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.

Dual Stage Inflator Modules

Dual stage inflator modules have two deployment stages. If stage 1 was used to deploy the inflator module, stage 2 may still be active. Therefore, a deployed dual stage inflator module must be treated as an active module. If disposal of a deployed or undeployed dual stage module is required both deployment loops must be energized to deploy the air bag.

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, Side Impact 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
    • J 38826-75 Steering wheel module adapter
    • J 38826-80 IP module adapter
  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 .
    • When removing the side impact module, refer to Driver and Passenger Seat Side Inflatable Restraint Module Replacement .

    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. Important: Dual stage deployments are only used in steering wheel and IP inflator modules. If stage 1 was used to deploy the inflator module, stage 2 may still be active. If disposal of a deployed or undeployed dual stage module is required, both deployment loops must be energized to deploy the air bag.

  11. When deploying a steering wheel module, place the steering wheel module in the center of the cleared area.

  12. Object Number: 453892  Size: SH
  13. When deploying an IP module, refer to the following instructions:
  14. • 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: 483663  Size: SH
  15. When deploying a side impact module, refer to the following instructions:
  16. • Place the J 39401-B  (3) in the center of the cleared area.
    • Fill the deployment fixture (3) with water or sand.
    • Mount the side impact module (1) in the deployment fixture (3) with the vinyl/plastic trim facing up.
    • Adjust and secure the J 39401-B arms (4) to the deployment fixture (3).
    • To mount, use 2 M 6 x 1.0 nuts (2) with washers to secure the side impact module (1) to the deployment fixture arms (4).
    • Tighten all fasteners prior to deployment.

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

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

  22. Object Number: 68656  Size: SH
  23. Connect the inflator module (1) to the adapter (2) on the SIR deployment harness (3).
  24. 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.

  25. Clear the area of people.

  26. Object Number: 39382  Size: SH
  27. Separate the two banana plugs on the SIR deployment harness.

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


    Object Number: 9581  Size: SH
  33. Seat one banana plug into the other in order to short the deployment harness leads.
  34. 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.

  35. Object Number: 9433  Size: SH
  36. Put on a pair of shop gloves.
  37. Disconnect the pigtail adapter from the inflator module as soon as possible.
  38. Dispose of the deployed inflator module through normal refuse channels.
  39. 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: Refer to SIR Inflatable Module Deployment Outside Vehicle Caution in the Preface section.


    Object Number: 819731  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

    Important: This vehicle is equipped with dual stage air bags. The steering wheel module and I/P module will each have 4 wires. Refer to SIR Connector End Views for determining high and low circuits.

  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 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.
  11. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
  12. 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 inflator module.

  13. Object Number: 566918  Size: SH
  14. Twist together two connector wire leads, the high circuits from both stages of the steering wheel module, to one set of deployment wires. Refer to SIR Connector End Views in order to determine the correct circuits.
  15. Inspect that the connection is secure.

  16. Object Number: 566922  Size: SH
  17. Bend flat the twisted connection.

  18. Object Number: 566927  Size: SH
  19. Secure and insulate the connection using electrical tape.

  20. Object Number: 566932  Size: SH
  21. Twist together two connector wire leads, the low circuits from both stages of the steering wheel module, to one set of deployment wires. Refer to SIR Connector End Views in order to determine the correct circuits.
  22. Inspect that the connection is secure.

  23. Object Number: 566936  Size: SH
  24. Bend flat the twisted connection.

  25. Object Number: 566942  Size: SH
  26. Secure and insulate the connection using electrical tape.
  27. Connect the deployment harness to the steering wheel module connector.

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

  30. Object Number: 595705  Size: SH
  31. Disconnect the LF side impact module connector (1) from the vehicle wiring harness (2) located under the LF seat.

  32. Object Number: 39392  Size: SH
  33. Cut the LF side impact module harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
  34. Strip 13 mm (0.5 in) of insulation from each of the LF side impact module connector wire leads.

  35. Object Number: 68651  Size: SH
  36. Cut 2 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.
  37. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
  38. 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 impact module.

  39. Object Number: 142309  Size: SH
  40. Twist together one connector wire lead to one deployment wire.
  41. Inspect that the previous connection is secure.

  42. Object Number: 142310  Size: SH
  43. Bend flat the twisted connection.
  44. Secure and insulate the connection using electrical tape.

  45. Object Number: 142311  Size: SH
  46. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.

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

  49. Object Number: 748421  Size: SH
  50. Disconnect the inflatable restraint IP module connector (1) located behind the IP module (3).

  51. Object Number: 39392  Size: SH

    Important: This vehicle is equipped with dual stage air bags. The steering wheel module and IP module will each have 4 wires. Refer to SIR Connector End Views for determining high and low circuits.

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

  54. Object Number: 68651  Size: SH
  55. 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 deployment harness.
  56. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
  57. Twist together one end from each of the wires in order to short the wires.

  58. Object Number: 566918  Size: SH
  59. Twist together two connector wire leads, the high circuits from both stages of the IP module, to one set of deployment wires. Refer to SIR Connector End Views in order to determine the correct circuits.
  60. Inspect that the connection is secure.

  61. Object Number: 566922  Size: SH
  62. Bend flat the twisted connection.

  63. Object Number: 566927  Size: SH
  64. Secure and insulate the connection using electrical tape.

  65. Object Number: 566932  Size: SH
  66. Twist together two connector wire leads, the low circuits from both stages of the IP module, to one set of deployment wires. Refer to SIR Connector End Views in order to determine the correct circuits.
  67. Inspect that the connection is secure.

  68. Object Number: 566936  Size: SH
  69. Bend flat the twisted connection.

  70. Object Number: 566942  Size: SH
  71. Secure and insulate the connection using electrical tape.
  72. Connect the deployment harness to the IP module connector.

  73. Object Number: 188440  Size: SH
  74. Route the deployment harness out of the vehicle's passenger side.

  75. Object Number: 595705  Size: SH
  76. Disconnect the RF side impact module connector (1) from the vehicle wiring harness (2) located under the RF seat.

  77. Object Number: 39392  Size: SH
  78. Cut the RF side impact module harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
  79. Strip 13 mm (0.5 in) of insulation from each of the RF side impact module connector wire leads.

  80. Object Number: 68651  Size: SH
  81. 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.
  82. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
  83. 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.

  84. Object Number: 142309  Size: SH
  85. Twist together one connector wire lead to one deployment wire.
  86. Inspect that the previous connection is secure.

  87. Object Number: 142310  Size: SH
  88. Bend flat the twisted connection.
  89. Secure and insulate the connection using electrical tape.

  90. Object Number: 142311  Size: SH
  91. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.

  92. Object Number: 188440  Size: SH
  93. Route the deployment harness out of the vehicle's passenger side.
  94. Stretch the two driver side harnesses to full length.
  95. Stretch the two passenger side harnesses to full length.
  96. Completely cover the windshield and front door window openings with a drop cloth.

  97. Object Number: 188435  Size: SH
  98. 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.
  99. Separate the two ends of the IP module deployment harness wires.
  100. Connect the IP module deployment harness wires to the power source in order to deploy the IP module.
  101. Disconnect the IP module deployment harness wires from the power source.
  102. Separate the two ends of the RF side impact module deployment harness wires.
  103. Connect the RF side impact module deployment harness wires to the power source in order to deploy the RF side impact module.
  104. Disconnect the RF side impact module deployment harness wires from the power source.

  105. Object Number: 188440  Size: SH
  106. Twist together one end of each wire of the IP module on the passenger side deployment harness in order to short the wires.
  107. Twist together one end of each wire of the RF side impact module on the passenger side deployment harness in order to short the wires.

  108. Object Number: 188442  Size: SH
  109. 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.
  110. Separate the two ends of the steering wheel module deployment harness wires.
  111. Connect the steering wheel module deployment harness wires to the power source in order to deploy the steering wheel module.
  112. Disconnect the steering wheel module deployment harness wires from the power source.
  113. Separate the two ends of the LF side impact module deployment harness wires.
  114. Connect the LF side impact module deployment harness wires to the power source in order to deploy the side impact module.
  115. Disconnect the LF side impact module deployment harness wires from the power source.

  116. Object Number: 188444  Size: SH
  117. Twist together one end of each wire of the steering wheel module on the driver side deployment harness in order to short the wires.
  118. Twist together one end of each wire of the LF side impact module on the driver side deployment harness in order to short the wires.
  119. Remove the drop cloth from the vehicle.
  120. Disconnect all harnesses from the vehicle.
  121. Discard the harnesses.
  122. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
  123. If one or more of the inflator modules did not deploy, perform the following steps to remove the undeployed module(s) from the vehicle:
  124. •  Inflatable Restraint Steering Wheel Module Replacement
    •  Inflatable Restraint Instrument Panel Module Replacement
    •  Driver and Passenger Seat Side Inflatable Restraint Module Replacement
  125. Contact the Technical Assistance Group for further assistance.