Caution: Refer to SIR Inflator Module Handling and Storage Caution in the Preface section.

Use special care when handling or storing live, undeployed, inflator modules. Inflator module deployment produces a rapid generation of gas. This may cause the inflator module, or an object in front of the inflator module, to project through the air in the event of an unlikely deployment.

Dual stage inflator modules have two deployment stages. If stage 1 was used to deploy the inflator module, stage 2 may still be active. Therefore, a deployed dual stage inflator module must be treated as an active module. If disposal of a deployed or undeployed dual stage module is required both deployment loops must be energized to deploy the air bag.

During the course of a vehicle's useful life, certain situations may arise which will require the disposal of a live, undeployed, inflator module. Do not dispose of a live, undeployed, inflator module through normal disposal channels until the inflator module has been deployed. The following information covers the proper procedures for disposing of a live, undeployed, inflator module.

Do not deploy an inflator module in the following situations:

Inflator modules 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 in a given situation.

Deploy inflator modules 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.

Caution: Refer to SIR Inflator Module Disposal Caution in the Preface section.

Tools Required

1. Turn OFF the ignition.
2. Remove the ignition key.
3. Put on safety glasses.
4. Remove the inflator module. Refer to the following:

•	When removing the steering wheel module, refer to Inflatable Restraint Steering Wheel Module Replacement .

•	When removing the IP module, refer to Inflatable Restraint Instrument Panel Module Replacement .

•	When removing the side impact module, refer to Driver and Passenger Seat Side Inflatable Restraint Module Replacement .




5. Place the inflator module with the vinyl trim cover facing up and away from the surface on a work bench, floor or deployment fixture.



6. Clear an area on the floor approximately 1.85 m (6 ft) in diameter for deployment of the inflator module. If possible, use a paved, outdoor location free of activity. Otherwise, use an area free of activity on the shop floor. Make sure you have sufficient ventilation.
7. Make sure no loose or flammable objects are in the area.

Important: Dual stage deployments are only used in steering wheel and IP inflator modules. If stage 1 was used to deploy the inflator module, stage 2 may still be active. If disposal of a deployed or undeployed dual stage module is required, both deployment loops must be energized to deploy the air bag.

8. When deploying a steering wheel module, place the steering wheel module in the center of the cleared area.



9. When deploying an IP module, refer to the following instructions:

•	Place the J 39401-B  (2) in the center of the cleared area.

•	Fill the deployment fixture (2) with water or sand.

•	Mount the IP module (1) in the deployment fixture (2) with the vinyl/plastic trim facing up.

•	To mount, use 4 M 6 bolts (6), nuts (8), and washers (7) to properly secure the IP module (1) to the deployment fixture (2).

•	Tighten all fasteners prior to deployment.




10. When deploying a side impact module, refer to the following instructions:

•	Place the J 39401-B  (3) in the center of the cleared area.

•	Fill the deployment fixture (3) with water or sand.

•	Mount the side impact module (1) in the deployment fixture (3) with the vinyl/plastic trim facing up.

•	Adjust and secure the J 39401-B arms (4) to the deployment fixture (3).

•	To mount, use 2 M 6 x 1.0 nuts (2) with washers to secure the side impact module (1) to the deployment fixture arms (4).

•	Tighten all fasteners prior to deployment.




11. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed.
12. Short the 2 SIR deployment harness (1) leads together using one banana plug seated into the other.
13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1).



14. Extend the SIR deployment harness and adapter to full length from the deployment fixture.



15. Connect the inflator module (1) to the adapter (2) on the SIR deployment harness (3).

Important: 

•	The rapid expansion of gas involved with deploying an inflator module is very loud. Notify all people in the immediate area that an inflator module will be deployed.

•	When the inflator module deploys, the deployment fixture may jump vertically. This is a normal reaction of the inflator module due to the force of the rapid expansion of gas inside the inflator module.

16. Clear the area of people.



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



18. Place a 12 V minimum/2 A minimum power source, i.e. vehicle battery, near the shorted end of the SIR deployment harness.
19. Connect the SIR deployment harness wires to the power source. Inflator module deployment will occur when contact is made.
20. Disconnect the SIR deployment harness from the power source.

Caution: Refer to SIR Deployed Inflator Modules Are Hot Caution in the Preface section.




21. Seat one banana plug into the other in order to short the deployment harness leads.
22. If the inflator module did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group for further assistance. Otherwise, proceed to the following steps.



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

Deploy 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: Refer to SIR Inflatable Module Deployment Outside Vehicle Caution in the Preface section.

1. Turn OFF the ignition.
2. Remove the ignition key.
3. Put on safety glasses.
4. Remove all loose objects from the front seats.
5. Disconnect the inflatable restraint steering wheel module connector (2) located next to the steering column.




Important: This vehicle is equipped with dual stage air bags. The steering wheel module and I/P module will each have 4 wires. Refer to SIR Connector End Views for determining high and low circuits.

6. Cut the steering wheel module 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 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. Use these wires to fabricate the deployment harness.
9. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
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 inflator module.



11. Twist together two connector wire leads, the high circuits from both stages of the steering wheel module, to one set of deployment wires. Refer to SIR Connector End Views in order to determine the correct circuits.
12. Inspect that the connection is secure.



13. Bend flat the twisted connection.



14. Secure and insulate the connection using electrical tape.



15. Twist together two connector wire leads, the low circuits from both stages of the steering wheel module, to one set of deployment wires. Refer to SIR Connector End Views in order to determine the correct circuits.
16. Inspect that the connection is secure.



17. Bend flat the twisted connection.



18. Secure and insulate the connection using electrical tape.
19. Connect the deployment harness to the steering wheel module connector.



20. Route the deployment harness out of the vehicle's driver side.



21. Disconnect the LF side impact module connector (1) from the vehicle wiring harness (2) located under the LF seat.



22. Cut the LF side impact module harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
23. Strip 13 mm (0.5 in) of insulation from each of the LF side impact module connector wire leads.



24. Cut 2 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. Use these wires to fabricate the deployment harness.
25. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
26. 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 side impact module.



27. Twist together one connector wire lead to one deployment wire.
28. Inspect that the previous connection is secure.



29. Bend flat the twisted connection.
30. Secure and insulate the connection using electrical tape.



31. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.



32. Route the deployment harness out of the vehicle's driver side.



33. Disconnect the inflatable restraint IP module connector (1) located behind the IP module (3).




Important: This vehicle is equipped with dual stage air bags. The steering wheel module and IP module will each have 4 wires. Refer to SIR Connector End Views for determining high and low circuits.

34. Cut the IP module harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
35. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.



36. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used to fabricate the deployment harness.
37. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
38. Twist together one end from each of the wires in order to short the wires.



39. Twist together two connector wire leads, the high circuits from both stages of the IP module, to one set of deployment wires. Refer to SIR Connector End Views in order to determine the correct circuits.
40. Inspect that the connection is secure.



41. Bend flat the twisted connection.



42. Secure and insulate the connection using electrical tape.



43. Twist together two connector wire leads, the low circuits from both stages of the IP module, to one set of deployment wires. Refer to SIR Connector End Views in order to determine the correct circuits.
44. Inspect that the connection is secure.



45. Bend flat the twisted connection.



46. Secure and insulate the connection using electrical tape.
47. Connect the deployment harness to the IP module connector.



48. Route the deployment harness out of the vehicle's passenger side.



49. Disconnect the RF side impact module connector (1) from the vehicle wiring harness (2) located under the RF seat.



50. Cut the RF side impact module harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
51. Strip 13 mm (0.5 in) of insulation from each of the RF side impact module connector wire leads.



52. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. Use these wires to fabricate the deployment harness.
53. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
54. 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 side air bag module.



55. Twist together one connector wire lead to one deployment wire.
56. Inspect that the previous connection is secure.



57. Bend flat the twisted connection.
58. Secure and insulate the connection using electrical tape.



59. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.



60. Route the deployment harness out of the vehicle's passenger side.
61. Stretch the two driver side harnesses to full length.
62. Stretch the two passenger side harnesses to full length.
63. Completely cover the windshield and front door window openings with a drop cloth.



64. Place a power source, 12 V minimum/2 A minimum, i.e., a vehicle battery, near the shorted ends of the passenger side deployment harnesses.
65. Separate the two ends of the IP module deployment harness wires.
66. Connect the IP module deployment harness wires to the power source in order to deploy the IP module.
67. Disconnect the IP module deployment harness wires from the power source.
68. Separate the two ends of the RF side impact module deployment harness wires.
69. Connect the RF side impact module deployment harness wires to the power source in order to deploy the RF side impact module.
70. Disconnect the RF side impact module deployment harness wires from the power source.



71. Twist together one end of each wire of the IP module on the passenger side deployment harness in order to short the wires.
72. Twist together one end of each wire of the RF side impact module on the passenger side deployment harness in order to short the wires.



73. Move the power source, 12 V minimum/2 A minimum, i.e., a vehicle battery, near the shorted ends of the driver side deployment harnesses.
74. Separate the two ends of the steering wheel module deployment harness wires.
75. Connect the steering wheel module deployment harness wires to the power source in order to deploy the steering wheel module.
76. Disconnect the steering wheel module deployment harness wires from the power source.
77. Separate the two ends of the LF side impact module deployment harness wires.
78. Connect the LF side impact module deployment harness wires to the power source in order to deploy the side impact module.
79. Disconnect the LF side impact module deployment harness wires from the power source.



80. Twist together one end of each wire of the steering wheel module on the driver side deployment harness in order to short the wires.
81. Twist together one end of each wire of the LF side impact module on the driver side deployment harness in order to short the wires.
82. Remove the drop cloth from the vehicle.
83. Disconnect all harnesses from the vehicle.
84. Discard the harnesses.
85. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
86. If one or more of the inflator modules did not deploy, perform the following steps to remove the undeployed module(s) from the vehicle:

•	Inflatable Restraint Steering Wheel Module Replacement

•	Inflatable Restraint Instrument Panel Module Replacement

•	Driver and Passenger Seat Side Inflatable Restraint Module Replacement

87. Contact the Technical Assistance Group for further assistance.