For 1990-2009 cars

#### Tools Required

• | SA9413NE SIR Deployment Fixture

• | SA9207Z-A SIR Deployment Harness

• | SA9414Z-99 Driver's Air Bag Adapter

### Service Precautions

Caution: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs.

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/or storing a live, 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.

### Scrapping Procedure for 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.

During the course of a vehicle's useful life, certain situations may arise which will require the disposal of a live, undeployed, inflator module. Do not dispose of a live, undeployed, inflator module through normal disposal channels until the inflator module has been deployed. The following information covers the proper procedures for the disposing of a live, undeployed, inflator module.

DO NOT DEPLOY the inflator module in the following situations:

• | After replacement of an inflator module under warranty. The inflator module may need to be returned undeployed to the manufacturer.

• | If the vehicle is the subject of a Product Liability Report related to the SIR or seat belt system. When a vehicle is subject to a Product Liability report, DO NOT ALTER the SIR or seat belt system in any manner.

• | If the vehicle is involved in a campaign affecting the inflator modules. Follow the instructions in the Campaign Service Bulletin for proper SIR handling 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 Inside The Vehicle - Driver, Passenger, Left Curtain, and/or Right Curtain

Deployment inside 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.

• | 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 SIR components from another vehicle. Always replace SIR components with NEW COMPONENTS.

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

• | Wear safety glasses throughout the entire procedure

• | Select a deployment area clear of people, loose objects, or flammable material.

### Deployment Procedure

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

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

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

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

14. Stretch deployment harness wires from vehicle to their full length.
15. Verify that 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.

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

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

• | Wear safety glasses throughout the entire procedure

• | Select a deployment area clear of people, loose objects, or flammable material.

18. 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.
19. Dispose of the deployed inflator module through normal refuse channels after it has cooled for at least ten minutes.
20. Wash hands with a mild soap.
21. In the unlikely event that the inflator module did not deploy after following this procedure:

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

21.2. | Remove inflator module from vehicle. Refer to Inflatable Restraint Steering Wheel Module Replacement , Inflatable Restraint Instrument Panel Module Replacement , or Inflatable Restraint Roof Side Rail Module Replacement - Front .

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

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

### Deployment Outside The Vehicle (Driver, Passenger, And 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 SIR service precautions and proper inflator module handling.

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

• | Wear safety glasses throughout the entire procedure

• | Select a deployment area clear of people, loose objects, or flammable material.

### Deployment Procedure

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

• | When removing the driver inflator module, refer to Inflatable Restraint Steering Wheel Module Replacement .

• | When removing the passenger inflator module, refer to Inflatable Restraint Instrument Panel Module Replacement .

• | When removing a curtain inflator module, refer to Inflatable Restraint Roof Side Rail Module Replacement - Front .

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.
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 SIR Deployment Fixture 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 passenger inflator module in the deployment fixture using the Flange/Arm Mounting Method shown in illustration.

• | Securely hand-tighten all fasteners prior to deployment.

9. When deploying a curtain inflator impact module-front, 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 illustration.

• | Securely hand-tighten all fasteners prior to deployment.

10. Inspect the SA9207Z-A and the appropriate pigtail adapter, SA9414Z-99 Driver's Air Bag Adapter for the driver air bag or SA9207Z -A for the passenger air bag or curtain air bag, for damage. Replace as needed.
11. Short the 2 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.

Important: Make sure that the adapter connector is fully seated into 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. Connect the appropriate pigtail adapter (1) to the universal SIR deployment harness (2).
13. Extend the SIR deployment harness and adapter to full length from the deployment fixture or area.
14. Connect the inflator module (1) to the adapter (2) on the SIR deployment harness.
15. Verify 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.

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. Verify area around the inflator module is clear of all people, loose objects, or flammable material.
17. Separate the two banana plugs on the SIR deployment harness that were shorted together earlier in the procedure.
18. Place a 12V minimum/2A minimum power source near the shorted end of the deployment harness. A vehicle battery is suggested.
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.
21. Short the two deployment harness leads together by fully seating one banana plug into the other.

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.

22. 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.
23. 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.
24. 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 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 replaces if necessary. The pigtail adapter, SA9414Z-99 or SA9207Z-A , may become damaged because of high temperatures and should be discarded after deployment outside vehicle.
25. Dispose of the deployed inflator module through normal refuse channels after it has cooled for at least 10 minutes.
26. Wash hands with a mild soap.