For 1990-2009 cars

# SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) PASSENGER SIDE

#### SUBJECT: SUPPLEMENTAL INFLATOR RESTRAINT (SIR) PASSENGER-SIDE INFLATOR MODULE SCRAPPING PROCEDURE

#### MODELS: 1992-94 MODELS WITH PASSENGER SIDE SUPPLEMENTAL INFLATABLE RESTRAINT (SIR)

THIS BULLETIN OUTLINES THE SCRAPPING OF UNDEPLOYED PASSENGER-SIDE INFLATOR MODULES. THIS PROCEDURE SHOULD BE USED ONLY FOR DEALERS IN ALASKA, HAWAII, US TERRITORIES AND FOREIGN COUNTRIES. PASSENGER-SIDE INFLATOR MODULES REPLACED IN THE CONTINENTAL UNITED STATES SHOULD BE RETURNED FOR ANALYSIS FOLLOWING THE PROCEDURES OUTLINED IN BULLETIN NUMBER 319004R.

THIS BULLETIN, IN CONJUNCTION WITH BULLETIN NUMBER 319004R, CANCELS AND REPLACES BULLETIN NUMBER 209006 (CHEVROLET 93-72-9J, PONTIAC 93-9-5 AND CADILLAC 93-I-13).

PASSENGER INFLATOR MODULE SCRAPPING PROCEDURE ALASKA, HAWAII, US TERRITORIES, AND FOREIGN COUNTRIES ONLY

#### TOOLS REQUIRED:

J38826 - SIR DEPLOYMENT HARNESS J39401 - PASSENGER SIDE SIR MODULE DEPLOYMENT FIXTURE

DURING THE COURSE OF A VEHICLE'S USEFUL LIFE, CERTAIN SITUATIONS MAY ARISE WHICH WILL NECESSITATE THE DISPOSAL OF A LIVE (UNDEPLOYED) INFLATOR MODULE. THIS INFORMATION COVERS PROPER PROCEDURES FOR DISPOSING OF A LIVE PASSENGER INFLATOR MODULE. INFORMATION FOR DISPOSING OF A LIVE DRIVER INFLATOR MODULE CAN BE FOUND IN THE APPLICABLE SERVICE MANUAL OR IN A SERVICE BULLETIN.

BEFORE A LIVE INFLATOR MODULE CAN BE DISPOSED OF, IT MUST BE DEPLOYED. LIVE INFLATOR MODULES MUST NOT BE DISPOSED OF THROUGH NORMAL REFUSE CHANNELS.

#### CAUTION:

FAILURE TO FOLLOW PROPER SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) INFLATOR MODULE DISPOSAL PROCEDURES CAN RESULT IN AIR BAG DEPLOYMENT WHICH MAY CAUSE PERSONAL INJURY. UNDEPLOYED INFLATOR MODULES MUST NOT BE DISPOSED OF THROUGH NORMAL REFUSE CHANNELS. THE UNDEPLOYED INFLATOR MODULE CONTAINS SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS OR PERSONAL INJURY IF THE SEALED CONTAINER IS DAMAGED DURING DISPOSAL. DISPOSAL IN ANY MANNER INCONSISTENT WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE, AND/OR LOCAL LAWS.

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 DEPLOY THE INFLATOR MODULE AND DO NOT ALTER THE SIR SYSTEM IN ANY MANNER. REFER TO THE APPLICABLE SERVICE BULLETIN ON SIR SHIPPING PROCEDURES (BULLETIN APPLIES TO U.S ONLY, EXCEPT ALASKA AND HAWAII AND ALL FOREIGN COUNTRIES) FOR DETAILS ON HANDLING SIR SYSTEMS INVOLVED WITH GM-1241. IF A VEHICLE IS THE SUBJECT OF A CAMPAIGN AFFECTING INFLATOR MODULES, DO NOT DEPLOY THE INFLATOR MODULE. FOLLOW INSTRUCTIONS IN THE CAMPAIGN SERVICE BULLETIN FOR PROPER DISPOSITION OF THE INFLATOR MODULE.

IN SITUATIONS WHICH REQUIRE DEPLOYMENT OF A LIVE INFLATOR MODULE, DEPLOYMENT MAY BE ACCOMPLISHED IN OR OUT OF THE VEHICLE. THE METHOD EMPLOYED DEPENDS UPON FINAL DISPOSITION OF THE PARTICULAR VEHICLE, AS NOTED IN "DEPLOYMENT OUT OF VEHICLE" AND "DEPLOYMENT IN VEHICLE" SHOWN BELOW.

DEPLOYMENT OUT OF VEHICLE

DEPLOYMENT OUT OF THE VEHICLE IS PROPER WHEN THE VEHICLE IS TO BE RETURNED TO SERVICE. THIS INCLUDES, FOR EXAMPLE, SITUATIONS IN WHICH A FUNCTIONALLY OR COSMETICALLY DEFICIENT INFLATOR MODULE IS REPLACED. DEPLOYMENT AND DISPOSAL OF AN INFLATOR MODULE IS, OF COURSE, SUBJECT TO ANY REQUIRED RETENTION PERIOD.

FOR DEPLOYMENT OF A LIVE INFLATOR MODULE OUT OF THE VEHICLE, THE DEPLOYMENT PROCEDURE MUST BE FOLLOWED EXACTLY. ALWAYS WEAR SAFETY GLASSES DURING THIS DEPLOYMENT PROCEDURE UNTIL THE DEPLOYED INFLATOR MODULE IS SCRAPPED. BEFORE PERFORMING THE PROCEDURES YOU SHOULD BE FAMILIAR WITH SERVICING THE SIR SYSTEM AND WITH PROPER HANDLING OF THE INFLATOR MODULE. PROCEDURES SHOULD BE READ FULLY BEFORE THEY ARE PERFORMED.

THE FOLLOWING PROCEDURE REQUIRES USE OF J 38826 SIR DEPLOYMENT HARNESS WITH THE APPROPRIATE PIGTAIL ADAPTER. THE PROCEDURE ALSO REQUIRES THE USE OF J 39401 PASSENGER SIDE SIR MODULE DEPLOYMENT FIXTURE. DO NOT ATTEMPT THIS PROCEDURE WITHOUT J 38826 AND ADAPTER, AND J 39401.

#### CAUTION:

FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RE- SULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT HARNESS TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT HARNESS TO THE INFLATOR MODULE. DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECT- ED TO A POWER SOURCE UNTIL THE AIRBAG IS TO BE DEPLOYED. THE INFLATOR MODULE WILL IMMEDIATELY DEPLOY THE AIRBAG WHEN A POWER SOURCE IS CONNECTED TO IT. WEAR SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL PROCEDURE.

! IMPORTANT THIS INFORMATION APPLIES ONLY TO PASSENGER INFLATOR MODULES. INFORMATION FOR DISPOSING OF A LIVE DRIVER INFLATOR MODULE CAN BE FOUND IN THE APPLICABLE SERVICE MANUAL OR IN A SERVICE BULLETIN.

1. TURN IGNITION SWITCH TO "LOCK", REMOVE KEY, AND PUT ON SAFETY GLASSES. 2. INSPECT J 38826 SIR DEPLOYMENT HARNESS AND APPROPRIATE PIGTAIL ADAPTER FOR DAMAGE. IF HARNESS OR PIGTAIL IS DAMAGED, DISCARD AND OBTAIN A REPLACEMENT. 3. SHORT THE TWO SIR DEPLOYMENT HARNESS LEADS TOGETHER BY FULLY SEATING ONE BANANA PLUG INTO THE OTHER. THE SIR DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. REFER TO FIGURE 1. 4. CONNECT THE APPROPRIATE PIGTAIL ADAPTER TO THE SIR DEPLOYMENT HARNESS. REFER TO FIGURE 1. 5. REMOVE INFLATOR MODULE FROM VEHICLE. REFER TO "ON-VEHICLE SERVICE" IN SECTION 9J.

#### CAUTION:

WHEN STORING A LIVE INFLATOR MODULE OR WHEN LEAVING A LIVE INFLATOR MODULE UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN PERSONAL INJURY.

6. CLEAR A SPACE ON THE GROUND APPROXIMATELY 185 CM (SIX FEET) IN DIAMETER WHERE THE FIXTURE WITH ATTACHED INFLATOR MODULE IS TO BE PLACED FOR DEPLOYMENT. A PAVED OUTDOOR LOCATION WHERE THERE IS NO ACTIVITY IS PREFERRED. IF AN OUTDOOR LOCATION IS NOT AVAILABLE, A SPACE ON THE SHOP FLOOR WHERE THERE IS NO ACTIVITY AND SUFFICIENT VENTILATION IS RECOMMENDED. ENSURE THAT NO LOOSE OR FLAMMABLE OBJECTS ARE WITHIN THE DEPLOYMENT AREA. 7. PLACE THE J 39401 ON THE GROUND IN THE SPACE CLEARED IN STEP 6, IF IT HAS NOT ALREADY BEEN PLACED THERE. REFER TO FIGURE 2. 8. FILL PLASTIC RESERVOIR IN FIXTURE WITH WATER OR SAND. THIS IS NECESSARY TO PROVIDE SUFFICIENT STABILIZATION OF THE FIXTURE DURING DEPLOYMENT. 9. ATTACH THE PASSENGER INFLATOR MODULE IN THE J 39401 PASSENGER SIDE SIR MODULE DEPLOYMENT FIXTURE USING THE FLANGE/ARM MOUNTING METHOD OR STUD MOUNTING METHOD AS APPROPRIATE (MOST APPLICATIONS WILL WORK BEST WITH THE FLANGE/ARM MOUNTING METHOD). REFER TO FIGURE 3. INFLATOR MODULE MUST BE MOUNTED SUCH THAT THE BAG WILL DEPLOY UP- WARD. SECURELY HAND-TIGHTEN ALL FASTENERS PRIOR TO DEPLOYMENT.

! IMPORTANT WHEN USING THE STUD MOUNTING METHOD, THE MOUNTING NUTS FOR ATTACHING THE INFLATOR MODULE TO THE VEHICLE MUST BE REMOVED FROM THE MODULE. J 39401-1 MOUNTING NUTS (4 REQUIRED) MUST BE USED TO ATTACH THE MODULE TO THE FIXTURE TO ENSURE SUFFICIENT THREAD ENGAGEMENT.

WHEN USING THE FLANGE/ARM MOUNTING METHOD, USE THE J 39401-13 HOLD- DOWN NUTS (4 REQUIRED) WHENEVER POSSIBLE. HOWEVER, IF CLEARANCE RE- STRICTIONS DO NOT ALLOW THE USE OF THE J 39401-13 NUTS, (4) M6 X 1.0 NUTS WITH WASHERS MAY BE USED.

10. STRETCH THE SIR DEPLOYMENT HARNESS AND PIGTAIL ADAPTER FROM THE INFLATOR MODULE TO ITS FULL LENGTH. REFER TO FIGURE 4. 11. PLACE A POWER SOURCE NEAR THE SHORTED END OF THE SIR DEPLOYMENT HARNESS. (RECOMMENDED APPLICATION: 12 VOLTS MINIMUM, 2 AMPS MINI- MUM. A VEHICLE BATTERY IS SUGGESTED.) 12. CONNECT THE INFLATOR MODULE TO THE PIGTAIL ADAPTER ON THE SIR DEPLOYMENT HARNESS. THE SIR DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE INFLATOR MODULE WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. REFER TO FIGURE 5.

! IMPORTANT ENSURE THAT THE PIGTAIL ADAPTER IS FIRMLY SEATED INTO THE INFLATOR MODULE CONNECTOR. FAILURE TO FULLY SEAT THE CONNECTORS MAY LEAVE THE SHORTING BAR LOCATED IN THE INFLATOR MODULE CONNECTOR FUNCTION- ING (SHORTING THE DEPLOYMENT CIRCUIT) AND MAY RESULT IN NONDEPLOY- MENT OF THE INFLATOR MODULE.

13. VERIFY THAT THE AREA AROUND THE INFLATOR MODULE IS CLEAR OF ALL PEOPLE AND LOOSE OR FLAMMABLE OBJECTS. 14. VERIFY THAT THE INFLATOR MODULE IS FIRMLY AND PROPERLY SECURED IN J 39401. 15. NOTIFY ALL PEOPLE IN THE IMMEDIATE AREA OF YOUR INTENTION TO DEPLOY THE INFLATOR MODULE. THE DEPLOYMENT WILL BE ACCOMPANIED BY A SUBSTANTIAL NOISE WHICH MAY STARTLE THE UNINFORMED. 16. SEPARATE THE TWO BANANA PLUGS ON THE SIR DEPLOYMENT HARNESS THAT WERE SHORTED TOGETHER IN STEP 3. REFER TO FIGURE 6.

#### NOTICE: WHEN AIR BAG DEPLOYS, THE RAPID GAS EXPANSION WILL CREATE A SUBSTANTIAL NOISE. NOTIFY ALL PEOPLE IN THE IMMEDIATE AREA THAT YOU INTEND TO DEPLOY THE INFLATOR MODULE.

#### CAUTION:

DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE INFLATOR MODULE WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT HARNESS TO THE POWER SOURCE SHOULD ALWAYS BE THE LAST STEP IN THE INFLATOR MODULE DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL INJURY.

17. CONNECT THE SIR DEPLOYMENT HARNESS WIRES TO THE POWER SOURCE TO IMMEDIATELY DEPLOY THE INFLATOR MODULE. REFER TO FIGURE 7. 18. DISCONNECT THE SIR DEPLOYMENT HARNESS FROM THE POWER SOURCE. 19. SHORT THE TWO SIR DEPLOYMENT HARNESS LEADS TOGETHER BY FULLY SEATING ONE BANANA PLUG INTO THE OTHER. REFER TO FIGURE 1. 20. IN THE UNLIKELY EVENT THAT THE INFLATOR MODULE DID NOT DEPLOY AFTER FOLLOWING THESE PROCEDURES, PROCEED IMMEDIATELY WITH STEPS 25 THROUGH 28. IF THE INFLATOR MODULE DEPLOYED AS INTENDED, PROCEED WITH STEPS 21 THROUGH 24. 21. PUT ON A PAIR OF SHOP GLOVES TO PROTECT YOUR HANDS FROM POSSIBLE IRRITATION AND HEAT WHEN HANDLING THE DEPLOYED INFLATOR MODULE.

AFTER THE INFLATOR MODULE HAS BEEN 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 BYPRODUCTS OF THE CHEMICAL REACTION. SODIUM HYDROXIDE DUST (SIMILAR TO LYE SOAP) IS PRODUCED AS A BYPRODUCT OF THE DEPLOYMENT REACTION. THE SODIUM HYDROXIDE QUICKLY REACTS WITH THE ATMOSPHERIC MOISTURE AND IS CONVERTED TO SODIUM CARBONATE AND SODIUM BICARBONATE (BAKING SODA). THEREFORE, IT IS UNLIKELY THAT SODIUM HYDROXIDE WILL BE PRESENT FOR VERY LONG AFTER DEPLOYMENT. AS A PRECAUTION, HOWEVER, GLOVES AND SAFETY GLASSES ARE RECOMMENDED TO PREVENT ANY POSSIBLE IRRITATION OF THE SKIN OR EYES.

#### CAUTION:

SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDLING A DEPLOYED INFLATOR MODULE. AFTER DEPLOYMENT, THE METAL SURFACES OF THE INFLATOR MODULE WILL BE HOT. ALLOW THE INFLATOR MODULE TO COOL BEFORE HANDLING ANY METAL PORTION OF IT. DO NOT PLACE THE DE- PLOYED INFLATOR MODULE NEAR ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN FIRE OR PERSONAL INJURY.

AFTER AN INFLATOR MODULE HAS BEEN DEPLOYED, THE METAL CANISTER AND SURROUNDING AREAS OF THE INFLATOR MODULE WILL BE HOT. DO NOT TOUCH THE METAL AREAS OF THE INFLATOR MODULE FOR ABOUT TEN MINUTES AFTER DEPLOYMENT. IF THE DEPLOYED INFLATOR MODULE MUST BE MOVED BE- FORE IT IS COOL, WEAR GLOVES AND HANDLE BY THE AIR BAG ITSELF. REFER TO FIGURE 8.

22. DISCONNECT THE PIGTAIL ADAPTER FROM THE INFLATOR MODULE AS SOON AFTER DEPLOYMENT AS POSSIBLE TO AVOID DAMAGE TO THE PIGTAIL ADAPTER OR SIR DEPLOYMENT HARNESS FROM CONTACTING THE HOT INFLATOR MODULE CANISTER. THE PIGTAIL ADAPTER AND SIR DEPLOYMENT HARNESS ARE DESIGNED TO BE REUSED. THEY SHOULD, HOWEVER, BE INSPECTED FOR DAMAGE AFTER EACH DEPLOYMENT AND REPLACED IF NECESSARY. 23. DISPOSE OF THE DEPLOYED INFLATOR MODULE THROUGH NORMAL REFUSE CHANNELS AFTER IT HAS COOLED FOR AT LEAST 10 MINUTES. 24. WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARD.

#### NOTICE: THE REMAINING STEPS ARE TO BE FOLLOWED IN THE UNLIKELY EVENT THAT THE INFLATOR MODULE DID NOT DEPLOY AFTER FOLLOWING THE ABOVE PROCEDURES.

25. ENSURE THAT THE SIR DEPLOYMENT HARNESS HAS BEEN DISCONNECTED FROM THE POWER SOURCE AND THAT ITS TWO BANANA PLUGS HAVE BEEN SHORTED TOGETHER BY FULLY SEATING ONE BANANA PLUG INTO THE OTHER. REFER TO FIGURE 1. 26. DISCONNECT THE PIGTAIL ADAPTER FROM THE INFLATOR MODULE.

#### CAUTION:

WHEN STORING A LIVE INFLATOR MODULE OR WHEN LEAVING A LIVE INFLATOR MODULE UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCE- DURES MAY RESULT IN PERSONAL INJURY.

27. TEMPORARILY STORE THE INFLATOR MODULE WITH THE BAG FACING UP, AWAY FROM THE SURFACE UPON WHICH IT RESTS. REFER TO FIGURE 9. 28. CALL THE TECHNICAL ASSISTANCE GROUP FOR FURTHER ASSISTANCE.

DEPLOYMENT IN VEHICLE

DEPLOYMENT IN THE VEHICLE IS PROPER WHEN THE VEHICLE IS TO BE DESTROYED OR SALVAGED FOR COMPONENT PARTS. THIS INCLUDES, BUT IS NOT LIMITED TO, THE FOLLOWING SITUATIONS:

1. THE VEHICLE HAS COMPLETED ITS USEFUL LIFE. 2. THE VEHICLE HAS BEEN DAMAGED BEYOND REPAIR IN A NON-DEPLOYMENT TYPE OF ACCIDENT. 3. THE VEHICLE HAS BEEN STRIPPED OR DAMAGED BEYOND REPAIR IN A THEFT. 4. THE VEHICLE WILL BE SALVAGED FOR COMPONENT PARTS TO BE USED ON A VEHICLE WITH A DIFFERENT VEHICLE IDENTIFICATION NUMBER (VIN) AS OPPOSED TO BEING REBUILT AS THE SAME VIN. THIS IS DONE TO ENSURE SIR SYSTEM INTEGRITY SINCE ONLY NEW SIR SYSTEM COMPONENTS, WITH THE EXCEPTION OF REMANUFACTURED PARTS AS NOTED BELOW, MAY BE USED IN SERVICING AN SIR EQUIPPED VEHICLE. REMANUFACTURED PARTS PURCHASED FROM AN AUTHORIZED GENERAL MOTORS DEALER MAY BE USED FOR SIR REPAIRS.

REFER TO APPLICABLE MODEL AND YEAR SERVICE MANUAL FOR THE IN-VEHICLE PASSENGER INFLATOR MODULE DEPLOYMENT PROCEDURE.

FIGURES: 9

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.

COPYRIGHT 1993 GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.