For 1990-2009 cars

### Live (Undeployed) Inflator Module

Caution: When you are carrying an undeployed inflator module:

• | Do not carry the inflator module by the wires or connector on the inflator module

• | Make sure the bag opening points away from you

When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result.

Use special care when handling and storing a live (undeployed) inflator module. An air bag deployment produces rapid gas generation. This may cause the inflator module, or an object in front of the inflator module, to jettison through the air in the unlikely event of an accidental deployment.

### Shipping Procedures for Live (Undeployed) Inflator Modules

Service personnel should refer to the latest Service Bulletins for proper SIR inflator module shipping procedures.

### Scrapping Procedure

During the course of a vehicle's useful life, you may need to dispose of a live (undeployed) inflator module. The following information covers the proper procedures for disposing of a live inflator module. Before you dispose of a live inflator module, you must deploy the inflator module. Do not dispose of live inflator modules through normal refuse channels.

Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws.

Do not deploy an air bag in the following situations:

• | If you replace an inflator module under warranty, you may need to return the inflator module, undeployed, to Delphi Interior & Lighting Systems. Refer to the latest service bulletin regarding SIR shipping procedures.

• | If a vehicle is the subject of a Product Liability Report related to the SIR system and is subject to a Preliminary Investigation (GM-1241), do not alter the SIR system in any manner. Refer to the latest service bulletin on SIR shipping procedures.

• | If a vehicle is involved in a campaign affecting the inflator modules, follow the instructions in the Campaign Service Bulletin for proper SIR handling and shipping 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 (Inflatable Restraint Steering Wheel Module)

Deploy the inflatable restraint steering wheel 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, you determine that the inflator module does not function properly.

• | The inflator module is scratched or ripped on the cover.

• | The inflator module pigtail (if equipped) is damaged.

• | The inflator module connector is damaged.

• | An inflator module connector terminal is damaged.

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

Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws.

#### Tools Required

• | J 38826

• | An appropriate pigtail adapter

CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury.

1. Turn the ignition switch to the OFF position.
2. Remove the ignition key.
3. Put on safety glasses.
4. Inspect the J 38826 .
5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other.
6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1).
7. Remove the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement .
8. Remove all horn/steering wheel control buttons from the module, if equipped.

Caution: When you are carrying an undeployed inflator module:

• | Do not carry the inflator module by the wires or connector on the inflator module

• | Make sure the bag opening points away from you

When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result.
9. Place the module with the vinyl trim cover facing up and away from the surface on a work bench.
10. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the 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.
11. Ensure that no loose or flammable objects are in the area.
12. Place the module in the space with the vinyl trim cover facing up.
13. Extend the SIR deployment harness and adapter to full length from the module.
14. Place a 12 V minimum/2 A minimum power source (i.e., vehicle battery) near the shorted end of the harness.
15. Connect the module (1) to the adapter (2) on the SIR deployment harness (3).
16. Firmly seat the adapter into the module connector.
17. Clear the area of people.

CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury.

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

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

Important: When the air bag deploys, the inflator module may jump about 30 cm (1 ft) vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag.

19. Connect the SIR deployment harness wires to the power source.
20. Disconnect the SIR deployment harness from the power source after the air bag deploys.
21. Seat one banana plug into the other in order to short the deployment harness leads.
22. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps.

CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury:

• | Allow sufficient time for cooling before touching any metal surface of the inflator module.

• | Do not place the deployed inflator module near any flammable objects.

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 module through normal refuse channels.
27. Wash hands with a mild soap.

### Deployment Outside Vehicle (Inflatable Restraint Instrument Panel Module)

#### Tools Required

• | J 39401-B

• | J 38826

• | An appropriate pigtail adapter

Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws.

CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury.

Deploy the inflatable restraint instrument panel 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, you determine that the inflator module does not function properly.

• | The inflator module is scratched or ripped on the cover.

• | The inflator module pigtail (if equipped) is damaged.

• | The inflator module connector is damaged.

• | An inflator module connector terminal is damaged.

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

Important: Refer to the latest General Motors Service Bulletins before deploying a passenger inflator module.

1. Turn the ignition switch to the OFF position.
2. Remove the ignition key.
3. Put on safety glasses.
4. Inspect the J 38826
5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other.
6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1).
7. Remove the inflatable restraint instrument panel module. Refer to Inflatable Restraint Instrument Panel Module Replacement .

Caution: When you are carrying an undeployed inflator module:

• | Do not carry the inflator module by the wires or connector on the inflator module

• | Make sure the bag opening points away from you

When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result.
8. Place the module with the vinyl trim cover facing up and away from the surface on a work bench.
9. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the 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.
10. Ensure that no loose or flammable objects are in the area.
11. Place the J 39401-B
12. Fill the fixture plastic reservoir with water or sand.
13. Secure the J 39401-7A arms (5) to the deployment fixture (2) using carriage bolts (3) and nuts (4).
14. Mount the module (1) in the SIR deployment fixture (2) with the vinyl trim cover facing up using one of the following mounting methods.

Important: Securely hand tighten all fasteners prior to deployment.

15. To mount, use four M 6 bolts (6), nuts (8), and washers (7) in order to secure the module (1) to the deployment fixture (2).
16. Extend the SIR deployment harness and adapter to full length from the module.
17. Place a 12 V minimum/2 A minimum power source (i.e., vehicle battery) near the shorted end of the harness.
18. Connect the module (1) to the adapter (2) on the SIR deployment harness (3).
19. Firmly seat the adapter into the module connector.
20. Clear the area of people.

CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury.

21. Separate the 2 banana plugs on the SIR deployment harness.

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

Important: When the air bag deploys, the SIR deployment fixture may jump vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag.

22. Connect the SIR deployment harness wires to the power source.
23. Disconnect the SIR deployment harness from the power source after the air bag deploys.
24. Seat one banana plug into the other in order to short the deployment harness leads.
25. If the air bag did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps.

CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot. To help avoid a fire or personal injury:

• | Allow sufficient time for cooling before touching any metal surface of the inflator module.

• | Do not place the deployed inflator module near any flammable objects.

26. Put on a pair of shop gloves.
27. Disconnect the pigtail adapter from the inflator module as soon as possible.
28. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed.
29. Dispose of the deployed module through normal refuse channels.
30. Wash hands with a mild soap.

### Deployment Inside Vehicle (Vehicle Scrapping Procedure)

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.

CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury.

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. Disconnect the inflatable restraint steering wheel module yellow 2-way connector.
6. Cut the yellow 2-way 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 4.6 M (15 ft) deployment wires from a 0.8 mm² (18 gage) or thicker multi-strand wire. Use these wires to fabricate the driver 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 air bag.
11. Twist together one connector wire lead to one deployment wire.
12. Inspect that the previous connection is secure.
13. Bend flat the twisted connection.
14. Secure and insulate the connection using electrical tape.
15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
16. Connect the deployment harness to the inflatable restraint steering wheel module yellow 2-way connector.
17. Route the deployment harness out of the vehicle's driver side.
18. Disconnect the inflatable restraint IP module yellow 2-way harness connector.
19. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
21. Cut two 6.1 M (20 ft) deployment wires from a 0.8 mm² (18 gage) or thicker multi-strand wire. These wires will be used to fabricate the passenger deployment harness.
22. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
23. Twist together one end from each of the wires in order to short the wires.
24. Twist together one connector wire lead to one deployment wire.
25. Bend flat the twisted connection.
26. Secure and insulate the connection using electrical tape.
27. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
28. Connect the deployment harness to the inflatable restraint IP module yellow 2-way connector.
29. Route the deployment harness out of the passenger side of the vehicle.
30. Clear the inside and outside of the vehicle of any people or loose and flammable objects.
31. Stretch the driver harness to full length.
32. Stretch the passenger harness to full length.
33. Completely cover the windshield and front door window openings with a drop cloth.
34. Place a power source, 12V minimum/2A minimum (i.e., a vehicle battery) near the shorted end of the harness.
35. Separate the two ends of the driver deployment harness wires.
36. Connect the driver deployment harness wires to the power source in order to deploy the inflatable restraint steering wheel module.
37. Disconnect the driver deployment harness wires from the power source.
38. Separate the two ends of the passenger deployment harness wires.
39. Connect the passenger deployment harness wires to the power source in order to deploy the inflatable restraint IP module.
40. Disconnect the passenger deployment harness wires from the power source.
41. Twist together one end of each wire on the driver deployment harness in order to short the wires.
42. Twist together one end of each wire on the passenger deployment harness in order to short the wires.
43. Remove the drop cloth from the vehicle.
44. Disconnect both harnesses from the vehicle.
45. Discard the harnesses.
46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.

46.1. | Remove the undeployed module(s) from the vehicle.

46.2. | Temporarily store the module(s).

46.3. | Call the Technical Assistance Group for further assistance.

### Handling a Deployed Inflator Module

After the inflator module has deployed, the surface of the air bag may contain a powdery residue. this powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the deployment. Gloves and safety glasses are recommended, however, as a precaution. Gloves and safety glasses help to prevent possible irritation of the skin or eyes.