Chevrolet Cobalt Service & Repair Manual: Component Service

Driver Air Bag Module, Replace

Removal

1. On models equipped with driver air bag module mounting bolts, remove covers and mounting bolts for rear of steering wheel.
2. On models equipped with driver air bag module retaining springs, proceed as follows:
  a. Insert suitable flat-bladed screwdriver into openings.
  b. Rotate screwdriver counterclockwise to release four retaining springs securing air bag module to wheel, Fig. 1.
  c. Gently pull on air bag module while releasing springs.
3. On models equipped with spring loaded driver air bag module, proceed as follows:
  a. Rotate steering wheel 90° counterclockwise until two slots on rear side are facing straight up.
  b. Insert driver air bag module removal tool No. J-44298, or equivalent, into slots, Fig. 2.
  c. Push handle back toward instrument panel while releasing two spring loaded fasteners.
  d. Rotate steering wheel 180° clockwise until two slots on rear side are facing straight up.
  e. Repeat removal steps on this side of steering wheel.
4. On all models, disconnect driver air bag module and horn electrical connectors.
5. Remove air bag module from steering wheel.

Installation

1. On models equipped with driver air bag module mounting bolts, install driver air bag module and tighten mounting bolts.
2. On models equipped with driver air bag module retaining springs and spring loaded fasteners, press air bag module firmly into steering wheel and ensure all its fasteners lock securely into place.

Clockspring, Replace

Removal

1. Ensure front wheels are in straight-ahead position.
2. Remove driver air bag as outlined under "Driver Air Bag Module, Replace."
3. Remove steering wheel mounting nut.
4. Mark wheel and shaft for installation alignment.
5. Remove steering wheel using suitable puller tool and puller leg attachment tool.
6. Disconnect clockspring and electrical connectors.
7. On models equipped with tilt steering column, remove tilt control lever.
8. On all models, remove upper and lower steering column covers.
9. Mark steering column block tooth and shaft centering points for installation alignment.
10. Mark clockspring mounting orientation for installation alignment.
11. Remove retaining ring, clockspring and wave washer. Ensure clockspring remains centered.

Centering

Identify type of clockspring, Figs. 3 through 133.
1. Hold components with bottom facing upward.
2. While holding clockspring, depress spring lock to rotate hub six revolutions in direction of arrow.
3. Rotate coil hub in opposite direction approximately 2 1/2 turns.
4. Release spring lock between locking tabs.
5. On models equipped with clockspring Type 1, proceed as follows:
  a. Hold clockspring with face up.
  b. While depressing spring service lock, rotate coil hub clockwise until coil ribbon stops.
  c. Slowly rotate coil hub counterclockwise until centering window appears yellow and both arrows align.
  d. Release spring service lock between locking tabs.
  e. Clockspring is now properly centered.
  f. Align clockspring with horn tower and slide it onto steering shaft.
6. On models equipped with clockspring Type 2, proceed as follows:
  a. Hold clockspring with face up
  b. Rotate coil hub clockwise until coil ribbon stops.
  c. Slowly rotate coil hub counterclockwise until centering window appears yellow and both arrows align.
  d. Clockspring is now properly centered.
  e. Hold clockspring in centered position, align it with horn tower and slide it onto steering shaft.
7. On models equipped with clockspring Type 3, proceed as follows:
  a. Hold clockspring with rear side up.
  b. While depressing spring service lock, rotate coil hub clockwise until coil ribbon stops.
  c. Keeping service lock depressed, rotate coil hub counterclockwise 2 1/2 turns.
  d. Release spring service lock between locking tabs.
  e. Clockspring is now properly centered.
  f. Align clockspring with horn tower and slide it onto steering shaft.

Installation

1. Ensure clockspring is properly centered.
2. Ensure block tooth and shaft centering marks are properly aligned.
3. Install clockspring onto steering column, ensuring it is positioned as noted during removal procedure.
4. Pull gently on wiring to remove any kinks hiding inside steering column.
5. Install steering column upper and lower covers, then snap them together.
6. Install tilt control lever.
7. Install steering wheel and driver air bag module.

Passenger Air Bag Module, Replace

1. Remove trim plate from righthand side of instrument panel.
2. Press inner glove compartment sides together, then lower compartment door past stops.
3. Remove glove compartment accessory hole cover bolts, then the cover.
4. Remove instrument panel inflatable restraint module attaching bolts.
5. Remove Connector Position Assurance (CPA) retainer from restraint module electrical connector, then disconnect electrical connector.
6. Remove restraint module from instrument panel.
7. Reverse procedure to install.
8. Torque passenger air bag module to 89 inch lbs.

Roof Panel Air Bag Module, Replace

1. Remove assist handle retaining screws, then the assist handles from headliner.
2. Remove sunshade assembly support bezel attaching screws.
3. Remove sunshade support bezel and sunshade retainers.
4. Remove front pillar trim panel attaching screws, then the panel from front pillar.
5. Remove coat hook.
6. Remove upper seat belt bolt, then the upper trim panel assembly from center pillar.
7. Remove headliner assembly.
8. Remove panel air bag module attaching bolts.
9. Remove Connector Position Assurance (CPA) retainer from roof panel air bag module electrical connector.
10. Disconnect roof panel air bag module electrical connector, then remove module from roof.
11. Reverse procedure to install.
12. Torque roof panel air bag module to 71 inch lbs.

Impact Sensor, Replace

Front

1. Loosen forward discriminating sensor mounting bolts.
2. Remove Connector Position Assurance (CPA) cover from sensor connector.
3. Disconnect sensor electrical connector.
4. Remove sensor mounting bolts, then the sensor.
5. Reverse procedure to install.
6. Torque impact sensor to 71 inch lbs.

Side

1. Remove upper extension trim panel assembly from door trim panel.
2. Remove door trim panel pull cup trim plate, then the pull cup.
3. Remove window regulator crank retaining clip, then the regulator crank.
4. Remove door inside handle cover.
5. Remove door handle retaining screws and door handle assembly.
6. Remove door trim panel push pin retainers, then the trim panel.
7. Position water deflector aside.
8. Remove Connector Position Assurance (CPA) cover, then disconnect sensor electrical connector.
9. Loosen impact sensor mounting bolts, then remove sensor.
10. Reverse procedure to install.
11. Torque impact sensor to 71 inch lbs.

Seat Belt Pretensioner, Replace

1. Move front seat to full forward position.
2. Remove seat belt anchor mounting bolt.
3. Remove seat belt adjuster attaching bolt, then the seat belt adjuster.
4. Remove upper seat belt bolts.
5. Remove upper trim panel from center pillar.
6. Remove sill plate from front door opening.
7. On sedan models, remove sill plate from rear door opening.
8. On all models, pull carpeting away from center pillar.
9. Remove center pillar lower trim panel.
10. Remove seat belt retractor mounting bolt, then the retractor assembly.
11. Reverse procedure to install.

Sensing & Diagnostic Module (SDM), Replace

1. Remove cup holder from floor console.
2. Remove armrest to floor console attaching bolts, then the armrest.
3. Set parking brake, then remove park brake trim plate from console.
4. Remove Connector Position Assurance (CPA) retainer, then disconnect Sensing and Diagnostic Module (SDM) electrical connector.
5. Remove SDM retaining nuts, then the SDM from console.
6. Reverse procedure to install, noting the following:
  a. AIR BAG indicator may remain On after SDM has been replaced.
  b. DTC B1001 may set requiring SDM part number to be set in multiple modules.
  c. If indicator remains On after enabling SIR system, ensure SDM is set properly.
  d. Reprogram Body Control Module (BCM) using a suitably programmed scan tool.
  e. Torque sensing and diagnostic module to 89 inch lbs.

Inflatable Restraint Passenger Presence System (PPS), Replace

1. Remove passenger front seat assembly mounting bolts.
2. Disconnect seat electrical connectors, then tilt seat forward to release front of seat tracks.
3. Remove seat from vehicle.
4. Remove seat cushion cover and pad.
5. Remove Passenger Presence System (PPS) sensors. Note wiring harness routing for installation reference.
6. Disconnect PPS module electrical connector.
7. Remove PPS module retaining rivets, then remove module.
8. Reverse procedure to install. Rezero PPS system as outlined under "Passenger Presence System Rezeroing Procedure."

Sensing & Diagnostic Module (SDM), Programming

If the SRS or Air Bag warning lamp stays lit after SDM replacement, proceed as follows:
1. Connect a suitably programmed scan tool to DLC.
2. Select "Special Functions" option from SIR Menu, then press Enter.
3. Choose "Setup SDM Part Number" in BCM option, then press enter.
4. Follow scan tool prompts.
5. Cycle ignition Off and On. This turns warning lamp off and clears DTC.

BCM Programming & RPO Configuration

1. Ensure there are proper communications between BCM and PCM.
2. Maintain battery voltage while PCM is in Auto Learn procedure.
3. Select NEW BCM SETUP and program BCM with proper RPO code configuration using suitably programmed scan tool.
4. Turn ignition switch to ON position and leave on for 11 minutes.
5. Turn ignition switch to OFF position for 30 seconds.
6. Turn ignition switch to ON position and leave on for 11 minutes.
7. Turn ignition switch to OFF position for 30 seconds.
8. Turn ignition switch to ON position and leave on for 11 minutes or until Code P1630 sets.
9. Turn ignition switch to OFF position for 30 seconds.
10. Turn ignition switch to ON position and wait 30 seconds.
11. Try to start engine. If engine refuses to start, perform powertrain OBD system inspection.

Passenger Presence System (PPS) Rezeroing Procedure

The Passenger Presence System (PPS) is a calibrated system that requires rezeroing anytime the seat cushion trim attachments have been removed or the PPS has been replaced. Also, upon initializing the service kit, this DTC will be set and you must perform the rezeroing function in the scan tool. If the passenger seat has been steam cleaned, or been wet, or its relay humid, rezeroing may have to be performed after the seat has had a chance to dry out.
1. Empty front outboard passenger seat.
2. Ensure all SIR and PPS components, connectors and Connector Position Assurances (CPAs) are properly connected and mounted.
3. Connect a suitable scan tool to Data Link Connector (DLC).
4. Turn ON the ignition, with engine OFF.
5. Clear SIR and PPS DTC with scan tool, then request PPS rezeroing procedure.
6. Initiate the PPS rezeroing procedure, PPS will illuminate both PASSENGER AIR BAG ON and OFF indicators located on center of IPC until rezeroing procedure has been completed.
7. When rezeroing procedure has been successfully completed, PPS will display current system status on "PASSENGER AIR BAG ON/OFF" indicators located in center of IPC.
8. If rezeroing procedure was unsuccessful, both "PASSENGER AIR BAG ON & OFF" indicators will alternate from no illumination to full illumination in 1 second intervals for 5 seconds.
9. PPS will treat an unsuccessful rezero attempt as a system fault.
10. If rezeroing procedure was unsuccessful, repeat this procedure. Due to communication status between SDM and PPS module, this procedure may have to be repeated several times until a successful rezero attempt has been achieved.

Passenger Presence System (PPS) Preload Test Procedure

1. Empty front outboard passenger seat.
2. Connect a suitable scan tool to Data Link Connector (DLC).
3. Clear SIR and PPS DTCs with scan tool.
4. If any current codes are set except preload DTCs, then service that DTC first.
5. With scan tool go to Body, then to PPS system.
6. Request PPS codes. If DTC 1052-1057 is present, refer to DTC 1052, 1053, 1054, 1055, 1056, or 1057 diagnosis and repair.
7. When no preload DTCs are found in PPS, then clear all history DTCs in both the PPS and SIR system

Air Bag Module Disposal

Some vehicles with SIR systems that have live (undeployed) air bag module may have to be scrapped because they have completed their useful life or have been severely damaged in a non-deployment type accident. The following procedures should be followed when scrapping a vehicle with undeployed module.
When a deployed air bag module has been removed from a vehicle, it may be disposed of with any other scrap material. Handle with gloves and safety glasses, then wash hands afterward. These module contain explosive material and must be deactivated before disposal. Failure to deactivate before disposal may result in personal injury.

Air Bag Module Deployment

Inside VehicleDriver's
1. Turn ignition switch to LOCK position and remove key.
2. Ensure driver air bag module is secured to steering wheel and there is nobody in vehicle.
3. Remove all loose objects from vehicle.
4. Disconnect lower steering column connector and remove shorting clip from connector.
5. Cut lower steering column connector from vehicle harness leaving at least six inches of wire at connector.
6. Splice two 18 gauge (or thicker) wires, at least 20 feet long, into driver air bag module circuit wiring at base of steering column.
7. Stretch wires away from vehicle to their full length.
8. Ensure no people, animals or objects are in area of unit.
9. Apply 12 volts from fully charged battery across wires to deploy module. Do not touch air bag module for 30 minutes because of heat generated by deployment. If air bag module fails to deploy, contact General Motors.
Passenger's
1. Turn ignition switch to LOCK position and remove key.
2. Ensure passenger air bag module is secured to instrument panel and there is nobody in vehicle.
3. Remove all loose objects from vehicle.
4. Disconnect passenger air bag module connector and remove shorting clip from connector.
5. Cut passenger air bag module connector from vehicle harness leaving at least six inches of wire at connector.
6. Splice two 18 gauge (or thicker) wires, at least 20 feet long, into the passenger air bag module circuit.
7. Stretch wires away from vehicle to their full length.
8. Ensure no people, animals or objects are in area of unit.
9. Apply 12 volts from fully charged battery across wires to deploy module. Do not touch air bag module for 30 minutes because of heat generated by deployment. If air bag module fails to deploy, contact General Motors.
Outside VehicleDriver's
1. Disarm air bag system as outlined under "Air Bag System Disarming & Arming."
2. Remove driver air bag module as outlined under " Driver Air Bag Module, Replace."
3. Position air bag module in secured paved outdoor location free of activity.
4. Connect deployment harness tool No. J-38826, or equivalent, to air bag module.
5. Ensure air bag module is positioned with pad side facing upward.
6. Stretch wires away from air bag module to their full length.
7. Ensure no people, animals or objects are in area of air bag module.
8. Apply 12 volts from fully charged battery across wires to deploy module. Do not touch air bag module for 30 minutes because of heat generated by deployment. If air bag module fails to deploy, contact General Motors.
Passenger
1. Disarm air bag system as outlined under "Air Bag System Disarming & Arming."
2. Remove passenger air bag module as outlined under " Passenger Air Bag Module, Replace."
3. Fill reservoir of deployment fixture tool No. J-39401-B, or equivalent, with water or sand.
4. Mount module into deployment fixture tool with trim cover facing upward.
5. Position module and deployment fixture tool in secured paved outdoor location free of activity.
6. Connect deployment harness tool No. J-38826, or equivalent, to air bag module.
7. Ensure air bag module is positioned with pad side facing upward.
8. Stretch wires away from air bag module to their full length.
9. Ensure no people, animals or objects are in area of air bag unit.
10. Apply 12 volts from fully charged battery across wires to deploy module. Do not touch air bag module for 30 minutes because of heat generated by deployment. If air bag module fails to deploy, contact General Motors.

Seat Belt Pretensioner Deployment

Inside Vehicle
1. Turn ignition switch to LOCK position and remove key.
2. Ensure seat belt pretensioner is secured to vehicle and there is nobody inside vehicle.
3. Remove all loose objects from vehicle.
4. Disconnect seat belt pretensioner connector and remove shorting clip from connector.
5. Cut pretensioner connector from vehicle harness leaving at least six inches of wire at connector.
6. Splice two 18 gauge (or thicker) wires, at least 20 feet long, into the seat belt pretensioner circuit.
7. Stretch wires away from vehicle to their full length.
8. Ensure no people, animals or objects are in area of unit.
9. Apply 12 volts from fully charged battery across wires to deploy pretensioner. Do not touch pretensioner for 30 minutes because of heat generated by deployment. If seat belt pretensioner fails to deploy, contact General Motors.
Outside Vehicle
1. Disarm air bag system as outlined under "Air Bag System Disarming & Arming."
2. Remove driver air bag module as outlined under "Seat Belt Pretensioner, Replace."
3. Clamp seat belt pretensioner in a vise near attachment bolt hole.
4. Vise should be in an area with a clear space of at least six feet in diameter.
5. Connect deployment harness tool No. J-38826, or equivalent, to seat belt pretensioner harness.
6. Stretch deployment harness wires away from pretensioner.
7. Ensure no people, animals or objects are in area of unit.
8. Apply 12 volts from fully charged battery across wires to deploy pretensioner. Do not touch pretensioner for 30 minutes because of heat generated by deployment. If pretensioner fails to deploy, contact General Motors.

Side Impact Air Bag Module Deployment

Inside Vehicle
1. Turn ignition switch to LOCK position and remove key.
2. Remove all loose objects from vehicle.
3. Disconnect side impact air bag module electrical connector and remove shorting clip from connector.
4. Cut side impact air bag module connector from vehicle harness leaving at least six inches of wire at connector.
5. Splice two 18 gauge (or thicker) wires, at least 20 feet long, into the side impact air bag module circuit.
6. Stretch wires away from vehicle to their full length.
7. Ensure no people, animals or objects are in area of unit.
8. Apply 12 volts from fully charged battery across wires to deploy module. Do not touch air bag module for 30 minutes because of heat generated by deployment. If air bag module fails to deploy, contact General Motors.
Outside Vehicle
1. Disarm air bag system as outlined under "Air Bag System Disarming & Arming."
2. Remove driver air bag module as outlined under " Driver Air Bag Module, Replace."
3. Position air bag module in secured paved outdoor location free of activity.
4. Connect deployment harness tool No. J-38826, or equivalent, to air bag module.
5. Ensure air bag module is positioned with pad side facing upward.
6. Stretch wires away from air bag module to their full length.
7. Ensure no people, animals or objects are in area of air bag unit.
8. Apply 12 volts from fully charged battery across wires to deploy module. Do not touch air bag module for 30 minutes because of heat generated by deployment. If air bag module fails to deploy, contact General Motors.

Fig. 1 Driver air bag module retaining spring release procedure

Fig. 2 Driver air bag module spring loaded fastener release procedure

Fig. 3 Clockspring centering. Type 3 w/center window & spring service lock

    Component Locations
    Refer to Fig. 1 for air bag component locations. Fig. 1 Component locations ...

    Description & Operation
    The SIR system helps supplement the protection offered by the driver and front passenger seat belts by deploying air bag module from the center of steering wheel, passenger's instru ...

    See also:

    Chevrolet Cobalt Owners Manual. Lower Anchors and Tethers for Children (LATCH)
    The LATCH system holds a child restraint during driving or in a crash. This system is designed to make installation of a child restraint easier. The LATCH system uses anchors in the vehicle and attachments on the child restraint that are made for use with the LATCH system. Make sure that a LAT ...

    Chevrolet Cobalt Owners Manual

    Chevrolet Cobalt Service Manual


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