Special Tools

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

Take special care when handling or storing a live (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.

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

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 a live and undeployed inflator module through normal disposal channels until the inflator module has been deployed. If scrapping a deployed dual stage inflator module, both stages must be energized. The following information covers the proper procedures for disposing of a live and undeployed inflator module. Do not deploy the inflator module in the following situations:

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:

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:

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

Warning: Refer to SIR Inflator Module Disposal Warning 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:

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

•	If you are removing the instrument panel (I/P) module, refer to Inflatable Restraint Instrument Panel Module Replacement.

•	If you are removing the side impact module (left and/or right), refer to Driver or Passenger Seat Side Inflatable Restraint Module Replacement or Rear Seat Body 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.



6. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the inflator module or deployment fixture. 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.
7. Make sure no loose or flammable objects are in the area.

Note: Dual stage air bag deployments are only used in steering wheel and instrument panel (I/P) inflator modules, if the vehicle is equipped. If stage 1 was used to deploy a dual stage 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. If you have a steering wheel inflator module, place the inflator module in the center of the space.



9. If you have an I/P inflator module, refer to the following instructions:

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

•	Fill the deployment fixture with water or sand.

•	Using the proper nuts and bolts, mount the I/P module (1) to the deployment fixture (2), with the vinyl trim facing up.

•	Tighten all fasteners that hold the I/P module (1) to the deployment fixture (2).




10. If you have 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 with water or sand.

•	Using the proper nuts and mount the side impact module (1) to the deployment fixture (3), with the vinyl trim facing up.

•	Adjust and secure the fixture arms (4) to the deployment fixture (3).

•	Tighten all fasteners that hold the side impact module (1) to the deployment fixture (3).




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

Note: Refer to Tools Required list for the correct adapter.

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.




Note: On the steering wheel dual stage inflator module both connectors must be attached to the deployment harness adapter. This will ensure that both stage 1 and stage 2 of the deployment loops are energized, regardless of the deployment state.

15. Connect the inflator module to the adapter (2) on the SIR deployment harness (1).
16. Place a 12 volt minimum/2 amp minimum power source, i.e., vehicle battery, near the shorted end of the harness.

Note: 

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

•	When the inflator module deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of the inflator module due to the force of the rapid expansion of gas inside the inflator module.

•	If you are deploying a dual stage inflator module with stage 1 already deployed, the fixture may not move and the noise may have been reduced.

17. Clear the area of people.



18. Separate the 2 banana plugs on 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 after the inflator module deploys.
21. 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.

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

22. Seat one banana plug into the other in order to short the deployment harness leads.



23. Put on a pair of shop gloves.
24. Disconnect the pigtail adapter from the inflator module as soon as possible.
25. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed.
26. Dispose of the deployed inflator module through normal refuse channels.
27. 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:

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

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. Disable the SIR System. Refer to SIR Disabling and Enabling.

Warning: A deployed dual stage inflator module will look the same whether one or both stages were used. Always assume a deployed dual stage inflator module has an active stage 2. Improper handling or servicing can activate the inflator module and cause personal injury.

6. Disconnect the steering wheel module yellow connector (4) located next to steering column (2).




Note: If the vehicle is equipped with dual stage air bags, the steering wheel module and I/P module will each have 4 wires and standard air bags will only have 2 wires. Refer to Component Connector End Views for determining high and low circuits.

7. Cut the yellow harness connector out of the vehicle, 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 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 driver 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. Twist together the 2 connector wire leads of the high circuits from both stages of the steering wheel module to one of the deployment harness wires. Refer to Component Connector End Views in order to determine the correct circuits.
13. Inspect that the 3 wire connection is secure.



14. Bend flat the twisted connection.



15. Secure and insulate the 3-wire connection to deployment harness using electrical tape.



16. Twist together 2 connector wire leads of the low circuits from both stages of the steering wheel module to one sets of deployment wires. Refer to Component Connector End Views in order to determine the correct circuits.
17. Inspect that the 3 wire connection is secure.



18. Bend flat the twisted connection.



19. Secure and insulate the 3-wire connection to deployment harness using electrical tape.



20. Connect the deployment harness to the steering wheel module in-line connector.



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



22. Disconnect the driver side impact module yellow connector (1) from the vehicle wiring harness located under the driver seat.



23. Cut the 2 side impact module wires leading to the yellow harness connector, leaving at least 16 cm (6 in) of wire at the connector.
24. Strip 13 mm (0.5 in) of insulation from each of the side impact module connector wire leads.



25. 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.
26. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
27. 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.



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



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



32. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
33. Connect the deployment harness to the side impact module LF.



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



35. Disconnect the I/P module yellow harness connector (2) above passenger side sound insulator.




Note: If vehicle is equipped with dual stage air bags, the I/P module will each have 4 wires and standard air bags will only have 2 wires. Refer to Component Connector End Views for determining high and low circuits.

36. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
37. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.



38. 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 passenger deployment harness.
39. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
40. Twist together one end from each of the wires in order to short the wires.



41. Twist together the 2 connector wire leads of the high circuits from both stages of the I/P module to one of the deployment harness wires. Refer to Component Connector End Views in order to determine the correct circuits.
42. Ensure the 3-wire connection is secure.



43. Bend flat the twisted connection.



44. Secure and insulate the 3-wire connection to deployment harness using electrical tape.



45. Twist together the two connector wire leads of the low circuits from both stages of the I/P module to the deployment harness wire. Refer to Component Connector End Views in order to determine the correct circuits.
46. Ensure the 3-wire connection is secure.



47. Bend flat the twisted connection.



48. Secure and insulate the 3-wire connection to deployment harness using electrical tape.
49. Connect the deployment harness to the I/P module in-line connector.



50. Route the deployment harness out of the passenger side of the vehicle.



51. Disconnect the passenger side impact module yellow connector (1) from the vehicle wiring harness (4) located under the passenger seat.



52. Cut the 2 side impact module wires leading to the yellow harness connector, leaving at least 16 cm (6 in) of wire at the connector.
53. Strip 13 mm (0.5 in) of insulation from each of the side impact module connector wire leads.



54. 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.
55. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
56. 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.



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



59. Bend flat the twisted connection.
60. Secure and insulate the connection using electrical tape.



61. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
62. Connect the deployment harness to the side impact module RF.



63. Route the deployment harness out of the passenger side of the vehicle.
64. Completely cover the windshield and front door window openings with a drop cloth.
65. Stretch out all of the deployment harness wires on the left and right side of the vehicle to their full length.
66. Deploy each deployment loop one at a time.
67. Place a power source, 12-volt minimum/2-amp minimum, i.e., a vehicle battery, near the shorted end of the harnesses.
68. Separate the one set of wires and touch the wires ends to the power source in order to deploy the inflator modules, doing one module at a time.
69. Disconnect the deployment harness from the power source and twist the wire ends together.
70. Continue the same process with the remaining deployment harnesses that are available.
71. Remove the drop cloth from the vehicle.
72. Disconnect all harnesses from the vehicle.
73. Discard the harnesses.
74. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
75. If one or all of the inflator modules did not deploy, perform the following steps to remove the undeployed modules from the vehicle:

•	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.

•	If the side impact module (left and/or right) did not deploy, refer to Driver or Passenger Seat Side Inflatable Restraint Module Replacement or Rear Seat Body Side Inflatable Restraint Module Replacement.

76. Call Technical Assistance Group.