GM Service Manual Online
For 1990-2009 cars only

Live and Undeployed Inflator Module

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.


Object Number: 9039  Size: SH

Take special care when handling 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.

Dual Stage Inflator Module

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

Scrapping Procedure

During the course of a vehicle's useful life, certain situations may arise which will require the disposal of a live and undeployed inflator module. Do not dispose a live and undeployed inflator module through normal disposal channels until the inflator module has been deployed. If scrapping a deployed dual stage inflator module, both stages must be energized. The following information covers the proper procedures for the disposing of a live and 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, GM1241, related to the SIR or seat belt system. When a vehicle is the subject of 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 Outside Vehicle - Steering Wheel Module, IP Module, and Side Impact Module

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, 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: 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.

Tools Required

    • J 38826 SIR Deployment Harness
    • J 39401-B Deployment Fixture
    • J 38826-25 Side Impact Module Adapter
    • J 38826-75 Steering Wheel Module Adapter (Dual Stage Air Bags)
    • J 38826-80 IP Module Adapter (Dual Stage Air Bags)
  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. • If the steering wheel module did not deploy, refer to Inflatable Restraint Steering Wheel Module Replacement .
    • If the IP module did not deploy, refer to Inflatable Restraint Instrument Panel Module Replacement .
    • If the side impact module - LF did not deploy, refer to Inflatable Restraint Side Impact Module Replacement - Left Side .
    • If the side impact module -- RF did not deploy, refer to Inflatable Restraint Side Impact Module Replacement - Right Side .

    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.

  7. Object Number: 68646  Size: SH
  8. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the inflator module or deployment fixture. If possible, use a paved, outdoor location free of activity. Otherwise, use a space 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 air bags deployments are only used in steering wheel and IP inflator modules, if the vehicle is equipped. If stage 1 was use to deploy a dual stage 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. If you have a steering wheel inflator module, place the inflator module in the center of the space.

  12. Object Number: 453892  Size: SH
  13. If you have an IP inflator module, refer to the following instructions:
  14. • Place the J 39401-B SIR deployment fixture (2) in the center of the cleared area.
    • Fill the deployment fixture with water or sand.
    • Using the proper nuts and bolts, mount the IP module (1) to the deployment fixture (2), with the vinyl trim facing up.
    • Tighten all fasteners that hold the IP module (1) to the deployment fixture (2).

    Object Number: 483663  Size: SH
  15. If you have a side impact module, refer to the following instructions:
  16. • Place the J 39401-B SIR deployment fixture (3) in the center of the cleared area.
    • Fill the deployment fixture with water or sand.
    • Using the proper nuts and mount the side impact module (1) to the deployment fixture (3), with the vinyl trim facing up.
    • Adjust and secure the fixture arms (4) to the deployment fixture (3).
    • Tighten all fasteners that hold the side impact module (1) to the deployment fixture (3).

    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 leads (1) together using one banana plug seated into the other.
  19. Important: Refer to Tools Required list for the correct adapter.

  20. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1).

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

  23. Object Number: 68656  Size: SH

    Important: On the steering wheel dual stage inflator module both connectors must be attached to the deployment harness adapter. This will ensure that both stage 1 and stage 2 of the deployment loops are energized, regardless of the deployment state.

  24. Connect the inflator module to the adapter (2) on the SIR deployment harness (1).
  25. Place a 12 V minimum/2 A minimum power source (i.e., vehicle battery) near the shorted end of the harness.
  26. Important: 

       • The rapid expansion of gas involved with deploying an inflator module is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module.
       • When the inflator module deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of the inflator module due to the force of the rapid expansion of gas inside the inflator module.
       • If you are deploying a dual stage inflator module with stage 1 already deployed, the fixture may not move and the noise may have been reduced.

  27. Clear the area of people.

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

  30. Object Number: 39388  Size: SH
  31. Connect the SIR deployment harness wires to the power source. Inflator module deployment will occur when contact is made.

  32. Object Number: 9581  Size: SH
  33. Disconnect the SIR deployment harness from the power source after the inflator module deploys.
  34. If the inflator module did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps.
  35. 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.

  36. Seat one banana plug into the other in order to short the deployment harness leads.

  37. Object Number: 9433  Size: SH
  38. Put on a pair of shop gloves.
  39. Disconnect the pigtail adapter from the inflator module as soon as possible.
  40. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed.
  41. Dispose of the deployed inflator module through normal refuse channels.
  42. Wash hands with a mild soap.

Deployment Inside Vehicle - Vehicle Scrapping Procedure

Deploy the 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: 628317  Size: SH
  1. Turn the ignition switch to the OFF position.
  2. Remove the ignition key.
  3. Put on safety glasses.
  4. Remove all loose objects from the front seats.
  5. Disable the SIR system. Refer to Disabling the SIR System .
  6. Caution: A deployed dual stage inflator module will look the same whether one or both stages were used, always assume a deployed dual stage inflator module has an active stage 2. Improper handling or servicing can activate the inflator module and cause personal injury.

  7. Disconnect the inflatable restraint steering wheel module yellow connector (4) located next to steering column (2).

  8. Object Number: 566915  Size: MH

    Important: If vehicle is equipped with dual stage air bags the steering wheel module and IP module will each have 4 wires and standard air bags will only have 2 wires. Refer to SIR Connector End Views for determining high and low circuits.

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

  11. Object Number: 68651  Size: SH
  12. 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 driver deployment harness.
  13. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
  14. 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.

  15. Object Number: 566918  Size: SH
  16. Twist together the two connector wire leads of the high circuits from both stages of the IP module to one of the deployment harness wires. Refer to SIR Connector End Views in order to determine the correct circuits.
  17. Inspect that the 3 wire connection is secure.

  18. Object Number: 566922  Size: SH
  19. Bend flat the twisted connection.

  20. Object Number: 566927  Size: SH
  21. Secure and insulate the 3 wire connection to deployment harness using electrical tape.

  22. Object Number: 566932  Size: SH
  23. Twist together 2 connector wire leads of the low circuits from both stages of the steering wheel module to one sets of deployment wires. Refer to SIR Connector End Views in order to determine the correct circuits.
  24. Inspect that the 3 wire connection is secure.

  25. Object Number: 566936  Size: SH
  26. Bend flat the twisted connection.

  27. Object Number: 566942  Size: SH
  28. Secure and insulate the 3 wire connection to deployment harness using electrical tape.

  29. Object Number: 628317  Size: SH
  30. Connect the deployment harness to the steering wheel module in-line connector.

  31. Object Number: 260613  Size: SH
  32. Route the deployment harness out of the driver side of the vehicle.

  33. Object Number: 628320  Size: SH
  34. Disconnect the driver side impact module yellow connector (1) from the vehicle wiring harness (4) located under the driver seat.

  35. Object Number: 68649  Size: SH
  36. Cut the 2 side impact module wires leading to the yellow harness connector, leaving at least 16 cm (6 in) of wire at the connector.
  37. Strip 13 mm (0.5 in) of insulation from each of the side impact module connector wire leads.

  38. Object Number: 68651  Size: SH
  39. 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.
  40. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
  41. 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 side impact module.

  42. Object Number: 39393  Size: SH
  43. Twist together 1 connector wire lead to one deployment wire.
  44. Inspect that the previous connection is secure.

  45. Object Number: 39408  Size: SH
  46. Bend flat the twisted connection.
  47. Secure and insulate the connection using electrical tape.

  48. Object Number: 39414  Size: SH
  49. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
  50. Connect the deployment harness to the side impact module - LF.

  51. Object Number: 260613  Size: SH
  52. Route the deployment harness out of the driver side of the vehicle.

  53. Object Number: 262989  Size: SH
  54. Disconnect the IP module yellow harness connector (2) above passenger side sound insulator.

  55. Object Number: 566915  Size: MH

    Important: If vehicle is equipped with dual stage air bags the IP module will each have 4 wires and standard air bags will only have 2 wires. Refer to SIR Connector End Views for determining high and low circuits.

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

  58. Object Number: 68651  Size: SH
  59. 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.
  60. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
  61. Twist together one end from each of the wires in order to short the wires.

  62. Object Number: 566918  Size: SH
  63. Twist together the two connector wire leads of the high circuits from both stages of the IP module to one of the deployment harness wires. Refer to SIR Connector End Views in order to determine the correct circuits.
  64. Inspect that the 3 wire connection is secure.

  65. Object Number: 566922  Size: SH
  66. Bend flat the twisted connection.

  67. Object Number: 566927  Size: SH
  68. Secure and insulate the 3 wire connection to deployment harness using electrical tape.

  69. Object Number: 566932  Size: SH
  70. Twist together the two connector wire leads of the low circuits from both stages of the IP module to the deployment harness wire. Refer to SIR Connector End Views in order to determine the correct circuits.
  71. Inspect that the 3 wire connection is secure.

  72. Object Number: 566936  Size: SH
  73. Bend flat the twisted connection.

  74. Object Number: 566942  Size: SH
  75. Secure and insulate the 3 wire connection to deployment harness using electrical tape.
  76. Connect the deployment harness to the IP module in-line connector.

  77. Object Number: 260615  Size: SH
  78. Route the deployment harness out of the passenger side of the vehicle.

  79. Object Number: 628324  Size: SH
  80. Disconnect the passenger side impact module yellow connector (1) from the vehicle wiring harness (4) located under the passenger seat.

  81. Object Number: 68649  Size: SH
  82. Cut the two side impact module wires leading to the yellow harness connector, leaving at least 16 cm (6 in) of wire at the connector.
  83. Strip 13 mm (0.5 in) of insulation from each of the side impact module connector wire leads.

  84. Object Number: 68651  Size: SH
  85. 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.
  86. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
  87. 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.

  88. Object Number: 68652  Size: SH
  89. Twist together one connector wire lead to one deployment wire.
  90. Inspect that the previous connection is secure.

  91. Object Number: 68660  Size: SH
  92. Bend flat the twisted connection.
  93. Secure and insulate the connection using electrical tape.

  94. Object Number: 68662  Size: SH
  95. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
  96. Connect the deployment harness to the side impact module - RF.

  97. Object Number: 260615  Size: SH
  98. Route the deployment harness out of the passenger side of the vehicle.
  99. Completely cover the windshield and front door window openings with a drop cloth.
  100. Stretch out all of the deployment harness wires on the left and right side of the vehicle to their full length.
  101. Deploy each deployment loop one at a time.
  102. Place a power source, 12 V minimum/2 A minimum, i.e., a vehicle battery, near the shorted end of the harnesses.
  103. 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.
  104. Disconnect the deployment harness from the power source and twist the wire ends together.
  105. Continue the same process with the remaining deployment harnesses that are available.
  106. Remove the drop cloth from the vehicle.
  107. Disconnect all harnesses from the vehicle.
  108. Discard the harnesses.
  109. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
  110. If one or all of the inflator modules did not deploy, perform the following steps to remove the undeployed module(s) from the vehicle:
  111. • If the steering wheel module did not deploy, refer to Inflatable Restraint Steering Wheel Module Replacement .
    • If the IP module did not deploy, refer to Inflatable Restraint Instrument Panel Module Replacement .
    • If the side impact module - LF did not deploy, refer to Inflatable Restraint Side Impact Module Replacement - Left Side .
    • If the side impact module -- RF did not deploy, refer to Inflatable Restraint Side Impact Module Replacement - Right Side .
  112. Call Technical Assistance Group.