steering ISUZU TF SERIES 2004 Workshop Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 21 of 4264
SUPPLEMENTAL RESTRAINT SYSTEM 9A-1
RESTRAINTS
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
SERVICING
PAGE
Service Precaution ............................................................................................................ 9A- 3
General Description ...................................................................................................... 9A- 4
Restraint Devices ..................................................................................................... 9A- 4
System Description .................................................................................................. 9A- 5
SRS Component And Wiring Location View ............................................................... 9A- 6
Component Description ............................................................................................... 9A- 8
SRS Control Unit ...................................................................................................... 9A- 8
"Air Bag" Warning Lamp.......................................................................................... 9A- 8
SRS Coil Assembly................................................................................................... 9A- 9
Air Bag Assemblies .................................................................................................. 9A- 9
Seat Belt with Pretensioner (If so equipped) ......................................................... 9A- 10
Steering Column ....................................................................................................... 9A- 10
Knee Bolster ............................................................................................................. 9A- 10
Definitions...................................................................................................................... 9A- 10
Diagnosis .......................................................................................................................9A- 12
Diagnostic Trouble Codes ....................................................................................... 9A- 12
Scan Tool Diagnostics ............................................................................................. 9A- 12
Use Of Special Tools ................................................................................................ 9A- 12
SRS Connector Body Face Views................................................................................ 9A- 13
Repairs And Inspections Required After An Accident ............................................... 9A- 14
Accident With Deployment-Component Replacement And Inspections ............. 9A- 14
Accident With or Without Deployment-Component Inspection ........................... 9A- 14
SRS Control Unit Replacement Guidelines ............................................................ 9A- 14
Wiring Damage ......................................................................................................... 9A- 14
SRS Connector (Plastic Body And Terminal Metal Pin) Damage ......................... 9A- 14
SRS Wire Pigtail Damage......................................................................................... 9A- 14
Page 23 of 4264
SUPPLEMENTAL RESTRAINT SYSTEM 9A-3
PAGE
Steering Wheel ................................................................................................................... 9A- 35
Service Precautions ...................................................................................................... 9A- 35
Removal .........................................................................................................................9A- 35
Installation ..................................................................................................................... 9A- 36
SRS Coil Assembly ............................................................................................................ 9A- 37
Service Precautions ...................................................................................................... 9A- 37
Removal. ........................................................................................................................9A- 37
Installation. .................................................................................................................... 9A- 38
Steering Column ................................................................................................................9A- 40
Service Precautions ...................................................................................................... 9A- 40
Removal .........................................................................................................................9A- 40
Installation ..................................................................................................................... 9A- 41
Passenger Air Bag Assembly ........................................................................................... 9A- 44
Service Precautions ...................................................................................................... 9A- 44
Removal .........................................................................................................................9A- 44
Installation ..................................................................................................................... 9A- 45
Pretensioner Seat Belt (If so quipped) ............................................................................. 9A- 46
Removal .........................................................................................................................9A- 46
Installation ..................................................................................................................... 9A- 46
Main Data and Specifications ........................................................................................... 9A- 47
Fastener Tightening Specification............................................................................... 9A- 47
Special Tools...................................................................................................................... 9A- 48
5-8840-2421-0 SRS Driver/Passenger Load Tool........................................................ 9A- 48
5-8840-0285-0 DVM........................................................................................................ 9A- 48
Scan Tool .......................................................................................................................9A- 48
5-8840-0385-0 Connector Test Adapter Kit ................................................................. 9A- 49
5-8840-2468-0 SRS Deployment Tool .......................................................................... 9A- 49
5-8840-2420-0 SRS Deployment Fixture ...................................................................... 9A- 49
5-8840-2796-0 SRS Adapter for Load Tool .................................................................. 9A- 49
5-8840-2795-0 SRS Adapter for Deployment Tool ...................................................... 9A- 50
5-8521-0016-0 Steering Wheel remover ...................................................................... 9A- 50
Page 24 of 4264
9A-4 SUPPLEMENTAL RESTRAINT SYSTEM
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE
TO FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS
SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners
or fastener joint interfaces. Generally, such
coatings adversely affect the fastener torque and
the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specifications.
Following these instructions can help you avoid
damage to parts and systems.
General Description
CAUTION: When fasteners are removed, always
reinstall them at the same location from which
they were removed. If a fastener needs to be
replaced, use the correct part number fastener fo
r
that application. If the correct part numbe
r
fastener is not available, a fastener of equal size
and strength (or stronger) may be used.
Fasteners that are not reused, and those requiring
thread locking compound will be called out. The
correct torque value must be used when installing
fasteners that require it. If the above conditions
are not followed, parts or system damage could
result.
Restraint Devices
827RW006
Legent
(1) Deployed Air Bag
(2) Knee Bolster
(3) Seat Belt
The Supplemental Restraint System (SRS) helps
supplement the protection offered by the driver and
front passenger seat belts by deploying an air bag
from the center of the steering wheel and from the
front of the passenger side of the instrument panel.
The air bag deploys when the vehicle is involved in a
frontal crash of sufficient force up to 30 degrees off the
centerline of the vehicle. To further absorb the crash
energy there is a knee bolster located beneath the
instrument panel for both the driver and passenger,
and the steering column is collapsible.
827RW005
Page 29 of 4264
SUPPLEMENTAL RESTRAINT SYSTEM 9A-9
060R300007
SRS Coil Assembly
The SRS coil assembly consists of two current
carrying coils. This is attached to the steering column
and allow rotation of the steering wheel while
maintaining continuous contact of the driver
deployment loop to the driver air bag assembly.
There is a shorting clip on the yellow connector near
the base of steering column which connects the SRS
coil to the SRS wiring harness.
The shorting clip shorts to the SRS coil and driver air
bag assembly when the yellow connector is
disconnected. The circuit to the driver air bag
assembly is shorted in this way to help prevent
unwanted deployment of the air bag when servicing
the steering column or other SRS components.
060R300047
Air Bag Assemblies
The air bag assembly consist of an inflatable air bag
assembly and an inflator. When the vehicle is in a
frontal crash of sufficient force.
The SRS control unit causes current flow through the
deployment loops. Current passing through the inflator
ignites the material in the air bag assembly. The gas
produced from this reaction rapidly inflates the air bag
assembly.
There is a shorting clip on the driver air bag assembly
connector which connects the SRS coil assembly. The
shorting clip shorts across the driver air bag assembly
circuits when driver air bag assembly connector is
disconnected.
The circuit to the driver air bag assembly is shorted in
this way to help prevent unwanted deployment of the
air bag when servicing the driver air bag assembly, the
steering column or other SRS components.
060R300012
There is a shorting clip on the passenger air bag
assembly connector which connects to the SRS
harness. The shorting clip shorts across the
passenger air bag assembly circuit when the
passenger air bag assembly connector is
disconnected. The circuit to the passenger air bag
assembly is shorted in this way to help prevent
unwanted deployment of the air bag when servicing
the passenger air bag assembly, the instrument panel
or other SRS components.
Page 30 of 4264
9A-10 SUPPLEMENTAL RESTRAINT SYSTEM
060R300013
Seat Belt with Pretensioner (If so
equipped)
The seat belt comprises a seat belt and a cylinder (a
cylinder filled with powder and an ignition device). In
cases of frontal collision which cause a shock
exceeding a specified level, the controller lets current
flow to the inflation circuit. The current ignites the
cylinder of the seat belt, producing gas. The gas helps
tighten the seat belt to restrain firmly the driver’s upper
half in his seat.
RTW49JSH000201
Steering Column
The steering column absorbs energy and is designed
to compress in a frontal crash to decrease the chance
of injury to the driver.
060R300038
Knee Bolster
The knee bolsters are used to absorb energy to
protect knees and control the forward movement of
the vehicle's front seat occupants during a frontal
crash, by limiting leg movement.
Definitions
Air Bag
An inflatable cloth cushion designed to deploy in
certain frontal crashes. It supplements the protection
offered by the seat belts by distributing the impact load
more evenly over the vehicle occupant's head and
torso.
Asynchronous
Performed in a nonperiodic fashion, (i.e., no defined
time or interval).
B+
Battery voltage, (B+) The voltage available at the
battery at the time of the indicated measurement.
With the key “ON” and the engine not running, the
system voltage will likely be between 12 and 12.5
volts. At idle, the voltage may be 14 to 16 volts. The
voltage could be as low as 10 volts during engine
cranking.
Bulb Check
The SRS control unit will cause the “AIR BAG” warning
lamp to flash seven times and then go “OFF”
whenever the ignition switch transitions to the ON
position from any other ignition switch position and no
malfunctions are detected.
Page 31 of 4264
SUPPLEMENTAL RESTRAINT SYSTEM 9A-11
“Continuous Monitoring”
Tests performed by the SRS control unit on the SRS
every 100 milliseconds while “Ignition 1” voltage is in
the normal operating voltage range at the SRS control
unit.
Data Link Connector (DLC)
Formerly “DLC” a connector which allows
communication with an external computer, such as a
scan tool.
Datum Line
A base line parallel to the plane of the underbody or
frame from which all vertical measurements originate.
Deploy
To inflate the air bag.
Deployment Loops
The circuits which supply current to the air bag
assemblies to deploy the air bag.
Diagnostic Trouble Code (DTC)
Formerly “Code”, a numerical designator used by the
SRS control unit to indicate specific SRS malfunctions.
Driver Current Source
An output of the SRS control unit which applies current
into the driver air bag assembly circuit during the
“Initiator Assembly Resistance Test”.
“Initiator Assembly Resistance Test”
Tests performed once each ignition cycle when no
malfunctions are detected during “Turn–ON” or
“Continuous Monitoring”. This test checks for the
correct SRS control unit configuration for the vehicle,
shorts to “Ignition 1” in the deployment loops, high
resistance or opens in the “Driver Side” and
“Passenger Side” circuits and measures the resistance
of the inflator assembly consisting of 1) Initiators, 2)
SRS coil assembly (driver side only), 3) Connectors
and associated wiring.
Normal Operating Voltage Range
The voltage measured between the SRS control unit
“Ignition 1” terminals and “Ground” terminals is
between 9 and 16 volts.
Passenger Current Source
An output of the SRS control unit which applies current
into the passenger air bag assembly circuit during the
“Initiator Assembly Resistance Test”.
Passenger Air Bag Assembly
An assembly located in the front of the passenger side
of the instrument panel consisting of an inflatable bag,
an inflator and an initiator.
Scan Tool
An external computer used to read diagnostic
information from on–board computers via the data link
connector.
SRS control unit
SRS control unit which provides reserve energy to the
deployment loops, deploys the air bags when required
and performs diagnostic monitoring of all SRS
components.
Serial Data
Information representing the status of the SRS.
SRS
Supplemental Restraint System.
SRS Coil Assembly
An assembly of two current–carrying coils in the driver
deployment loop that allows the rotation of the steering
wheel while maintaining the continuous contact of the
driver deployment loop to the driver air bag assembly.
SRS Wiring Harness
The wires and connectors that electrically connect the
components in the SRS.
“Turn–ON”
Test which the SRS control unit performs on the SRS
once during each ignition cycle immediately after
“Ignition 1” voltage is applied to the SRS control unit
and before “Continuous Monitoring”.
Page 34 of 4264
9A-14 SUPPLEMENTAL RESTRAINT SYSTEM
Repairs And Inspections Required
After An Accident
If any SRS components are damaged, they must be
replaced. If SRS component mounting points are
damaged, they must be replaced.
Never use SRS parts from another vehicle. This
does not include remanufactured parts purchased
from an authorized dealer; they may be used fo
r
SRS repairs.
Do not attempt to service the SRS control unit, the
SRS coil assembly, or the air bag assembly.
Service of these items is by replacement only.
Verify the part number of replacement air bag
assembly.
CAUTION: Never use the air bag assembly from
another vehicle and difference model year air bag
assembly.
Use only new air bag assembly proper to the
TFR/S which is being repaired.
CAUTION: Proper operation of the sensors and
supplemental restraint system (SRS) requires that
any repairs to the vehicle structure return it to the
original production configuration. Deployment
requires, at a minimum, replacement of the SRS
control unit, air bag assembly and dimensional
inspection of the steering column. Any visible
damage to the SRS control unit mounting bracket
(s) requires replacement, and the steering column
must be dimensionally inspected, whethe
r
deployment occurred or not.
Accident With Deployment – Component
Replacement And Inspections
Certain SRS components must be replaced or
inspected for damage after a frontal crash involving air
bag deployment. Those components are:
Air bag assembly
SRS control unit
CAUTION: Refer to “SRS control unit
Replacement Guidelines” below for important
information on SRS control unit replacement in
both deployment and non deployment crashes.
SRS coil assembly — Inspect wiring and connecto
r
for any signs of scorching, melting, or damage due
to excessive heat. Replace if damaged. Refer to
section “SRS Coil Assembly” in this manual.
Accident With or Without Deployment –
Component Inspection
Certain SRS system components and rotation parts
must be inspected after any crash, whether the air bag
deployed or not. Those components are:
Steering column —Refer to Inspection Required
“After an Accident” in this manual.
Knee bolsters and mounting points —Inspect fo
r
any distortion, bending, cracking, or other damage.
I/P steering column reinforcement plate —Inspect
for any distortion, bending, cracking, or othe
r
damage.
I/P braces —Inspect for any distortion, bending,
cracking, or other damage.
Seat belts and mounting points — Refer to “Seat
Belts” in Section “Seat Belt” of this workshop
manual.
SRS Control Unit Replacement Guidelines
SRS control unit replacement policy requires
replacement of SRS control unit, after crash involving
air bag deployment when “SRS Warning Lamp” turn
“ON”, “SRS Diagnosis” should be done according to
Section “Restraint Control System.”
Wiring Damage
If any SRS wire harness is damaged, it should be
replaced. Don't repair SRS harness. It is replace only.
SRS Connector (Plastic Body And
Terminal Metal Pin) Damage
If any connector or terminal in the SRS wire harness
(except pigtails) is damaged, it should be replaced.
SRS Wire Pigtail Damage
If the wiring pigtail (a wire or wires attached directly to
the device, not by a connector) is damaged, the entire
component (with pigtail) must be replaced. Examples
of “pigtail” components are the driver air bag
assembly, the passenger air bag assembly, and the
SRS coil assembly.
Page 35 of 4264
SUPPLEMENTAL RESTRAINT SYSTEM 9A-15
On–Vehicle Service
Service Precaution
WARNING: WHEN PERFORMING SERVICE ON OR
AROUND SRS COMPONENTS OR SRS WIRING,
FOLLOW THE PROCEDURES LISTED BELOW TO
TEMPORARILY DISABLE THE SRS. FAILURE TO
FOLLOW PROCEDURES COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY OR OTHERWISE UNNEEDED SRS
REPAIRS.
The SRS control unit in Driver–Passenger SRS can
maintain sufficient voltage to cause a deployment for
up to 15 seconds after the ignition switch is turned
“OFF,” the battery is disconnected, or the fuse
powering the SRS control unit is removed.
Many of the service procedures require removal of the
“SRS” fuse, and disconnection of the air bag assembly
from the deployment loop to avoid an accidental
deployment. If the air bag assembly is disconnected
from the deployment loop as noted in the “Disabling
the SRS” procedure that follows, service can begin
immediately without waiting for the 15 second time
period to expire.
Disabling The SRS
Removal
Turn the ignition switch to “LOCK” and remove key.
1. Remove SRS fuse “SRS”, from the side of the
driver side of instrument panel fuse block o
r
disconnect battery.
2. Disconnect yellow connector at the base o
f
steering column.
3. Remove glove box assembly, refer to “Passenge
r
Air Bag Assembly Replacement” in this manual.
4. Disconnect yellow connector behind the glove box
assembly.
CAUTION: With the “SRS” fuse removed and
ignition switch “ON”, the “AIR BAG” warning lamp
will be “ON”. This is normal operation and does
not indicate an SRS malfunction.
Enabling The SRS
Installation
CAUTION: Never use the air bag assembly from
another vehicle and difference model year air bag
assembly.
Use only new air bag assembly proper to the
TFR/S which is being repaired.
Turn ignition switch to “LOCK” and remove key.
1. Connect yellow connector passenger air bag
assembly.
2. Install glove box assembly. Refer to “Passenger ai
r
bag assembly replacement” in this manual.
3. Connect yellow connector at the base of steering
column.
4. Install “AIR BAG” fuse “SRS” to the side of the
driver side of instrument panel fuse block o
r
connect battery.
Turn ignition switch to “ON” and verify that the “AIR
BAG” warning lamp flashes seven times and then
turns “OFF.” If it does not operate as described,
perform the “SRS Diagnostic System Check” in this
manual.
Handling / Installation / Diagnosis
1. Air bag assembly should not be subjected to
temperatures above 65
C (150F).
2.
Air bag assembly, and SRS control unit should not
be used if they have been dropped from a height
of 100 centimeters (3.28 feet) or more.
3. When a SRS control unit is replaced, it must be
oriented with the arrow on the sensor pointing
toward the front of the vehicle. It is very important
for the SRS control unit to be located flat on the
mounting surface, parallel to the vehicle datum
line. It is important that the SRS control unit
mounting surface is free of any dirt or other foreign
material.
4. Do not apply power to the SRS unless all
components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble
code.
5. The “SRS Diagnostic System Check” must be the
starting point of any SRS diagnostics. The “SRS
Diagnostic System Check” will verify proper “AIR
BAG” warning lamp operation and will lead you to
the correct chart to diagnose any SRS
malfunctions. Bypassing these procedures ma
y
result in extended diagnostic time, incorrect
diagnosis, and incorrect parts replacement.
Page 42 of 4264
9A-22 SUPPLEMENTAL RESTRAINT SYSTEM
20.The passenger inflator requires no special
precaution after deployment. 95% of the
particulate emission are potassium ckloride (KLC),
which is commonly sold as an edible salt-
substitutes. even if water is applied. Pos
t
deployment products are relatively pH neutral.
Disposing the inflator by burying it in a landfill will
not produce any hazardous products. As with an
y
dusty environment, safety goggles, dust mask and
gloves should be worn.
WARNING: SAFETY PRECAUTIONS MUST BE
OBSERVED WHEN HANDLING A DEPLOYED AI
R
BAG ASSEMBLY. AFTER DEPLOYMENT, THE
METAL SURFACES OF THE AIR BAG ASSEMBLY
WILL BE HOT. ALLOW THE AIR BAG ASSEMBLY
TO COOL BEFORE HANDLING ANY METAL
PORTION OF IT. DO NOT PLACE THE DEPLOYED
INFLATOR MODULE NEAR ANY FLAMMABLE
OBJECTS. FAILURE TO FOLLOW PROCEDURES
MAY RESULT IN FIRE OR PERSONAL INJURY.
AFTER AN AIR BAG ASSEMBLY HAS BEEN
DEPLOYED, THE METAL CANISTER AND
SURROUNDING AREAS OF THE AIR BAG
ASSEMBLY WILL BE HOT. DO NOT TOUCH THE
METAL AREAS OF THE AIR BAG ASSEMBLY FO
R
ABOUT THIRTY MINUTES AFTER DEPLOYMENT.
IF THE DEPLOYED AIR BAG ASSEMBLY MUST BE
MOVED BEFORE IT IS COOL, WEAR GLOVES AND
HANDLE BY THE AIR BAG ITSELF.
21. Disconnect the pigtail adapter from the air bag
assembly as soon after deployment as possible to
avoid damage to the pigtail adapter or SRS
deployment harness from contacting the hot ai
r
bag assembly canister. The pigtail adapter and
SRS deployment harness are designed to be
reused. They should, however, be inspected fo
r
damage after each deployment and replaced if
necessary.
22. Dispose of the deployed air bag assembly through
normal refuse channels after it has cooled for a
t
least 30 minutes.
23. Wash your hands with mild soap and wate
r
afterward.
NOTE: The remaining steps are to be followed in the
unlikely event that the air bag assembly did not deplo
y
after following the above procedures.
24. Ensure that the SRS deployment harness has
been disconnected from the power source and tha
t
its two banana plugs have been shorted together
by fully seating one banana plug into the other.
25. Disconnect the pigtail adapter from the air bag
assembly.
WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
ASSEMBLY UNATTENDED ON A BENCH OR
OTHER SURFACE, ALWAYS FACE THE BAG UP
AND AWAY FROM THE SURFACE. THIS IS
NECESSARY SO THAT A FREE SPACE IS
PROVIDED TO ALLOW THE AIR BAG TO EXPAND
IN THE UNLIKELY EVENT OF ACCIDENTAL
DEPLOYMENT. FAILURE TO FOLLOW
PROCEDURES MAY RESULT IN PERSONAL
INJURY.
26. Temporarily store the air bag assembly with the
bag facing up, away from the surface upon which it
rests.
Deployment Inside Vehicle (Vehicle
Scrapping Procedure)
Deployment inside vehicle is proper when the vehicle
is to be destroyed or salvaged for component parts.
This includes, but is not limited to, the following
situations:
1. The vehicle has completed its useful life.
2. The vehicle has been damaged beyond repair in a
nondeployment type accident.
3. The vehicle has been stripped or damaged beyond
repair in a theft.
4. The vehicle will be salvaged for component parts
to be used on a vehicle with a different Vehicle
Identification Number (VIN) as opposed to being
rebuilt as same VIN. Never use SRS components
from another vehicle.
WARNING: FAILURE TO FOLLOW PROPER SRS
AIR BAG ASSEMBLY DISPOSAL PROCEDURES
CAN RESULT IN AIR BAG DEPLOYMENT WHICH
MAY CAUSE PERSONAL INJURY. UNDEPLOYED
AIR B
AG ASSEMBLIES MUST NOT BE DISPOSED
OF THROUGH NORMAL REFUSE CHANNELS.
THE UNDEPLOYED AIR BAG ASSEMBLY
CONTAINS SUBSTANCES THAT CAN CAUSE
SEVERE ILLNESS OR PERSONAL INJURY IF THE
SEALED CONTAINER IS DAMAGED DURING
DISPOSAL. DISPOSAL IN ANY MANNE
R
INCONSISTENT WITH PROPER PROCEDURES
MAY BE A VIOLATION OF FEDERAL, STATE
AND/OR LOCAL LAWS.
1. Turn ignition switch to “LOCK,” remove key and
put on safety glasses.
2. Remove all loose objects from front seats.
3. Disconnect driver air bag assembly, yellow
connector located at the base of the steering
column.
4. Cut the driver air bag assembly yellow harness
connector from the vehicle leaving at least 15 cm
(six inches) of wire at the connector.
Page 43 of 4264
SUPPLEMENTAL RESTRAINT SYSTEM 9A-23
5. Strip 13 mm (1/2 inch) of insulation from yellow –
green and yellow – black wire lead of the
connector.
6. Cut two 900 cm (30 feet) deployment wires from
0.8 mm
2 (18 gauge) or thicker multi–strand wire.
These wires will be used to fabricate the drive
r
deployment harness.
7. Strip 13 mm (1/2 inch) of insulation from both ends
of the wires cut in the previous step.
8. Short the wires by twisting together one end from
each. Deployment wires shall remain shorted and
not be connected to a power source until the ai
r
bag is to be deployed.
WARNING: FAILURE TO FOLLOW PROCEDURES
IN THE ORDER LISTED COULD RESULT IN
PERSONAL INJURY. NEVER CONNECT
DEPLOYMENT WIRES TO ANY POWER SOURCE
BEFORE CONNECTING DEPLOYMENT WIRES TO
THE AIR BAG ASSEMBLY LEADS. DEPLOYMENT
WIRES SHALL REMAIN SHORTED AND BE NOT
CONNECTED TO A POWER SOURCE UNTIL THE
AIR BAG IS TO BE DEPLOYED. THE AIR BAG
ASSEMBLY WILL IMMEDIATELY DEPLOY THE AI
R
BAG WHEN A POWER SOURCE IS CONNECTED
TO IT. WEAR SAFETY GLASSES THROUGHOUT
THIS ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
9. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure.
10. Bend twisted connection made in the previous step
flat and wrap tightly with electrical tape to insulate
and secure.
11. Twist together, bend and tape the remaining
connector wire lead to the remaining deploymen
t
wire.
12. Connect the deployment harness to the driver ai
r
bag assembly, yellow connector at the base of the
steering column. Route deployment harness ou
t
the driver side of the vehicle.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED.
THE AIR BAG ASSEMBLY WILL IMMEDIATELY
DEPLOY THE AIR BAG WHEN A POWER SOURCE
IS CONNECTED TO IT.
Connecting the deployment wires to the powe
r
source should always be the final step in the air
bag assembly deployment procedure.
Failure to follow procedures in the order listed
could result in personal injury.
13. Disconnect passenger air bag assembly, yello
w
connector located behind glove box assembly.
14.Cut the passenger air bag assembly harness
connector from the vehicle leaving at least 15 cm
(six inches) of wire at the connector.
15. Strip 13 mm (1/2 inch) of insulation from blue–
white and pink–blue wire lead of the connector.
16. Cut two 900 cm (30 feet) deployment wires from
0.8 mm
2 (18 gauge) or thicker multi–strand wire.
These wires will be used to fabricate the
passenger deployment harness.
17. Strip 13 mm (1/2 inch) of insulation from both ends
of the wires cut in the previous step.
18. Short the wires by twisting together one end from
each. Deployment wires shall remain shorted and
not be connected to a power source until the ai
r
bag is to be deployed.
WARNING: FAILURE TO FOLLOW PROCEDURES
IN THE ORDER LISTED COULD RESULT IN
PERSONAL INJURY. NEVER CONNECT
DEPLOYMENT WIRES TO ANY POWER SOURCE
BEFORE CONNECTING DEPLOYMENT WIRES TO
THE AIR BAG ASSEMBLY LEADS. DEPLOYMENT
WIRES SHALL REMAIN SHORTED AND NOT BE
CONNECTED TO A POWER SOURCE UNTIL THE
AIR BAG IS TO BE DEPLOYED. THE AIR BAG
ASSEMBLY WILL IMMEDIATELY DEPLOY THE AI
R
BAG WHEN A POWER SOURCE IS CONNECTED
TO IT. WEAR SAFETY GLASSES THROUGHOUT
THIS ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
19. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure.
20. Bend twisted connection made in the previous step
flat and wrap tightly with electrical tape to insulate
and secure.
21. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment
wire.
22. Connect the deployment harness to the passenge
r
air bag assembly, yellow connector located behind
the glove box assembly. Route deployment
harness out the passenger side of the vehicle.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A
PO
WER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN A
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT WIRES
SHOULD ALWAYS BE THE FINAL STEP IN THE
AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE.
FAILURE TO FOLLOW PROCEDURES IN THE
ORDER LISTED COULD RESULT IN PERSONAL
INJURY.