Part 2

Inflator Module Handling and Scrapping (cont.)




65. Twist together one connector wire lead to one deployment wire.




66. Bend flat the twisted connection.
67. Secure and insulate the connection using electrical tape.




68. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
69. Connect the deployment harness to the roof rail module yellow connector.




70. Route the deployment harness out of the driver side of the vehicle.
71. Remove the close out panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side (LHD) (Service and Repair) .
72. Remove the I/P compartment. Refer to Instrument Panel Compartment Replacement (LHD) (Service and Repair) .




73. Release the electrical connector retaining clip (1) and disconnect the electrical connector (2) from the air bag (3).




74. Release the electrical connector retaining clip (1) and disconnect the electrical connector (2) from the air bag (3).




75. If vehicle is equipped with dual stage air bags the I/P module will each have 4 wires. Refer to PSD SIE TITLE Error: SIE linked to empty Cell ID 57511 , for determining high and low circuits.
76. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
77. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.




78. 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.
79. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
80. Twist together one end from each of the wires in order to short the wires.




81. 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 PSD SIE TITLE Error: SIE linked to empty Cell ID 57511 , in order to determine the correct circuits.
82. Inspect that the 3-wire connection is secure.




83. Bend flat the twisted connection.




84. Secure and insulate the 3-wire connection to deployment harness using electrical tape.




85. 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 PSD SIE TITLE Error: SIE linked to empty Cell ID 57511 , in order to determine the correct circuits.
86. Inspect that the 3-wire connection is secure.




87. Bend flat the twisted connection.




88. Secure and insulate the 3-wire connection to deployment harness using electrical tape.
89. Connect the deployment harness to the I/P module in-line connector.




90. Route the deployment harness out of the passenger side of the vehicle.
91. Remove the front seat outer rear adjuster cover. Refer to Driver or Passenger Seat Outer Adjuster Rear Finish Cover Replacement (Driver or Passenger Seat Outer Adjuster Rear Finish Cover Replacement) .
92. Remove the front seat outer front adjuster cover. Refer to Driver or Passenger Seat Outer Adjuster Front Finish Cover Replacement (Driver or Passenger Seat Outer Adjuster Front Finish Cover Replacement) .




93. Detach the connector housing assembly (1) from the floor panel.
94. Detach the passenger side air bag/pretensioner yellow connector (3 and 4) from the connector housing assembly (2).
95. Disconnect the passenger side air bag/pretensioner yellow connector (3) from the vehicle harness yellow connector (4).
96. Cut the yellow harness connector wires (2 for side air bag and 2 for pretensioner) leading to the yellow harness connector (4) from the vehicle, leaving at least 16 cm (6 in) of wire at the connector.




97. Strip 13 mm (0.5 in) of insulation from all 4 SIR wires connector leads (2 for side air bag and 2 for pretensioner).




98. 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.
99. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
100. 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.




101. 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 (Connector Views) , in order to determine the correct circuits.
102. Inspect that the 3-wire connection is secure.




103. Bend flat the twisted connection.




104. Secure and insulate the 3-wire connection to deployment harness using electrical tape.




105. Twist together 2 connector wire leads (the low circuits from side air bag and pretensioner) to one sets of deployment wires. Refer to PSD SIE TITLE Error: SIE linked to empty Cell ID 57511 , in order to determine the correct circuits.
106. Inspect that the 3-wire connection is secure.




107. Bend flat the twisted connection.




108. Secure and insulate the 3-wire connection to deployment harness using electrical tape.
109. Connect the deployment harness to the passenger side air bag/pretensioner yellow connector.




110. Route the deployment harness out of the passenger side of the vehicle.




111. Disconnect the driver side seat belt retractor pretensioner connector (1) from the vehicle harness connector (4).
112. Cut the harness connector leading to the harness connector (4) from the vehicle, leaving at least 16 cm (6 in) of wire at the connector.




113. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.




114. 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 seat belt retractor pretensioner deployment harness.
115. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
116. Twist together one end from each of the wires in order to short the wires.




117. Twist together one connector wire lead to one deployment wire.




118. Bend flat the twisted connection.
119. Secure and insulate the connection using electrical tape.




120. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
121. Connect the deployment harness to the seat belt retractor pretensioner connector.




122. Route the deployment harness out of the passenger side of the vehicle.




123. Disconnect the right/passenger roof rail yellow harness connector (1) from the right/roof rail air bag.




124. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
125. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.




126. 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.
127. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
128. Twist together one end from each of the wires in order to short the wires.




129. Twist together one connector wire lead to one deployment wire.




130. Bend flat the twisted connection.
131. Secure and insulate the connection using electrical tape.




132. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
133. Connect the deployment harness to the roof rail module yellow connector.




134. Route the deployment harness out of the passenger side of the vehicle.




135. Completely cover the windshield and front door window openings with a drop cloth.
136. Stretch out all of the deployment harness wires on the passenger side of the vehicle to their full length.
137. Deploy each deployment loop one at a time.
138. Place a power source, 12 V minimum/2 A minimum (i.e., a vehicle battery) near the shorted end of the harnesses.
139. 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.
140. Disconnect the deployment harness from the power source and twist the wire ends together.
141. Continue the same process with the remaining deployment harnesses that are available.




142. Stretch out all of the deployment harness wires on the driver side of the vehicle to their full length.
143. Deploy each deployment loop one at a time.
144. Place a power source, 12 V minimum/2 A minimum (i.e., a vehicle battery) near the shorted end of the harnesses.
145. 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.
146. Disconnect the deployment harness from the power source and twist the wire ends together.
147. Continue the same process with the remaining deployment harnesses that are available.
148. Remove the drop cloth from the vehicle.
149. Disconnect all harnesses from the vehicle.
150. Discard the harnesses.
151. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
152. If one or all of the inflator modules did not deploy, perform the following steps to remove the undeployed module(s) from the vehicle:

* Steering Wheel Inflatable Restraint Module Replacement (Service and Repair) .
* Instrument Panel Inflatable Restraint Module Replacement (Service and Repair) .
* Driver or Passenger Seat Side Inflatable Restraint Module Replacement (Service and Repair) .
* Inflatable Restraint Roof Side Rail Module Replacement (Service and Repair) .




Deployment Procedure - (Out Of Vehicle)

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