connector. Remove the Instrument panel.
4. Remove the passenger airbag module by removing
the mounting bolts from the airbag bracket.
5. Installation should follow the removal procedure in
the reverse order.
Tightening torque of the passenger airbag module
mounting bolt is 11 NSm (97 lb–in).

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 95
DAEWOO V–121 BL4
SIDE AIRBAG SENSOR
Removal and Installation Procedure
CAUTION : The sensing and diagnostic mod-
ule(SDM) can maintain sufficient voltage to
deploy the airbags and pretensioners for 1minute
after the ignition is OFF and the fuse has been re-
moved. If the airbags and pretensioners are not
disconnected, do not begin service until one
minute has passed after disconnecting power to
SDM. If the airbags are disconnected, service can
be executed immediately without waiting for
one–minute time period to expire. Failure to tem-
porarily disable the SIR during service can result
in unexpected deployment, personal injury and
unnecessary SIR repairs.
1. Disconnect the negative battery cable.
2. Remove the trim from B pillar.
3. Remove the side airbag sensor mounting bolts.
4. Remove the side airbag sensor.
5. Installation should follow the removal procedure in
the reverse order.
Tightening torque of the side airbag sensor mounting
bolts is 8 NSm (71 lb–in).
FRONT SEAT BELT PRETENSIONER
For removal and installation, refer to Section 8A, Seat
Belts.
AIRBAG MODULE DEPLOYMENT
(INSIDE OF VEHICLE)
Deploy the airbags before disposing them. If a vehicle
to be scrapped, the airbag may be deployed inside the
vehicle.
CAUTION : To avoid injury while deploying an air-
bag or a pretensioner in the vehicle, observe the
following precaution :
S Before deploying the airbags, remove all loose ob-
jects from the airbag’s expansion area.
S Deploy the airbags with the vehicle doors closed
and the side windows open.
S Deploy the airbags only in an evacuated area. Ser-
vice personnel who must be present during the de-
ployment should be at least 10 meters(33 feet) in
front of the vehicle.
S Do not connect the voltage source until after having
completed all other preparations for the deployment
of airbags.
S Allow a deployed airbag module or pretensioner
cool for 30 minutes before handling.
S Wear gloves and eye protection during the disposal
procedure.
S If the deployment fails, disconnect the voltage
source and wait 5 minutes before approaching the
vehicle.

8B – 96ISUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO V–121 BL4
Deployment Procedure
CAUTION : The sensing and diagnostic mod-
ule(SDM) can maintain sufficient voltage to
deploy the airbags and pretensioners for 1 min-
ute after the ignition is OFF and the fuse has been
removed. If the airbags and pretensioners are not
disconnected, do not begin service until one
minute has passed after disconnecting power to
SDM. If the airbags are disconnected, service can
be executed immediately without waiting for
one–minute time period to expire. Failure to tem-
porarily disable the SIR during service can result
in unexpected deployment, personal injury and
unnecessary SIR repairs.
1. Disconnect both battery cables and place the bat-
tery at least 10 meters (33 feet) from the vehicle.
2. Remove the driver side knee bolster or instrument
panel lower cover from the steering column. Refer
to Section 9G, Interior Trim.
3. At the lower steering column, cut the two wires
leading from the supplemental inflatable re-
straints(SIR) harness to the clock spring.
4. Strip 13mm(0.5 inch) of the insulation from the end
of the wires leading to the clock spring.
5. Use two additional wires, each at least 10 me-
ters(33 feet) long, to reach from the deployment
battery to the inflator module.
6. Strip 13mm(0.5 inch) of the insulation from the end
of these two additional wires.
7. Twist the two wires together at one end.
8. Place the twisted ends of the two wires near the
deployment battery. Do not connect the wires to the
battery at this time.
9. Using the free ends of the 10 meters(33 feet) wires
leading to the clock spring, make two splices, one
at each wires from the airbag modules.
10. Wrap the wires with insulation tape.
11. Now that the free ends of the 10 meters(33 feet)
wires are spliced to the airbag module wires, and
the ends that are twisted together are near the de-
ployment battery. Clear the area.
12. Untwist the wires that near the deployment battery.
13. Touch one wire to the positive battery terminal and
touch the other wire to the negative battery termi-
nal. The airbag will deploy.
14. Repeat this procedure for the passenger airbag,
side airbags and pretensioners.
15. Using proper precautions, dispose of the deployed
airbags/pretensioners. Refer to ”Deployed Airbag
Module Disposal Procedure” in this section.