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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 158 (SUPPLEMENTAL INFLATABLE RESTRAINT SYSTEM)DISPOSAL PROCEDURESON-VEHICLE DEPLOYMENT
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

On-Vehicle Deployment

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION On-Vehicle Deployment
WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, 2003 Chevrolet RV Cutaway, and 2003 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition off, remove key and put on safety glasses. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .
  2. Cut air bag module and seat belt pretensioner harness connectors from vehicle leaving at least 6" (152 mm) of wire at the connector for each wire lead. Strip 0.50" (13 mm) of insulation from each wire lead. Cut 2 deployment wires at least 20 feet (6.1 m) long from 18-gauge multi-strand wire. Strip 0.50" (13 mm) of insulation from each connector wire lead. Twist wires together at one end to short.
  3. For driver-side and passenger-side dual stage air bag module leads, twist together wires for Stage 1 and Stage 2 high-side deployment loops. See WIRING DIAGRAMS . Connect twisted wire pair to end of one deployment wire. See Fig 1. Bend twisted connection flat and wrap tightly with electrical tape to insulate. Repeat procedure for Stage 1 and Stage 2 low-side deployment loop leads.
  4. For driver-side and passenger-side single stage air bag modules and seat belt pretensioner leads, connect lead from connector wire to end of each deployment wire. See Fig 2. Bend twisted connection flat and wrap tightly with electrical tape to insulate. Repeat for remaining connector wire lead.
  5. Remove all loose objects from front seats. Ensure no one is in vehicle. Connect deployment harness to driver-side air bag module connector. Stretch wires away from vehicle as far as possible. Cover windshield and front door openings with a drop cloth. Separate wire ends. Connect wires to a 12-volt battery. Driver-side air bag module should deploy. If air bag module did not deploy, go to step  7. If air bag module did deploy, disconnect wires from battery. DO NOT touch metal surfaces of air bag module for at least 10 minutes due to heat generated during deployment.
  6. Repeat steps  2 through  5 for passenger-side air bag module and seat belt pretensioners. Wear gloves and safety glasses when handling deployed air bag modules. Wash hands with mild soap and water.
  7. If air bag modules or seat belt pretensioners did not deploy, carefully remove from vehicle. See AIR BAG MODULES  and SEAT BELT PRETENSIONER  under REMOVAL & INSTALLATION. Temporarily store air bag modules with trim cover facing up. Contact manufacturer for additional instructions.
Fig 1: Preparing Deployment Harness For Driver-side & Passenger-side Air Bag Module On-vehicle Deployment
G99J23977Courtesy of GENERAL MOTORS CORP.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.