For 1990-2009 cars

## Inflator Module Handling and Scrapping LWBLHD

### Handling Procedure

1. Do not apply power to a inflatable restraint except as specified.
2. Do not attempt to make any repairs to the inflatable restraint assembly or front/side-impact sensors. A damaged or defective component must be replaced.
3. Do not weld, solder, braze, hammer, machine drill, or otherwise heat any SIR component.
4. When handling a deployed inflatable restraint assembly or pretensioner:

• | Always wear gloves and safety glasses

• | Wash hands with mild soap and water afterwards. The surface of these components may contain chemicals as a result of the gas generated during combustion which can irritate your skin

5. When handling a steering column:

• | During any service operation that requires removal and reinstallation of a steering column fitted with an inflatable restraint assembly, always carry the steering column with two hands and with the steering wheel away from your body

• | Do not set a steering column on the floor with the steering wheel facing towards the floor

6. When carrying out steering gear removal and installation procedures, remove the ignition key from the lock and ensure the steering column is locked. If this operation is not carried out and the steering wheel is spun while the steering gear is removed, the clock spring coil will be destroyed. This will result in the SDM setting a DTC, and non-deployment of the steering wheel inflatable restraint assembly.

### Deployment Inside Vehicle (Vehicle Scrapping Procedure)

Important: 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

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 .
6. Disconnect the steering wheel module yellow connector (2) from vehicle harness yellow connector (1).
7. If vehicle is equipped with dual stage air bag the steering wheel module and I/P module will each have 4 wires. Refer to Component Connector End Views , for determining high and low circuits.
8. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
9. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
10. 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.
11. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
12. 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.
13. Twist together 2 connector wire leads (the high 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.
14. Inspect that the 3-wire connection is secure.
15. Bend flat the twisted connection.
16. Secure and insulate the 3-wire connection to deployment harness using electrical tape.
17. Twist together 2 connector wire leads (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.
18. Inspect that the 3-wire connection is secure.
19. Bend flat the twisted connection.
20. Secure and insulate the 3-wire connection to deployment harness using electrical tape.
21. Connect the deployment harness to the steering wheel module in-line connector.
22. Route the deployment harness out of the driver side of the vehicle.
23. Disconnect the driver side air bag/pretensioner yellow connector (1) from the vehicle wiring harness located under the front of driver seat.
24. Cut the 4 SIR wires (2 for side air bag and 2 for pretensioner) leading to the yellow harness connector from the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
25. Strip 13 mm (0.5 in) of insulation from all 4 SIR wires connector leads (2 for side air bag and 2 for pretensioner).
26. 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.
27. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
28. 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 and pretensioner.
29. Twist together 2 connector wire leads (the high circuits from side air bag and pretensioner ) to one sets of deployment wires. Refer to Component Connector End Views , in order to determine the correct circuits.
30. Inspect that the 3-wire connection is secure.
31. Bend flat the twisted connection.
32. Secure and insulate the 3-wire connection to deployment harness using electrical tape.
33. Twist together 2 connector wire leads (the low circuits from side air bag and pretensioner ) to one sets of deployment wires. Refer to Component Connector End Views , in order to determine the correct circuits.
34. Inspect that the 3-wire connection is secure.
35. Bend flat the twisted connection.
36. Secure and insulate the 3-wire connection to deployment harness using electrical tape.
37. Connect the deployment harness to the driver side air bag/pretensioner yellow connector.
38. Route the deployment harness out of the driver side of the vehicle.
39. Disconnect the left/driver roof rail yellow harness connector (1) from the left roof rail air bag.
40. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
41. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
42. 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 roof rail air bag deployment harness.
43. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
44. Twist together one end from each of the wires in order to short the wires.
45. Twist together one connector wire lead to one deployment wire.
46. Bend flat the twisted connection.
47. Secure and insulate the connection using electrical tape.
48. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
49. Connect the deployment harness to the roof rail module yellow connector.
50. Route the deployment harness out of the driver side of the vehicle.
51. Disconnect the I/P module yellow harness connector (1) from the vehicle harness connector (2).
52. If vehicle is equipped with dual stage air bags the I/P module will each have 4 wires. Refer to Component Connector End Views , for determining high and low circuits.
53. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
54. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
55. 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.
56. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
57. Twist together one end from each of the wires in order to short the wires.
58. Twist together 2 connector wire leads (the high 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.
59. Inspect that the 3-wire connection is secure.
60. Bend flat the twisted connection.
61. Secure and insulate the 3-wire connection to deployment harness using electrical tape.
62. Twist together 2 connector wire leads (the low circuits from both stages of the I/P module) to one sets of deployment wires. Refer to Component Connector End Views , in order to determine the correct circuits.
63. Inspect that the 3-wire connection is secure.
64. Bend flat the twisted connection.
65. Secure and insulate the 3-wire connection to deployment harness using electrical tape.
66. Connect the deployment harness to the I/P module in-line connector.
67. Route the deployment harness out of the passenger side of the vehicle.
68. Disconnect the passenger side air bag/pretensioner yellow connector (1) from the vehicle wiring harness located under the front of driver seat.
69. Cut the 4 SIR wires (2 for side air bag and 2 for pretensioner) leading to the yellow harness connector from the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
70. Strip 13 mm (0.5 in) of insulation from all 4 SIR wires connector leads (2 for side air bag and 2 for pretensioner).
71. 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.
72. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
73. 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 and pretensioner.
74. Twist together 2 connector wire leads (the high circuits from side air bag and pretensioner) to one sets of deployment wires. Refer to Component Connector End Views , in order to determine the correct circuits.
75. Inspect that the 3-wire connection is secure.
76. Bend flat the twisted connection.
77. Secure and insulate the 3-wire connection to deployment harness using electrical tape.
78. Twist together 2 connector wire leads (the low circuits from side air bag and pretensioner) to one sets of deployment wires. Refer to Component Connector End Views , in order to determine the correct circuits.
79. Inspect that the 3-wire connection is secure.
80. Bend flat the twisted connection.
81. Secure and insulate the 3-wire connection to deployment harness using electrical tape.
82. Connect the deployment harness to the passenger side air bag/pretensioner yellow connector.
83. Route the deployment harness out of the passenger side of the vehicle.
84. Disconnect the right/passenger roof rail air bag yellow harness connector (1) from the right roof rail air bag.
85. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
86. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
87. 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 roof rail air bag deployment harness.
88. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
89. Twist together one end from each of the wires in order to short the wires.
90. Twist together one connector wire lead to one deployment wire.
91. Bend flat the twisted connection.
92. Secure and insulate the connection using electrical tape.
93. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
94. Connect the deployment harness to the roof rail module yellow connector.
95. Route the deployment harness out of the passenger side of the vehicle.
96. Completely cover the windshield and front door window openings with a drop cloth.
97. Stretch out all of the deployment harness wires on the right side of the vehicle to their full length.
98. Deploy each deployment loop one at a time.
99. Place a power source, 12 V minimum/2 A minimum (i.e., a vehicle battery) near the shorted end of the harnesses.
100. 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.
101. Disconnect the deployment harness from the power source and twist the wire ends together.
102. Continue the same process with the remaining deployment harnesses that are available.
103. Stretch out all of the deployment harness wires on the left side of the vehicle to their full length.
104. Deploy each deployment loop one at a time.
105. Place a power source, 12 V minimum/2 A minimum (i.e., a vehicle battery) near the shorted end of the harnesses.
106. 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.
107. Disconnect the deployment harness from the power source and twist the wire ends together.
108. Continue the same process with the remaining deployment harnesses that are available.
109. Remove the drop cloth from the vehicle.
110. Disconnect all harnesses from the vehicle.
111. Discard the harnesses.
112. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
113. If one or all 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 or Passenger Seat Side Inflatable Restraint Module Replacement .

• | Inflatable Restraint Roof Side Rail Module Replacement

#### Deployment Procedure - (Out Of Vehicle)

Refer to TAS (Technical Assistant Service) for further instructions.