ION, L-Series, S-Series 1999-2005

Removal & Installation

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  1. Disable the SIR System.
  2.  
  3. Turn the steering wheel to the 3 o'clock position.
  4.  
  5. Remove the inflator module by inserting a stubby flat-blade screwdriver into the triangle-shaped hole in the rear steering wheel shroud.
  6.  
  7. Turn the screwdriver to release the spring fastener, while lifting up on the corner of the bag closest to that fastener.
  8.  
  9. Repeat for the second fastener.
  10.  
  11. Turn the steering wheel to 9 o'clock position.
  12.  
  13. Repeat steps 4-5 until all spring fasteners are released.
  14.  
  15. Disconnect the inflator module harness and the horn lead.
  16.  
  17. Remove the inflator module.
  18.  
  19. Disconnect the cruise control and switch connection, if equipped. Disconnect the harness from the steering wheel.
  20.  
  21. Remove the steering wheel attachment nut and discard the nut.
  22.  
  23. Install the special tools J1859-A and J42578.
    NOTE
    Always align the front wheels to the straight-ahead position when installing or removing a roll connector.


    NOTE
    If the yellow tab is not available, use tape to prevent the SIR coil from rotating.

  24.  
  25. Insert the yellow tab or use a piece of tape to prevent rotating the SIR coil.
  26.  

To install:

  1. Remove the yellow tab or tape from the SIR coil assembly.
  2.  
  3. Route the wiring through the steering wheel and install the steering wheel onto the steering shaft noting the orientation notch that locates the steering wheel in the correct position.
    NOTE
    A new steering wheel attachment nut must be used.

  4.  
  5. Install a new steering wheel attachment nut, and tighten the steering wheel nut to 30 ft. lbs. (40 Nm).
  6.  
  7. If equipped, connect the cruise control and switch connectors. Attach the harness to the wheel.
  8.  
  9. Install the SIR inflator module.
  10.  
  11. Connect the inflator module wiring harness and the horn lead. Be sure to install the
  12.  
  13. Connector Position Assurance (CPA) device.
  14.  
  15. Align the inflator module to the steering wheel and press to install. Be sure to seat all 4 attachment points.
  16.  
  17. Enable the SIR system.
  18.  


CAUTION
Safety precautions must be followed when handling a deployed inflator module (air bag). After deployment, the inflator module (air bag) surface may contain a small amount of sodium hydroxide, a by-product of the deployment reaction, that is irritating to the skin and eyes. Most of the powder on the inflator module (air bag) is harmless. as a precaution, wear gloves and safety glasses when handling a deployed inflator module (air bag), and wash your hands with mild soap and water afterwards.


CAUTION
When you are carrying an undeployed inflator module:



Do not carry the inflator module by the wires or connector on the inflator module
 
Make sure the bag opening points away from you
 

When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result.


CAUTION
Never rest a steering column assembly on the steering wheel with the inflator module (air bag) face down and column vertical. This is necessary so that a free space is provided to allow the inflator module (air bag) to expand in the unlikely event of accidental deployment. Otherwise, personal injury could result.


NOTE
In the event deployment has occurred, inspect coil assembly wire and driver inflator module for any signs of scorching, melting or other damage due to excessive heat. If the coil or inflator module has been damaged, replace it.

  1. Disable the SIR System.
  2.  
  3. Remove driver inflator module.
  4.  
  5. Disconnect cruise control (if equipped) switch connectors and disconnect harness from steering wheel.
    NOTE
    If roll connector is not properly oriented to steering column assembly, it will be damaged.

  6.  
  7. Remove steering wheel attachment nut and discard.

    Click image to see an enlarged view

    Fig. Install special tool J42578 by fitting puller legs into steering wheel puller holes

  8.  
  9. Install special tool J42578 by fitting puller legs into steering wheel puller holes.
  10.  
  11. Install puller bridge over puller legs and finger tighten steering wheel puller nuts on legs.
  12.  
  13. Insert center bolt through bridge and align with steering column shaft.
  14.  
  15. Tighten center bolt until steering wheel is disengaged.
  16.  
  17. Remove steering wheel while feeding wiring through wheel opening.
    NOTE
    If yellow tab is not available, use tape to prevent roll connector from rotating. Insert yellow tab or use a piece of tape to prevent coil assembly from rotating.

  18.  

To install:


NOTE
If roll connector is unintentionally rotated during steering wheel service, the roll connector must be repositioned.

  1. Remove yellow tab or tape from roll connector.
  2.  
  3. Route wiring through steering wheel and install steering wheel onto steering shaft noting orientation notch that locates steering wheel in correct position.
    NOTE
    A new steering wheel attachment nut must be used.

  4.  
  5. Install new steering wheel attachment nut, and tighten Steering Wheel Attachment Nut to 26 ft. lbs. (35 Nm).
  6.  
  7. Connect cruise control switch connectors (if equipped) and attach harness to wheel.
  8.  
  9. Install driver inflator module.
  10.  
  11. Enable the SIR System.
  12.  

  1. Disable the SIR system.
  2.  
  3. Remove the inflatable restraint steering wheel module.
  4.  
  5. If equipped with cruise control, disconnect the cruise control switch connector from the steering column.
  6.  
  7. Remove the steering wheel nut.
  8.  
  9. Remove the steering wheel. It may be necessary to use the special tools J1859-A and J42578 or equivalent to remove the steering wheel.
  10.  

To install:

Click image to see an enlarged view

Fig. The removal and installation of the steering wheel

  1. Align the steering wheel to the steering column and install the steering wheel.
  2.  
  3. Install the steering wheel nut and tighten the steering wheel nut to 30 ft. lbs. (41 Nm).
  4.  
  5. If equipped with cruise control, connect the cruise control switch connector.
  6.  
  7. Install the inflatable restraint steering wheel module.
  8.  
  9. Enable the SIR system.
  10.  

  1. Disable the SIR system.
  2.  
  3. Remove the inflatable restraint steering wheel module.
  4.  
  5. If equipped with cruise control, disconnect the cruise control switch connector from the steering column.
  6.  
  7. Remove the steering wheel nut.
  8.  
  9. Remove the steering wheel. It may be necessary to use the special tools J1859-A and J42578 or equivalent to remove the steering wheel.
  10.  

To install:

Click image to see an enlarged view

Fig. The removal and installation of the steering wheel

  1. Align the steering wheel to the steering column and install the steering wheel.
  2.  
  3. Install the steering wheel nut and tighten the steering wheel nut to 30 ft. lbs. (41 Nm).
  4.  
  5. If equipped with cruise control, connect the cruise control switch connector.
  6.  
  7. Install the inflatable restraint steering wheel module.
  8.  
  9. Enable the SIR system.
  10.  

 
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