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

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.

Dual stage inflator modules have two 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 the 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.

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:

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

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

•	If you are removing the side impact module - LF, refer to Inflatable Restraint Side Impact Module Replacement - Left Side .

•	If you are removing the side impact module -- RF, refer to Inflatable Restraint Side Impact Module Replacement - Right Side .

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




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 a space on the ground about 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. Ensure that you have sufficient ventilation.
7. Ensure that no loose or flammable objects are in the area.

Important: Dual stage deployments are only used in the steering wheel and 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 inflator module.

8. If you are deploying a steering wheel module, place the steering wheel module in the center of the space.



9. When deploying an I/P 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

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

•	To mount, use four M 6 bolts (6), nuts (8), and washers (7) in order to properly secure the I/P module (1) to the deployment fixture.

•	Securely 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 with water or sand

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

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

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

•	Securely tighten all fasteners prior to deployment.




11. Inspect the J 38826 SIR deployment harness (1) and the appropriate pigtail adapter (2) for damage. Replace as needed.
12. Short the two 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.




Important: On a 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 (1) to the adapter (2) on the SIR deployment harness (3).
16. Place a 12 V minimum/2 A minimum power source, such as a vehicle battery, near the shorted ends of the harness.

Important: 

•	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 two 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.

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

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.
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 adaptor 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:

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 coil connector (1).




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

6. Cut the yellow harness connector from the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
7. Strip 13 mm (0.5 in) of insulation from all four SIR wires connector leads.



8. 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.
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 the two connector wire leads of the high circuits from both stages of the steering wheel module to one of the deployment harness wires. Refer to SIR Connector End Views in order to determine the correct circuits.
12. Inspect that the 3 wire connection is secure.



13. Bend flat the twisted connection.



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



15. Twist together the two connector wire leads of the low circuits from both stages of the steering wheel module to the deployment harness wire. Refer to SIR Connector End Views in order to determine the correct circuits.
16. Inspect that the 3 wire connection is secure.



17. Bend flat the twisted connection.



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



19. Connect the deployment harness to the steering wheel module connector (1).



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



21. Disconnect the inflatable restraint side impact module - LF connector (1), located under the driver seat.



22. Cut the side impact module - LF 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 connector wire leads.



24. 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 side impact module - LF deployment harness.
25. Strip 13 mm (0.5 in) of insulation from both ends of these wires.
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 inflator 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. Connect the deployment harness to the side impact module - LF connector (1).



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



34. Disconnect the inflatable restraint I/P module connector (1), located at the RH side of the instrument panel.




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

35. Cut the 4 SIR wires leading to the connector from the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
36. Strip 13 mm (0.5 in) of insulation from all four SIR wires connector leads.



37. 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.
38. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
39. 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.



40. Twist together the two connector wire leads of the high circuits from both stages of the I/P module to one of the deployment harness wires. Refer to SIR Connector End Views in order to determine the correct circuits.
41. Inspect that the 3 wire connection is secure.



42. Bend flat the twisted connection.



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



44. 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 SIR Connector End Views in order to determine the correct circuits.
45. Inspect that the 3 wire connection is secure.



46. Bend flat the twisted connection.



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



48. Connect the deployment harness to the I/P module connector (1).



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



50. Disconnect the inflatable restraint side impact module - RF connector (1), located under the driver seat.



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



53. 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 side impact module - RF deployment harness.
54. Strip 13 mm (0.5 in) of insulation from both ends of these wires.
55. 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.



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



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



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



61. Connect the deployment harness to the side impact module - RF connector (1).



62. Route the deployment harness out of the driver side of the vehicle.
63. Completely cover the windshield and the front door openings with a drop cloth.
64. Stretch out all of the deployment harness wires on the left and right side of the vehicle to their full length.
65. Deploy each deployment loop one at a time.
66. Place a power source, 12 V minimum/2 A minimum, such as a vehicle battery, near the shorted end of the harnesses.
67. Separate one set of wires and touch the wire ends to the power source in order to deploy the inflator modules, doing only one inflator module at a time.
68. Disconnect the deployment harness from the power source and twist the wire ends together.
69. Continue the same process with the remaining deployment harnesses that are available.
70. Remove the drop cloth from the vehicle.
71. Disconnect all harnesses from the vehicle.
72. Discard the harnesses.
73. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
74. If one or more 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 - LF did not deploy, refer to Inflatable Restraint Side Impact Module Replacement - Left Side .

•	If the side impact module -- RF did not deploy, refer to Inflatable Restraint Side Impact Module Replacement - Right Side .

75. Call the Technical Assistance Group for further assistance.