Caution: When you are carrying an undeployed inflator module:

Live (Undeployed) Inflator Module

Take special care when handling or storing a live (undeployed) inflator module. An air bag deployment produces rapid gas generation. This may cause the inflator module, or an object in front of the inflator module, to jettison through the air in the event of an unlikely deployment.

Shipping Procedures

Refer to the latest service bulletins for proper SIR inflator module shipping procedures.

Scrapping Procedure

During the course of a vehicle's useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) inflator module. The following information covers the proper procedures for the disposing of a live inflator module. Deploy the inflator module before disposal. Do not dispose of the module through normal disposal channels.

Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws.

Do not deploy an air bag in the following situations:

Deployment Procedures

The inflator module can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best is a given situation:

Tools Required

Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws.

CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury.

Deploy the inflatable restraint steering wheel module, the inflatable restraint driver seat module, or the inflatable restraint passenger seat module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following:

Deployment and disposal of a malfunctioning inflator module is subject to any required retention period.

1. Turn the ignition switch to the OFF position.
2. Remove the ignition key.
3. Put on safety glasses.
4. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed.
5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other.
6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1).
7. Remove the inflator module from the vehicle. Refer to Inflatable Restraint Steering Wheel Module Replacement , Inflatable Restraint Seat Module Replacement - Driver , or Inflatable Restraint Seat Module Replacement - Passenger .

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.



8. Place the module with the vinyl trim cover facing up and away from the surface on a work bench.



9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation.
10. Make sure no loose or flammable objects are in the area.
11. Place the module in the space with the vinyl trim cover facing up.



12. Extend the SIR deployment harness and adapter to full length from the module.
13. Place a 12 V minimum/2 A minimum power source (i.e., vehicle battery) near the shorted end of the harness.



14. Connect the module (1) to the adapter (2) on the SIR deployment harness (3).
15. Firmly seat the adapter into the module connector.
16. Clear the area of people.




CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury.

17. Separate the two banana plugs on the SIR deployment harness.




Important: The rapid gas expansion involved with deploying an air bag is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module

Important: When the air bag deploys, the inflator module may jump about 90 cm (3 ft) vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag.

18. Connect the SIR deployment harness wires to the power source.



19. Disconnect the SIR deployment harness from the power source after the air bag deploys.
20. Seat one banana plug into the other in order to short the deployment harness leads.
21. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps.

CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury:

•	Allow sufficient time for cooling before touching any metal surface of the inflator module.

•	Do not place the deployed inflator module near any flammable objects.




22. Put on a pair of shop gloves.
23. Disconnect the pigtail adapter from the inflator module as soon as possible.
24. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed.
25. Dispose of the deployed module through normal refuse channels.
26. Wash hands with a mild soap.

Tools Required

Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws.

CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury.

Deploy the inflatable restraint IP module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following:

Deployment and disposal of a malfunctioning inflator module is subject to any required retention period.

1. Turn the ignition switch to the OFF position.
2. Remove the ignition key.
3. Put on safety glasses.
4. Inspect the J 38826 and the appropriate pigtail adaptor for damage. Replace as needed.
5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other.
6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1).
7. Remove the inflatable restraint IP module. Refer to Inflatable Restraint Instrument Panel Module Replacement .

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.



8. Place the module with the vinyl trim cover facing up and away from the surface on a work bench.



9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation.
10. Make sure no loose or flammable objects are in the area.
11. Place the J 39401-B SIR Deployment Fixture in the center of the cleared area.
12. Fill the fixture plastic reservoir with water or sand.

Important: Securely hand tighten all fasteners prior to deployment.

13. Mount the module (1) in the SIR deployment fixture (2) with the vinyl trim cover facing up using one of the following mounting methods.



14. To use the stud mount method, remove the original mounting nuts.
15. Use the J 39401-1 mounting nuts (3) in order to secure the IP module (1) to the fixture (2).



16. To use the flange mount method, use four of the J 39401-13 hold-down nuts (8) whenever possible in order to secure the module to the fixture.
17. If clearance restrictions do not allow the use of the J 39401-13 hold-down nuts, four M6 x 1.0 nuts with washers (7) may be used.



18. Extend the SIR deployment harness and adapter to full length from the module.
19. Place a 12 V minimum/2 A minimum power source (i.e., vehicle battery) near the shorted end of the harness.



20. Connect the module (1) to the adapter (2) on the SIR deployment harness (3).
21. Firmly seat the adapter into the module connector.
22. Clear the area of people.




CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury.

23. Separate the two banana plugs on the SIR deployment harness.




Important: The rapid gas expansion involved with deploying an air bag is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module

Important: When the air bag deploys, the SIR deployment fixture may jump vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag.

24. Connect the SIR deployment harness wires to the power source.



25. Disconnect the SIR deployment harness from the power source after the air bag deploys.
26. Seat one banana plug into the other in order to short the deployment harness leads.
27. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps.

CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury:

•	Allow sufficient time for cooling before touching any metal surface of the inflator module.

•	Do not place the deployed inflator module near any flammable objects.




28. Put on a pair of shop gloves.
29. Disconnect the pigtail adapter from the inflator module as soon as possible.
30. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed.
31. Dispose of the deployed module through normal refuse channels.
32. Wash hands with a mild soap.

Deploy the inflator modules inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations:

CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury.

1. Turn the ignition switch to the OFF position.
2. Remove the ignition key.
3. Put on safety glasses.
4. Remove all loose objects from the front seats.
5. Remove the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement .
6. Store the inflatable restraint steering wheel module in a safe place.
7. Cut the inflatable restraint steering wheel module 2-way integral harness connector from the coil, leaving at least 16 cm (6 in) of wire at the connector.
8. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.



9. Cut two 4.6 M (15 ft) deployment wires from a 0.8 mm² (18 gage) or thicker multi-strand wire. These wires will be used for the driver frontal deployment harness.
10. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
11. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag.



12. Twist together one connector wire lead to one deployment wire.



13. Bend flat the twisted connection.
14. Secure and insulate the connection using electrical tape.



15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
16. Connect the deployment harness to the inflatable restraint steering wheel module yellow 2-way connector.



17. Install the inflatable restraint steering wheel module to the steering column. Refer to Inflatable Restraint Steering Wheel Module Replacement .
18. Route the deployment harness out of the driver side of the vehicle.



19. Remove the inflatable restraint IP module. Refer to Inflatable Restraint Instrument Panel Module Replacement .
20. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
21. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.



22. Cut two 6.1 M (20 ft) deployment wires from a 0.8 mm² (18 gage) or thicker multi-strand wire. These wires will be used for the passenger frontal deployment harness.
23. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
24. Twist together one end from each of the wires in order to short the wires.



25. Twist together one connector wire lead to one deployment wire.



26. Bend flat the twisted connection.
27. Secure and insulate the connection using electrical tape.



28. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
29. Connect the deployment harness to the inflatable restraint IP module 2-way connector.



30. Install the inflatable restraint IP module. Refer to Inflatable Restraint Instrument Panel Module Replacement .
31. Route the deployment harness out of the passenger side of the vehicle.
32. Clear the inside and outside of the vehicle of any people or loose and flammable objects.
33. Completely cover the windshield and front door window openings with a drop cloth.



34. Stretch the driver deployment harness to full length.
35. Completely cover the windshield and front door window openings with a drop cloth.
36. Place a power source, 12 V minimum/2 A minimum (i.e., a vehicle battery) near the shorted end of the harness.
37. Separate the two ends of the driver frontal deployment harness wires.
38. Connect the driver frontal deployment harness wires to the power source in order to deploy the inflatable restraint steering wheel module.
39. Disconnect the driver frontal deployment harness wires from the power source.



40. Stretch the passenger deployment harness to full length.
41. Place a power source, 12 V minimum/2 A minimum (i.e., a vehicle battery) near the shorted end of the harness.
42. Separate the two ends of the passenger frontal deployment harness wires.
43. Connect the passenger frontal deployment harness wires to the power source in order to deploy the inflatable restraint IP module.
44. Disconnect the passenger frontal deployment harness wires from the power source.



45. Twist together one end of each wire on the driver deployment harness in order to short the wires.



46. Twist together one end of each wire on the passenger deployment harness in order to short the wires.
47. Remove the drop cloth from the vehicle.
48. Disconnect both harnesses from the vehicle.
49. Discard the harnesses.
50. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
51. If one or both of the modules did not deploy, perform the following steps:

51.1.

Remove the undeployed module(s) from the vehicle. Refer to Inflatable Restraint Steering Wheel Module Replacement or Inflatable Restraint Instrument Panel Module Replacement .

51.2.

Temporarily store the module(s).

51.3.

Call the Technical Assistance Group for further assistance.

Deploy the inflator modules inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations:

CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury.

1. Turn the ignition switch to the OFF position.
2. Remove the ignition key.
3. Put on safety glasses.
4. Remove all loose objects from the front seats.
5. Disconnect the inflatable restraint front side impact module (LH) 2-way connector located at the lower left of the driver seat.
6. Cut the 2-way harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.



8. Cut two 4.6 M (15 ft) deployment wires from a 0.8 mm² (18 gage) or thicker multi-strand wire. These wires will be used for the driver side deployment harness.
9. Strip 13 mm (0.5 in) of insulation from both ends of the wires.
10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag.



11. Twist together one connector wire lead to one deployment wire.



12. Bend flat the twisted connection.
13. Secure and insulate the connection using electrical tape.



14. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
15. Connect the deployment harness to the inflatable restraint front side impact module (LH) 2-way connector.



16. Route the driver side deployment harness out of the driver side of the vehicle.



17. Disconnect the inflatable restraint front side impact module (RH) 2-way harness connector located to the lower right of the front passenger seat.
18. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
19. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.



20. Cut two 4.6 M (15 ft) deployment wires from a 0.8 mm² (18 gage) or thicker multi-strand wire. These wires will be used for the passenger side deployment harness.
21. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
22. Twist together one end from each of the wires in order to short the wires.



23. Twist together one connector wire lead to one deployment wire.



24. Bend flat the twisted connection.
25. Secure and insulate the connection using electrical tape.



26. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
27. Connect the deployment harness to the inflatable restraint front side impact module (RH) 2-way connector.



28. Route the passenger side deployment harness out of the passenger side of the vehicle.
29. Clear the inside and outside of the vehicle of any people or loose and flammable objects.



30. Stretch the driver side deployment harness to full length.
31. Completely cover the windshield and front door window openings with a drop cloth.
32. Place a power source, 12 V minimum/2 A minimum (i.e., a vehicle battery) near the shorted end of the harness.
33. Separate the two ends of the driver side air bag deployment harness wires.
34. Connect the driver side deployment harness wires to the power source in order to deploy the inflatable restraint front side impact module (LH).
35. Disconnect the driver side deployment harness wires from the power source.



36. Stretch the passenger side deployment harness to full length.
37. Place a power source, 12 V minimum/2 A minimum (i.e., a vehicle battery) near the shorted end of the harness.
38. Separate the two ends of the passenger side deployment harness wires.
39. Connect the passenger side deployment harness wires to the power source in order to deploy the inflatable restraint front side impact (RH) module.
40. Disconnect the passenger side deployment harness wires from the power source.



41. Twist together one end of each wire on the driver side deployment harness in order to short the wires.



42. Twist together one end of each wire on the passenger side deployment harness in order to short the wires.
43. Remove the drop cloth from the vehicle.
44. Disconnect both harnesses from the vehicle.
45. Discard the harnesses.
46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
47. If one or both of the modules did not deploy, perform the following steps:

47.1.

Remove the undeployed module(s) from the vehicle. Refer to Inflatable Restraint Seat Module Replacement - Driver or Inflatable Restraint Seat Module Replacement - Passenger

47.2.

Temporarily store the module(s).

47.3.

Call the Technical Assistance Group for further assistance.

After the inflator module has deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the deployment. Gloves and safety glasses are recommended, however, as a precaution. Gloves and safety glasses help to prevent possible irritation of the skin or eyes.