For 1990-2009 cars

#### Tools Required

SA9413NE SIR Deployment Fixture

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 Inside the Vehicle -- Driver, Passenger, Left Curtain, and/or Right Curtain

Deployment inside the vehicle is proper when the vehicle is to be destroyed or salvaged for component parts. This includes, but is limited to, the following situations.

• | Vehicle has completed its useful life.

• | Vehicle has been damaged beyond repair in a non-deployment-type accident.

• | Vehicle has been stripped or damaged beyond repair in a theft.

Caution: Refer to SRS Inflator Module Deployment Caution in the Preface section.

• | Vehicle will be salvaged for component parts to be used on 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 COMPONENTS MAY BE USED IN SERVICING AN SIR EQUIPPED VEHICLE. Never use the SIR components from another vehicle. Always replace the SIR components with NEW COMPONENTS.

#### Deployment Procedure

Procedures for deployment of a live (undeployed) inflator module within the vehicle are as follows:

1. Lower driver and passenger windows. Turn the ignition switch OFF and remove the ignition key.
2. Check that all inflator modules which will be deployed are mounted securely.

• | driver inflator module is secured to steering wheel

• | passenger inflator module is secured to the instrument panel

• | left curtain inflator module is secured to left roof rail

• | right curtain inflator module is secured to right roof rail

3. Remove all loose objects from the front seat and the inflator module covers.
4. Disable the SIR system.
5. Refer to Disabling the SIR System and Enabling the SIR System
6. Cut the two wires of each yellow two-way connector away from the vehicle harness at least 150 mm (6 in) of wire at the connector.
7. Strip 13 mm (1/2 in) of insulation from each of the connector wire leads.
8. Cut two 4.6 m (15 ft) deployment wires from the multi-strand wire (18 gage or thicker). These deployment wires will be used to fabricate a deployment harness.
9. Strip the 13 mm (1/2 in) of insulation off both ends of each deployment wire cut in the previous step.
10. Short the two deployment wires by twisting together one end from the each. Deployment wires shall remain shorted and not be connected to a power source until the air bag is to be deployed.
11. Twist together one connector wire lead to one deployment sire. The connection should be mechanically secure.
12. Bend the twisted connection, (made in step 10), flat and wrap tightly with electrical tape to insulate and secure.
13. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire as in steps 10 and 11.
14. Connect the deployment harness to the yellow 2-way connector of the inflator module to be deployed.

- | for the driver inflator module or the passenger inflator module, connect to appropriate connector at the base of the steering column.

- | for the left curtain inflator module or right curtain inflator module, connect to the connector under the C-pillar trim.

15. Stretch the deployment harness wires from the vehicle to their full length.
16. Verify that the vehicle is clear of all people, loose objects, or flammable material.

Important: When deploying an inflator module, the rapid expansion of gas is very loud which may startle the uninformed. Notify the people in the immediate area that an inflator module will be deployed.

17. Separate the two ends of the deployment wires that were twisted together in step 9.
18. Temporarily connect the deployment wires to a 12 volts minimum/2 amps minimum power source to deploy the inflator module. A vehicle battery is suggested. (Inflator module deployment will occur when contact is made).

Caution: Refer to SRS Inflator Module Deployment Caution in the Preface section.

19. Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation when handling the deployed inflator module.
20. Dispose of the deployed inflator module through normal refuse channels after it has cooled for at least ten minutes.
21. Wash hands with a mild soap.
22. In the unlikely event that the inflator module did not deploy after following this procedure:

22.1. | Short the two deployment wires by twisting the ends together.

22.2. | Remove the inflator module from the vehicle. (Refer to either Driver Inflator Module, Passenger Inflator Module or Curtain Inflator Module removal procedures.

22.3. | Temporarily store the inflator module with its trim cover facing up, away from the surface on which it rests.

22.4. | Call the Saturn Technical Assistance Center for further instruction on disposal.

### Deployment Outside the Vehicle (Driver Inflator Module, Passenger Inflator Module, Curtain Inflator Module)

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.

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:

• | Using the SIR diagnostics, it is determined that the inflator module is malfunctioning.

• | The inflator module is cosmetically damaged (scratched or ripped).

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

• | The inflator module connector is damaged.

• | The inflator module connector terminals are damaged.

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

Before performing the deployment procedure, you should be familiar with the SIR service precautions and proper inflator module handling.

Caution: Refer to SRS Inflator Module Deployment Caution in the Preface section.

#### Deployment Procedure

Procedures for deployment of a live (undeployed) inflator module outside of the vehicle are as follows:

1. Turn off the ignition
2. Remove the ignition key.
3. Put on safety glasses.
4. Remove the inflator module from the vehicle. Refer to the following:

• | When removing the driver inflator module, refer to Driver Inflator Module removal procedure.

• | When removing the passenger inflator module, refer to Passenger Inflator module removal procedure.

• | When removing a curtain inflator module, refer to Curtain Inflator Module removal procedure in this service manual.

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

5. Temporarily place the inflator module, with the vinyl trim cover facing up and away from the surface, on a work bench or other surface away from all loose or flammable objects.
6. Select a paved outdoor location to perform deployment. Clear a space on the floor and make certain no loose objects or flammable material are within 4.6 m (15 ft) of the inflator module. Make sure you have sufficient ventilation.
7. When deploying a driver inflator module, place the inflator module in the center of the space with the vinyl trim cover facing up.
8. When deploying a passenger inflator module, refer to the following instructions:

• | Place the SA9413NE in the center of the cleared area.

• | Fill plastic reservoir in deployment fixture with water or sand to provide sufficient stabilization of fixture during deployment.

• | Attach curtain inflator module in the deployment fixture using the Flange/Arm Mounting Method shown in the illustration.

Important: Securely hand-tighten all fasteners prior to deployment.

9. Inspect the SA9207Z-A and the appropriate pigtail adapter, SA9414Z-99 for the driver air bag or SIR Deployment Adapter SA9207Z for the passenger air bag or curtain air bag, for damage. Replace as needed.
10. Short the two Universal SIR Deployment leads (2) together by fully seating one banana plug into the other, The Universal SIR Deployment Harness shall remain shorted and shall not be connected to a power source until the air bag is to be deployed.
11. Connect the appropriate pigtail adapter (1) to the Universal SIR Deployment Harness (2).

Important: Make sure that the adapter connector is fully seated into the inflator module connector. Failure to fully seat connectors may leave the shorting bar located in the inflator module connector active and may result in non-deployment of inflator module.

12. Extend the SIR deployment harness and adapter to full length from the deployment fixture or area.
13. Connect the inflator module (1) to the adapter (2) on the SIR deployment harness.
14. Verify the driver inflator module is resting with its vinyl trim cover facing up or that the passenger inflator or curtain inflator is mounted properly to the deployment fixture.
15. Verify the area around the inflator module is clear of all people, loose objects, or flammable material.

Important: When deploying an inflator module, the rapid expansion of gas is very loud which may startle the uninformed. Notify the people in the immediate area that an inflator module will be deployed.

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

16. Separate the two banana plugs on the SIR deployment harness that were shorted together earlier in the procedure.
17. Place a 12 V minimum/2A minimum power source near the shorted end of the deployment harness. A vehicle battery is suggested.
18. Connect the SIR deployment harness wires to the power source. Inflator module deployment will occur when contact is made.
19. Disconnect the SIR deployment harness from the power source.
20. Short the two deployment harness leads together by fully seating one banana plug into the other.

Caution: Refer to SRS Inflator Module Deployment Caution in the Preface section.

21. In the unlikely event that the inflator module did not deploy after following this procedure, disconnect the pigtail adapter and discontinue the procedure. Temporarily store inflator module with its trim cover facing up, away from the surface on which it rests. Call the Saturn Technical Assistance Center for further instructions. If the inflator module did deploy, proceed to the following steps.
22. Put on a pair of shop gloves to protect your hands from possible irritation and heat when handling deployed inflator module. Safety glasses should also be worn to protect your eyes.
23. Disconnect the pigtail adapter from the inflator module as soon as possible after deployment to avoid the possibility of damage to the pigtail adapter or the deployment harness due to possible contact with the hot inflator module canister. The deployment harness is designed to be reused. It should, however, be inspected for damage after each deployment and be replaced if necessary. The pigtail adapter, SA9414Z-99 or SA9207Z-A , may become damaged because of high temperatures and should be discarded after deployment outside the vehicle.
24. Dispose of the deployed inflator module through normal refuse channels after it has cooled for at least 10 minutes.
25. Wash hands with a mild soap.