Airbag - Side

Remove and replace the side airbag module integrated into the seat bolster, including proper disarming of the airbag system and verified reconnection of the deployment circuit.

Warnings

Tools required

Parts

• Side airbag module (seat-mounted) × 1 — Use OEM specification - verify left/right application
• Airbag connector locking clip (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition to OFF position and remove key from ignition
3. Open driver's door and leave open (to prevent lockout)
4. Locate battery in rear trunk compartment (2005 Viper has rear-mounted battery)
5. Disconnect negative battery cable first, then positive battery cable
6. Isolate battery cables away from battery terminals to prevent accidental reconnection
7. Wait minimum 10 minutes for airbag system capacitors to fully discharge - set a timer and do not proceed early
8. Verify which seat contains the side airbag requiring replacement (driver or passenger)
9. Move affected seat to full forward position for easier access to rear mounting bolts
10. Ensure adequate workspace around vehicle - you will be removing the entire seat

Procedure

1. 1

   Disconnect seat electrical connectors
   Locate the seat wiring harness connectors under the seat, typically at the inboard side near the seat track. The 2005 Viper seat harness includes power connections (if equipped) and the side airbag connector (yellow housing with locking mechanism). Press the locking tab on the yellow airbag connector and carefully disconnect. Disconnect any additional seat connectors (seat position sensors, power seat motors if equipped). Route connectors clear of seat mounting area.
   ⚠The yellow airbag connector has a secondary locking mechanism (small clip or slider). Ensure this is fully released before attempting to separate the connector halves, or you will break the locking tabs.
2. 2

   Remove seat mounting bolts
   Locate the four seat mounting bolts securing the seat tracks to the floor pan. These are typically Torx head bolts accessible from the top of the seat track mounting points (two front, two rear). Use the appropriate Torx driver to remove all four bolts (exact size per factory service manual — do not assume). Support the seat as you remove the final bolts to prevent it from shifting. Carefully lift the seat assembly up and out of the vehicle, watching for any snagged wiring or trim pieces. Place seat on a clean, protected work surface.
   ⚠Viper seats are heavy and awkward. Use proper lifting technique or get assistance to avoid back injury or dropping the seat.
   Torque spec

   Seat Mounting Bolts61 Nm (45 lb-ft)
3. 3

   Remove seat side bolster trim cover
   With seat removed and on work surface, identify the seat side bolster containing the airbag module (typically the outboard bolster on each seat). The side airbag is integrated into the outboard seat backrest bolster. Examine the bolster carefully for trim fasteners - the cover may be secured with hidden clips, hog rings from the underside, or a combination of methods. Starting at the bottom edge of the bolster cover, use upholstery trim tools to carefully release the cover fasteners working upward. On this platform, the cover typically releases via plastic clips that engage the seat frame. Work slowly to avoid tearing the upholstery or breaking clips.
   ℹ️Some Viper seats use integrated covers where the airbag module cannot be accessed without partial seat upholstery removal. If you encounter resistance or cannot locate obvious access points, consult factory service manual for specific seat design.
4. 4

   Access and disconnect side airbag module connector
   With the bolster cover peeled back or removed, locate the side airbag module - a flat, rectangular inflator pack integrated into the bolster foam. The airbag module has a dedicated electrical connector (yellow housing) attached directly to the module. This connector may have a secondary locking slider or clip. Carefully release the locking mechanism and disconnect the airbag module connector. Ensure the connector is routed clear of the module for the next step.
   ⚠️Even with battery disconnected and capacitors discharged, handle the airbag connector with care. Never probe connector terminals or bridge terminals with tools or test equipment.
5. 5

   Remove side airbag module mounting fasteners
   The side airbag module is secured to the seat frame structure with Torx bolts. Identify the mounting bolts securing the airbag module to the seat frame (exact count per factory service manual — verify before removal). Use the appropriate Torx driver to remove these fasteners. Note the exact location and orientation of each bolt for reassembly. The airbag module should now be free from the seat frame.
   Torque spec

   Side Airbag Module Bolts7 Nm (5 lb-ft)
6. 6

   Remove side airbag module from seat
   Carefully extract the side airbag module from the seat bolster cavity. The module may be partially integrated into the foam cushioning. Work slowly to separate the module from any foam or fabric attachment points without damaging the surrounding seat structure. Once free, place the old module with deployment surface facing UP on your work surface, away from any body parts or objects. Do not place anything on top of the module.
   ⚠️Even a used, non-deployed airbag module contains live pyrotechnic inflators. Treat it as a live explosive device until properly disposed of according to local regulations.
7. 7

   Prepare new side airbag module
   Remove the new side airbag module from its protective packaging. Verify the replacement part number against the factory parts catalog for this exact VIN and confirm it is correct for the specific seat side (driver/passenger, left/right) before installation. Inspect the new module for any shipping damage - verify the connector is intact, the module housing is not cracked, and the deployment surface fabric is not torn. Compare the mounting hole pattern to the original module to confirm correct application.
   ⚠New airbag modules are extremely sensitive to static discharge and physical impact. Handle only by the mounting brackets, never by the inflator body or deployment surface.
8. 8

   Install new side airbag module into seat
   Position the new airbag module into the seat bolster cavity in the exact orientation as the original. The deployment surface (fabric side) must face outboard toward the seat occupant. Align the module mounting holes with the seat frame mounting points. Ensure no wiring, foam, or fabric is pinched between the module and seat frame.
   ⚠️Incorrect airbag module orientation will cause the airbag to deploy in the wrong direction, potentially causing serious injury instead of preventing it. Verify deployment surface faces OUTBOARD before proceeding.
9. 9

   Install side airbag module mounting fasteners
   Install the Torx mounting bolts through the module brackets into the seat frame mounting points. Start all bolts by hand to ensure proper thread engagement. Once all bolts are started, use a torque wrench to tighten each bolt to the specified torque in a cross-pattern sequence (if more than 2 bolts). Verify the module is firmly secured to the seat frame with no movement or gaps.
   ⚠️Side airbag module bolt torque is CRITICAL for proper deployment. Under-torqued bolts allow module movement; over-torqued bolts can crack mounting brackets. Use a calibrated torque wrench.
   Torque spec

   Side Airbag Module Bolts7 Nm (5 lb-ft)
10. 10

    Reconnect side airbag module electrical connector
    Route the airbag module connector to the module, ensuring no sharp bends or pinch points in the wiring. Align the yellow connector halves and press together firmly until you hear/feel a positive click. Verify the primary locking mechanism is fully engaged. If the connector has a secondary locking slider or clip, engage it fully. Gently tug on the connector to confirm it is locked - it should not separate.
    ⚠️Incomplete connector engagement will prevent airbag deployment or cause intermittent circuit faults. The connector MUST be fully locked with both primary and secondary locking mechanisms engaged.
11. 11

    Reinstall seat side bolster trim cover
    Position the bolster trim cover back over the airbag module area. Ensure the cover material is not stretched too tight or bunched, as this can affect deployment. Reattach the cover using the original fastening method (clips, hog rings, etc.). Work from top to bottom, ensuring each fastener is fully seated. Verify the cover seams align properly and the bolster has the correct shape and appearance. The airbag deployment zone must be unobstructed - no additional padding, covers, or objects should be between the module and the seat surface.
    ⚠️ANY obstruction in the airbag deployment path (thick seat covers, aftermarket padding, objects in pockets) will prevent proper deployment or cause debris to become projectiles during deployment.
12. 12

    Reinstall seat assembly into vehicle
    Carefully lift the seat assembly and position it back into the vehicle over the four mounting locations on the floor pan. Align the seat track mounting holes with the floor pan threaded inserts. Have an assistant support the seat if needed. Install all four seat mounting bolts by hand first to ensure proper thread engagement and seat alignment. Once all bolts are started, use a torque wrench to tighten each bolt to specification in a cross-pattern sequence (front-left, rear-right, front-right, rear-left).
    ⚠️Seat mounting bolts are SAFETY-CRITICAL fasteners. Loose seat mounting bolts can allow seat movement or separation during a crash, causing severe injury. Use calibrated torque wrench and verify each bolt is at specification.
    Torque spec

    Seat Mounting Bolts61 Nm (45 lb-ft)
13. 13

    Reconnect seat electrical connectors
    Reconnect all seat wiring harness connectors under the seat in reverse order of removal. Start with the yellow airbag connector - align and press together firmly until locked, then engage any secondary locking mechanisms. Reconnect any additional connectors (power, sensors, etc.). Verify all connectors are fully seated and locked. Ensure no wiring is pinched or in contact with seat track moving parts.
    ⚠Route wiring clear of seat track mechanisms. Pinched wiring can cause intermittent faults or short circuits during seat movement.
14. 14

    Reconnect battery and initialize airbag system
    Return to rear trunk area and reconnect battery cables (positive first, then negative). Ensure connections are clean and tight. Close all vehicle doors. Insert key and turn ignition to ON position (do not start engine). The airbag warning light on the instrument cluster should illuminate for approximately 4-8 seconds during bulb check, then extinguish. If the airbag light remains illuminated, flashes, or does not illuminate at all, DO NOT return vehicle to service - there is a system fault requiring diagnosis.
    ⚠️An illuminated airbag warning light indicates a system fault. The airbag system may not deploy in a crash, or may deploy unexpectedly. Vehicle is not safe to drive with airbag system fault.
15. 15

    Perform scan tool verification
    Connect a professional-grade scan tool capable of reading Chrysler airbag system codes. Navigate to the airbag control module and read any stored diagnostic trouble codes (DTCs). If any codes related to the side airbag circuit are present, clear them and verify they do not return. Perform any available airbag system self-tests or readiness monitors through the scan tool. Verify the scan tool reports all airbag circuits as operational and the system status as 'Ready'. Document any fault codes or system status messages.
    ⚠️If ANY fault codes remain after clearing, or if codes return immediately, the airbag system is not functioning correctly. Do not return vehicle to service until all faults are diagnosed and resolved by a qualified technician.

Reassembly

1. Reassembly is covered in the procedure steps above - seat reinstallation and system verification are integral to this safety-critical procedure
2. Verify seat operates through full range of motion (if power seat) without binding or wiring interference
3. Verify seat belts route correctly and are not twisted or pinched by seat installation
4. Test seat manual adjustments (recline, fore/aft) to ensure nothing interferes with seat mechanisms

Verification

• With ignition ON, verify airbag warning light performs normal bulb check (illuminates briefly then extinguishes) - light should NOT remain illuminated
• Using scan tool, verify no airbag system fault codes are present and all circuits report operational status
• Perform visual inspection of seat bolster - trim cover should be smooth with no bunching or gaps, deployment zone unobstructed
• Verify all four seat mounting bolts are torqued to specification and seat is firmly secured to floor with no movement
• Verify seat electrical connectors are fully locked with no visible gaps in connector housings
• Test seat adjustment mechanisms to ensure no wiring interference or binding
• Perform final walk-around inspection - all tools removed from vehicle, all panels reinstalled, battery connections secure

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