GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2005 🢒 TopKick C-Series (Conventional) C4/C5 🢒 Restraints 🢒 SIR 🢒 Inflatable Restraint Front End Sensor Replacement

Removal Procedure

    Caution: Refer to SIR Caution in the Preface section.

    Caution: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling .
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    3. Object Number: 808086 Size: SH
  3. Remove the connector position assurance (CPA) from the harness connector to the inflatable restraint front end discriminating sensor.
  4. Disconnect the harness connector from the front end discriminating sensor.
  5. Remove the mounting fasteners (4) from the front end discriminating sensor.
  6. Remove the front end discriminating sensor (3) from the front end lower tie bar (1).

Installation Procedure

    Important: Utilize the first fastener repair and the second fastener repair in the event that the sensor mounting holes or fasteners are damaged to the extent that the sensor can no longer be properly mounted.

  1. Perform the following steps in order to complete the first fastener repair:
    2. 1.1. Remove the stripped fastener and discard the nut.
    1.2. Chisel off the damaged weld nut and discard the weld nut.
    1.3. Clean the front end lower tie bar surface where the new weld nut is to be installed.
    1.4. Install new weld nut GM P/N 11514034 into position.
    1.5. Migweld the new weld nut to the front end lower tie bar surface in the correct location.

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    1.6. Install sensor with new fastener GM P/N 11515926.

    Tighten
    Tighten the fastener to 10 N·m (89 lb in).

  2. Perform the following steps in order to complete the second fastener repair:
    3. 2.1. Remove the improperly installed rivet.
    2.2. Enlarge the mounting holes in the lower radiator support to 9.0 mm (0.35 in).
    2.3. Insert and properly seat the rivet.
    2.4. Install the sensor with the screw.

    Tighten
    Tighten the fasteners to 10 N·m (89 lb in).

  3. Remove any dirt, grease, or other contaminants from the mounting surface.

    4. Object Number: 808086 Size: SH
  4. Install the inflatable restraint front end discriminating sensor (3) horizontally to the front end lower tie bar (1).
  5. Point the arrow on the sensor toward the front of the vehicle.

    6. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  6. Install the mounting fasteners (4) to the front end discriminating sensor.

    7. Tighten
    Tighten the fasteners to 10 N·m (89 lb in).

  7. Connect the harness connector to the front end discriminating sensor.
  8. Install the CPA to the harness connector.
  9. Remove the safety stands and lower the vehicle.
  10. Enable the SIR system. Refer to SIR Disabling and Enabling .