SUPPLE. INFLATABLE RESTRAINT SYS. WIRING REPAIR PROCEDURES

VEHICLES AFFECTED: 1989-90 C,E,K,V

This bulletin replaces Product Service bulletin 89-8-143 dated 04/03/89, which should be discarded. This bulletin includes 1989-1990 c, e, k, v carlines.

Special wiring repair procedures have been developed for use on the Supplemental Inflatable Restraint (SIR) system due to the sensitive nature of the circuitry. The instructions in this bulletin are to be followed whenever servicing the SIR system wiring.

Terminal Repair Kit J-38125

Essential tool kit J-38125 contains special "sealed splices" for use in repairing SIR system wiring. A special crimping tool, heat torch, and instruction manual for these splices are also included.

Two critical features of the sealed splices are a special heat shrink sleeve with sealing adhesive to produce an environmentally sealed splice and a cross hatched (knurled) core crimp to provide necessary contact integrity for the sensitive, low energy circuits.

Tool kit J-38125 also serves as a generic terminal repair kit. The kit contains a large sampling of common GM electrical terminals and the correct tools to apply them to wires and remove them from connectors. The terminals in the kit are not to be used to replace damaged SIR system terminals unless otherwise indicated by the terminal package. Specifically, the DERM/resistor terminal repair assembly pack, is included in J-38125 for SIR use.

SIR Connector (Plastic Body) and Terminal (Metal Pin) Repair

If any connector or terminal in the SIR wire harness (except pigtails) is damaged, the component should be repaired using one of the connector repair assembly packs. These kits include an instruction sheet and the sealed splices which will be necessary to splice the new wires, connector, and terminals to the harness. Crimping tool J-38125-8 (the tool which is colour keyed to match the splices) from terminal repair kit J-38125 must be used to apply these splices.

The terminals in the SIR system are made of a special metal to provide necessary contact integrity for the sensitive low energy circuits. These terminals are only available in the connector repair assembly packs and no other terminal should be substituted.

If individual terminals are damaged on the DERM or resistor module, they should be repaired using the DERM/resistor terminal repair assembly pack. If individual terminals are damaged on any other SIR connection, the entire connection should be replaced using the appropriate Connector Repair Assembly Pack.

SIR Wire Pigtail Repair

If the wiring pigtail (wire attached directly to the device, not by a connector) of any SIR system component (Sensor, Coil Assembly, or Inflator Module) is damaged, the entire component (with pigtail) should be replaced. Absolutely no wire, connector, or terminal repair is to be attempted on the Dual Sensor, the Forward Discriminating Sensor, the Inflator Module, or the SIR Coil Assembly.

SIR Wire Repair

If any wire except the pigtail is damaged, the wire should be repaired by splicing in a new section of wire of the same gauge size (.5, .8, 1.0, etc.). The sealed splices and crimping tool from terminal repair kit J-38125 must be used for these splices. Carefully follow the instructions included in the kit for proper sealed splice application.

SIR System Wire Splice Repair

If any of the original equipment splices (S201, etc., three wires or more) in the SIR system wiring are damaged, they should be repaired by applying a new splice clip (not sealed) from terminal kit J-38125. Carefully follow the instructions included in the kit for proper splice clip application. Cloth duct tape may be substituted for splice tape if necessary.

Alternative Repair Methods

No alternative repair methods are available for the SIR system wiring and components. If the proper tools and/or components are not available, contact Technical Assistance to arrange for proper service of the SIR system.

1989-1990 SIR Connector Repair Assembly Packs (Part of J-38125)

Connector Repair Kit 6CA 4EZ 4EC 3EA/6EK 6VA ----------- --- ---- --- ------- ---- Resistor Module 12085214 12085214 12085214 12085214 12085214

Steering Column Base (C250) 12085215 12102101 12102101 12085215 12085215

Front Discriminating Sensor 12085216 12102100 12101764 12102100 12102100

Dual Arming Sensor 12085217 12102102 12102102 12102102 12102103

DERM 12085218 12085218 12085218 12085218 12085218

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.