GM Service Manual Online
For 1990-2009 cars only

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

Live and Undeployed Inflator Module


Object Number: 9039  Size: SH

Take special care when handling or storing a live and undeployed inflator module. An 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.

Scrapping Procedure

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

Do not deploy the inflator module in the following situations:

    • After replacement of an inflator module under warranty. The inflator module may need to be returned undeployed to the manufacturer.
    • If the vehicle is the subject of a product liability report, GM-1241, related to the SIR system. When a vehicle is the subject of a product liability report, do not alter the SIR system in any manner.
    • If the vehicle is involved in a campaign affecting the inflator modules. Follow the instructions in the campaign service bulletin for proper SIR handling procedures.

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 in a given situation:

Deployment Outside Vehicle - Steering Wheel Module and I/P Module

Tools Required

    • J 38826 SIR Deployment Harness
    • J 39401-B SIR Deployment Fixture
    • An appropriate pigtail adaptor

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

    • Using the SIR diagnostics, it is determined that the inflator module is malfunctioning.
    • The inflator module is cosmetically damaged, scratched, or ripped.
    • The inflator module pigtail, if equipped, is damaged.
    • The inflator module connector is damaged.
    • The inflator module connector terminals are damaged.

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.

  1. Turn OFF the ignition.
  2. Remove the ignition key.
  3. Put on safety glasses.
  4. Remove the inflator module. Refer to the following:
  5. • When removing the steering wheel module, refer to Inflatable Restraint Steering Wheel Module Replacement .
    • When removing the I/P module, refer to Inflatable Restraint Instrument Panel Module Replacement .

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


    Object Number: 9427  Size: SH
  6. Place the inflator module with the vinyl trim cover facing up and away from the surface on a work bench, floor, or deployment fixture.

  7. Object Number: 68646  Size: SH
  8. Clear a space 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 a space free of activity on the shop floor. Make sure you have sufficient ventilation.
  9. Make sure no loose or flammable objects are in the area.
  10. When deploying the steering wheel module, place the steering wheel module in the center of the space.

  11. Object Number: 453892  Size: SH
  12. When deploying the I/P module, refer to the following instructions:
  13. 9.1. Place the J 39401-B  (2) in the center of the cleared area.
    9.2. Fill the deployment fixture with water or sand.
    9.3. Mount the I/P module (1) in the deployment fixture (2) with the vinyl/plastic trim cover facing up.
    9.4. To mount, use 4 M 6 bolts (6), nuts (8), and washers (7) in order to properly secure the I/P module (1) to the J 39401-B .
    9.5. Tighten all fasteners prior to deployment.

    Object Number: 68645  Size: SH
  14. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed.
  15. Short the SIR deployment harness (1) leads together using 1 banana plug seated into the other.
  16. Connect the appropriate pigtail adapter (2) to the J 38826  (1).

  17. Object Number: 68655  Size: SH
  18. Extend the SIR deployment harness and adapter to full length from the deployment fixture.

  19. Object Number: 68656  Size: SH
  20. Connect the inflator module (1) to the adapter (2) on the J 38826  (3).
  21. Important: When deploying an inflator module the rapid expansion of gas involved with deploying an inflator module is very loud. Notify all the people in the immediate area that an inflator module will be deployed. When the inflator module deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of a deploying inflator module.

  22. Clear the area of people.

  23. Object Number: 39382  Size: SH
  24. Place a 12 volt minimum A minimum power source, i.e. vehicle battery, near the shorted end of the J 38826 .
  25. Separate the banana plugs on the J 38826 .

  26. Object Number: 39388  Size: SH

    Important: The inflator module will deploy when the SIR deployment harness wires contact the power source.

  27. Connect the SIR deployment harness wires to the power source. Inflator module deployment will occur when contact is made.
  28. Disconnect the SIR deployment harness from the power source.

  29. Object Number: 9581  Size: SH
  30. Seat one banana plug into the other in order to short the deployment harness leads.
  31. If the inflator module did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps.
  32. Caution: Refer to SIR Deployed Inflator Modules Are Hot Caution in the Preface section.


    Object Number: 9433  Size: SH
  33. Put on a pair of shop gloves.
  34. Disconnect the pigtail adapter from the inflator module as soon as possible.
  35. Dispose of the deployed inflator module through normal refuse channels.
  36. Wash hands with a mild soap.

Deployment Inside Vehicle - Vehicle Scrapping Procedure

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

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:

    • The vehicle has completed its useful life.
    • Irreparable damage occurs to the vehicle in a non-deployment type accident.
    • Irreparable damage occurs to the vehicle during a theft.
    • The vehicle is being salvaged for parts to be used on a vehicle with a different VIN as opposed to rebuilding as the same VIN.

    Object Number: 68614  Size: SH
  1. Disable the SIR system. Refer to SIR Disabling and Enabling .
  2. Put on safety glasses.
  3. Remove all loose objects from the front seats.
  4. Disconnect the inflatable restraint steering wheel module coil connector (1).

  5. Object Number: 39392  Size: SH
  6. Cut the steering wheel module coil 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. Object Number: 39390  Size: SH
  9. Cut two 4.6 m (15 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used for the steering wheel module 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 inflator module.

  12. Object Number: 39393  Size: SH
  13. Twist together one connector wire lead to 1 deployment wire.
  14. Inspect that the previous connection is secure.

  15. Object Number: 39408  Size: SH
  16. Bend flat the twisted connection.
  17. Secure and insulate the connection using electrical tape.

  18. Object Number: 39414  Size: SH
  19. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.

  20. Object Number: 68614  Size: SH
  21. Connect the deployment harness to the steering wheel module coil connector (1).

  22. Object Number: 68658  Size: SH
  23. Route the deployment harness out of the driver side of the vehicle.

  24. Object Number: 217468  Size: SH
  25. Disconnect the inflatable restraint I/P module connector.

  26. Object Number: 263002  Size: SH
  27. Cut the I/P module harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
  28. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.

  29. Object Number: 39390  Size: SH
  30. Cut two 4.6 m (15 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used for the I/P module deployment harness.
  31. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
  32. 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 the inflator module is ready to be deployed.

  33. Object Number: 263005  Size: SH
  34. Twist together one connector wire lead to 1 deployment wire.
  35. Inspect that the previous connection is secure.

  36. Object Number: 263008  Size: SH
  37. Bend flat the twisted connection.
  38. Secure and insulate the connection using electrical tape.

  39. Object Number: 263012  Size: SH
  40. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.

  41. Object Number: 217468  Size: SH
  42. Connect the deployment harness to the I/P module connector.

  43. Object Number: 68664  Size: SH
  44. Route the deployment harness out of the passenger side of the vehicle.
  45. Completely cover the windshield and the front door openings with a drop cloth.
  46. Deploy each deployment loop one at a time.
  47. Stretch out all of the deployment harness wires on the left and right side of the vehicle to their full length.
  48. Place a power source, 12 V minimum A minimum, i.e., a vehicle battery, near the shorted end of the harnesses.
  49. Important: The inflator module will deploy when the wire ends contact the power source.

  50. Separate one set of wires and touch the wire ends to the power source in order to deploy the inflator modules.
  51. Disconnect the deployment harness from the power source and twist the wire ends together.
  52. Continue the same process with the remaining deployment harnesses that are available.
  53. Remove the drop cloth from the vehicle.
  54. Disconnect all harnesses from the vehicle.
  55. Discard the harnesses.
  56. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
  57. If one or more of the inflator modules did not deploy, perform the following steps to remove the undeployed modules from the vehicle:
  58. • If the steering wheel module did not deploy, refer to Inflatable Restraint Steering Wheel Module Replacement .
    • If the I/P module did not deploy, refer to Inflatable Restraint Instrument Panel Module Replacement .
  59. Call the Technical Assistance Group for further assistance.