GM Service Manual Online
For 1990-2009 cars only

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

Live (Undeployed) Inflator Modules


Object Number: 9039  Size: SH

Use special care when handling or storing live (undeployed) inflator modules. 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 Procedures

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 disposing of a live (undeployed) inflator module.

Do not deploy an 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 (GM-1241) related to the SIR system. When a vehicle is the subject of a product liability report, do not alter the SIR 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

Inflator modules 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 Outside Vehicle-IP Module, and Steering Wheel Module

Deploy inflator modules 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, you determine 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.

Caution: Refer to SIR Inflator Module Disposal Caution in the Preface section.

Tools Required

    • J 38826 SIR Deployment Harness
    • J 39401-B SIR Deployment Fixture
    • An appropriate pigtail adaptor
  1. Turn OFF the ignition.
  2. Remove the ignition key.
  3. Put on safety glasses.
  4. Remove the inflator module. Refer to the following:
  5. • When removing the steering wheel module, refer to Inflatable Restraint Steering Wheel Module Replacement .
    • When removing the IP module, refer to Inflatable Restraint Instrument Panel Module Replacement .

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


    Object Number: 9427  Size: SH
  6. Place the inflator module with the vinyl trim cover facing up and away from the surface on a work bench, floor or deployment fixture.

  7. Object Number: 68646  Size: SH
  8. Clear an area on the floor approximately 1.85 m (6 ft) in diameter for deployment of the inflator module. If possible, use a paved, outdoor location free of activity. Otherwise, use an area free of activity on the shop floor. Make sure you have sufficient ventilation.
  9. Make sure no loose or flammable objects are in the area.
  10. When deploying a steering wheel module, place the steering wheel module in the center of the cleared area.

  11. Object Number: 453892  Size: SH
  12. When deploying an IP module, refer to the following instructions:
  13. • Place the J 39401-B  (2) in the center of the cleared area.
    • Fill the deployment fixture (2) with water or sand.
    • Mount the IP module (1) in the deployment fixture (2) with the vinyl/plastic trim facing up.
    • To mount, use 4 M 6 bolts (6), nuts (8), and washers (7) to properly secure the IP module (1) to the deployment fixture (2).
    • Tighten all fasteners prior to deployment.

    Object Number: 68645  Size: SH
  14. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed.
  15. Short the 2 SIR deployment harness (1) leads together using one banana plug seated into the other.
  16. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1).

  17. Object Number: 68655  Size: SH
  18. Extend the SIR deployment harness and adapter to full length from the deployment fixture.

  19. Object Number: 68656  Size: SH
  20. Connect the inflator module (1) to the adapter (2) on the SIR deployment harness (3).
  21. Important: 

       • The rapid expansion of gas involved with deploying an inflator module is very loud. Notify all people in the immediate area that an inflator module will be deployed.
       • When the inflator module deploys, the deployment fixture may jump vertically. This is a normal reaction of the inflator module due to the force of the rapid expansion of gas inside the inflator module.

  22. Clear the area of people.

  23. Object Number: 39382  Size: SH
  24. Separate the 2 banana plugs on the SIR deployment harness.

  25. Object Number: 39388  Size: SH
  26. Place a 12 V minimum/2 A minimum power source, i.e. vehicle battery, near the shorted end of the SIR deployment harness.
  27. Connect the SIR deployment harness wires to the power source. Inflator module deployment will occur when contact is made.
  28. Disconnect the SIR deployment harness from the power source.
  29. Caution: Refer to SIR Deployed Inflator Modules Are Hot Caution in the Preface section.


    Object Number: 9581  Size: SH
  30. Seat 1 banana plug into the other in order to short the deployment harness leads.
  31. If the inflator module did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group for further assistance. Otherwise, proceed to the following steps.

  32. Object Number: 9433  Size: SH
  33. Put on a pair of shop gloves.
  34. Disconnect the pigtail adapter from the inflator module as soon as possible.
  35. Dispose of the deployed inflator module through normal refuse channels.
  36. Wash hands with a mild soap.

Deployment Inside Vehicle-Vehicle Scrapping Procedures

Deploy 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.

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


    Object Number: 190000  Size: SH
  1. Turn OFF the ignition.
  2. Remove the ignition key.
  3. Put on safety glasses.
  4. Remove all loose objects from the front seats.
  5. Disconnect the inflatable restraint steering wheel module connector (2) located next to the steering column.

  6. Object Number: 39392  Size: SH
  7. Cut the steering wheel module harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
  8. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.

  9. Object Number: 68651  Size: SH
  10. Cut 2 6.1 m (15 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. Use these wires to fabricate the 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 1 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. Object Number: 39393  Size: SH
  14. Twist together 1 connector wire lead to 1 deployment wire.
  15. Inspect that the previous connection is secure.

  16. Object Number: 39408  Size: SH
  17. Bend flat the twisted connection.
  18. Secure and insulate the connection using electrical tape.

  19. Object Number: 39414  Size: SH
  20. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
  21. Connect the deployment harness to the steering wheel module connector.

  22. Object Number: 188444  Size: SH
  23. Route the deployment harness out of the vehicle's driver side.

  24. Object Number: 398308  Size: SH
  25. Disconnect the inflatable restraint IP module connector (1) located behind the main IP support. Access the connector by opening the glove box and pressing in on the sides. This will allow the glove box to extend beyond the stops and to fully open. The IP module connector will be attached to the main IP support.

  26. Object Number: 39392  Size: SH
  27. Cut the IP module harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
  28. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.

  29. Object Number: 68651  Size: SH
  30. Cut 2 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 deployment harness.
  31. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
  32. Twist together 1 end from each of the wires in order to short the wires.

  33. Object Number: 68652  Size: SH
  34. Twist together 1 connector wire lead to 1 deployment wire.

  35. Object Number: 68660  Size: SH
  36. Bend flat the twisted connection.
  37. Secure and insulate the connection using electrical tape.

  38. Object Number: 68662  Size: SH
  39. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
  40. Connect the deployment harness to the IP module connector.

  41. Object Number: 188440  Size: SH
  42. Route the deployment harness out of the vehicle's passenger side.
  43. Stretch the driver side harnesses to full length.
  44. Stretch the passenger side harnesses to full length.
  45. Completely cover the windshield and front door window openings with a drop cloth.

  46. Object Number: 188435  Size: SH
  47. Place a power source, 12 V minimum/2 A minimum, i.e., a vehicle battery, near the shorted ends of the passenger side deployment harnesses.
  48. Separate the 2 ends of the IP module deployment harness wires.
  49. Connect the IP module deployment harness wires to the power source in order to deploy the IP module.
  50. Disconnect the IP module deployment harness wires from the power source.

  51. Object Number: 188440  Size: SH
  52. Twist together 1 end of each wire of the IP module on the passenger side deployment harness in order to short the wires.

  53. Object Number: 188442  Size: SH
  54. Move the power source, 12 V minimum/2 A minimum , i.e., a vehicle battery, near the shorted ends of the driver side deployment harnesses.
  55. Separate the 2 ends of the steering wheel module deployment harness wires.
  56. Connect the steering wheel module deployment harness wires to the power source in order to deploy the steering wheel module.
  57. Disconnect the steering wheel module deployment harness wires from the power source.

  58. Object Number: 188444  Size: SH
  59. Twist together 1 end of each wire of the steering wheel module on the driver side deployment harness in order to short the wires.
  60. Remove the drop cloth from the vehicle.
  61. Disconnect all harnesses from the vehicle.
  62. Discard the harnesses.
  63. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
  64. If 1 or all of the inflator modules did not deploy, perform the following steps to remove the undeployed module(s) from the vehicle:
  65. •  Inflatable Restraint Steering Wheel Module Replacement
    •  Inflatable Restraint Instrument Panel Module Replacement
  66. Contact the Technical Assistance Group for further assistance.