ISUZU TROOPER 1998 Service Repair Manual
Manufacturer: ISUZU, Model Year: 1998, Model line: TROOPER, Model: ISUZU TROOPER 1998Pages: 3573, PDF Size: 60.36 MB
Page 3451 of 3573
SUPPLEMENTAL RESTRAINT SYSTEM 9J±14
10. Place a power source near the shorted end of the
SRS deployment harness. Recommended
application: 12 volts minimum, 2 amps minimum. A
vehicle battery is suggested.
11. Connect the driver air bag assembly to the pigtail
adapter on the SRS deployment harness.
Deployment harness shall remain shorted and not be
connected to a power source until the air bag is to be
deployed. The driver air bag assembly will
immediately deploy the air bag when a power source
is connected to it.
NOTE: Ensure that the pigtail adapter is firmly seated into
the driver air bag assembly connector. Failure to fully
seat the connectors may leave the shorting bar located in
the driver air bag assembly connector functioning
(shorted) and may result in nondeployment of the driver
air bag assembly.
12. Verify that the area around the driver air bag
assembly is clear of all people and loose or flammable
objects.
13. Verify that the driver air bag assembly is resting with
its trim cover facing up.
14. Notify all people in the immediate area that you intend
to deploy the driver air bag. The deployment will be
accompanied by a substantial noise which may
startle the uninformed.
15. Separate the two banana plugs on the SRS
deployment harness.
NOTE: When the air bag deploys, the driver air bag
assembly may jump about 3 m (ten feet) vertically. This
is a normal reaction of the driver air bag to the force of the
rapid gas expansion inside the air bag.
NOTE: W h e n t h e a i r b a g deploys, the rapid gas
expansion will create a substantial noise. Notify all
people in the immediate area that you intend to deploy the
driver air bag.
WARNING: D E P L O Y M E N T HARNESS 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 HARNESS TO
THE POWER SOURCE SHOULD ALWAYS BE THE
LAST STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
PROCEDURES IN THE ORDER LISTED MAY RESULT
IN PERSONAL INJURY.
16. Connect the SRS deployment harness wires to the
power source to immediately deploy the driver air
bag. Recommended application: 12 volts minimum, 2
amps minimum. A vehicle battery is suggested.
17. Disconnect the SRS deployment harness from the
power source.
18. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other.19. In the unlikely event that the driver air bag assembly
did not deploy after following these procedures,
proceed immediately with Steps 24 through 26. If the
driver air bag assembly did deploy, proceed with
Steps 20 through 23.
20. Put on a pair of shop gloves and safety glasses to
protect your hands and eyes from possible irritation
and heat when handling the deployed driver air bag
assembly. After the air bag assembly has been
deployed, the surface of the air bag may contain a
powdery residue. This solid particulate consists
primarily of by products of the chemical reaction,
Potassium Chloride and copper metal dust.
Compounds of Potassium Borate, Strontium
Chloride, Copper Chloride, and Ammonium Chloride
may be found in amounts of about 1 % (each) of the
total particulate.
WARNING: S A F E T Y P R ECAUTIONS MUST BE
OBSERVED WHEN HANDING A DEPLOYED AIR BAG
ASSEMBLY. AFTER DEPLOYMENT, THE METAL
SURFACES OF THE AIR BAG ASSEMBLY WILL BE
VERY HOT. ALLOW THE INFLATOR MODULE TO
COOL BEFORE HANDLING ANY METAL PORTION
OF IT. DO NOT PLACE THE DEPLOYED AIR BAG
ASSEMBLY NEAR ANY FLAMMABLE OBJECTS.
FAILURE TO FOLLOW PROCEDURES MAY RESULT
IN FIRE OR PERSONAL INJURY.
AFTER A DRIVER AIR BAG ASSEMBLY HAS BEEN
DEPLOYED, THE METAL CANISTER AND
SURROUNDING AREAS OF THE DRIVER AIR BAG
ASSEMBLY WILL BE VERY HOT. DO NOT TOUCH
THE METAL AREAS OF THE DRIVER AIR BAG
ASSEMBLY FOR ABOUT TEN MINUTES AFTER
DEPLOYMENT. IF THE DEPLOYED DRIVER AIR BAG
ASSEMBLY MUST BE MOVED BEFORE IT IS COOL,
WEAR GLOVES AND HANDLE BY THE AIR BAG OR
TRIM COVER.
21. Disconnect the pigtail adapter from the driver air bag
assembly as soon after deployment as possible. This
will prevent damage to the pigtail adapter or SRS
deployment harness due to possible contact with the
hot driver air bag assembly canister. The pigtail
adapter can be reused. They should, however, be
inspected for damage after each deployment and
replaced if necessary.
22. Dispose of the deployed driver air bag assembly
through normal refuse channels after it has cooled for
at least 30 minutes.
23. Wash your hands with mild soap and water afterward.
NOTE: The remaining steps are to be followed in the
unlikely event that the driver air bag assembly did not
deploy after following these procedures.
24. Ensure that the SRS deployment harness has been
disconnected from the power source and that its two
banana plugs have been shorted together by fully
seating one banana plug into the other.
25. Disconnect the pigtail adapter from the driver air bag
assembly.
WARNING: W H E N S T O R I N G A L I V E A I R B A G
ASSEMBLY OR WHEN LEAVING A LIVE INFLATOR
MODULE UNATTENDED ON A BENCH OR OTHER
Page 3452 of 3573
SUPPLEMENTAL RESTRAINT SYSTEM9J±15
S U R FA C E , A LWAY S FA C E T H E B A G A N D T R I M
COVER 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 driver air bag assembly with its
trim cover facing up, away from the surface upon
which it rests.
Deployment Outside Vehicle (Passenger
Air Bag Assembly)
WARNING: FAILURE TO FOLLOW PROPER SRS AIR
BAG ASSEMBLY DISPOSAL PROCEDURES CAN
RESULT IN AIR BAG DEPLOYMENT WHICH MAY
CAUSE PERSONAL INJURY. UNDEPLOYED AIR
BAG 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 MANNER INCONSISTENT WITH PROPER
PROCEDURES MAY BE A VIOLATION OF FEDERAL,
STATE AND/OR LOCAL LAWS.
Deployment out of the vehicle is proper when the vehicle
is to be returned to service. This includes, for example,
situations in which a functionally or cosmetically deficient
air bag assembly is replaced. Deployment and disposal
of an air bag assembly is, of course, subject to any
required retention period.
For deployment of a live air bag assembly out of the
vehicle, the deployment procedure must be followed
exactly. Always wear safety glasses during this
deployment procedure until the deployed air bag
assembly is scrapped. Before performing the
procedures, you should be familiar with servicing the SRS
system and with proper handling of the air bag assembly.
Procedures should be read fully before they are
performed.
The following procedure requires use of 5±8840±2468±0
SRS Deployment Harness with the appropriate pigtail
adapter. The procedure also requires the use of
5±8840±2420±0 Passenger Side SRS Module
Deployment Fixture. Do not attempt this procedure
without 5±8840±2468±0 and adapter, and
5±8840±2420±0.
WARNING: FAILURE TO FOLLOW PROCEDURES IN
THE ORDER LISTED MAY RESULT IN PERSONAL
INJURY. NEVER CONNECT DEPLOYMENT
HARNESS TO ANY POWER SOURCE BEFORE
CONNECTING DEPLOYMENT HARNESS TO THE AIR
BAG ASSEMBLY. DEPLOYMENT HARNESS 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. WEARSAFETY GLASSES THROUGHOUT THIS ENTIRE
DEPLOYMENT AND DISPOSAL PROCEDURE.
NOTE: This information applies only to passenger air bag
assembly. Information for disposing of a live driver air bag
assembly can be found in ªDeployment Outside Vehicleº
(Driver Air Bag Assembly) in this section.
1. Turn ignition switch to ªLOCKº remove key, and put on
safety glasses.
2. Inspect 5±8840±2468±0 SRS Deployment Harness
and appropriate pigtail adapter for damage. If
harness or pigtail is damaged, discard and obtain a
replacement.
3. Short the two SRS Deployment Harness leads
together by fully seating one banana plug into the
other. The SRS Deployment Harness shall remain
shorted and not be connected to a power source until
the air bag is to be deployed.
827RS003
4. Connect the appropriate pigtail adapter to the SRS
Deployment Harness
827RS004
Page 3453 of 3573
SUPPLEMENTAL RESTRAINT SYSTEM 9J±16
5. Remove passenger air bag assembly from vehicle.
Refer to ªPassenger Air Bag Assembly Removal º in
this Section 9J±3.
6. Clear a space on the ground approximately 183 cm
(six feet) in clearance where the fixture with attached
air bag assembly is to be placed for deployment. A
paved outdoor location where there is no activity is
preferred. If an outdoor location is not available, a
space on the shop floor where is no activity and
sufficient ventilation is recommended. Ensure that no
loose or flammable objects are within the deployment
area.
7. Place the 5±8840±2420±0 on the bench vice. This is
necessary to provide sufficient stabilization of the
fixture during deployment.
8. Attach the passenger air bag assembly in the
5±8840±2420±0. An air bag assembly must be
mounted such that the bag will deploy upward.
SECURELY HAND±TIGHTEN ALL FASTENERS
PRIOR TO DEPLOYMENT.
901RW199
9. Stretch the SRS Deployment Harness and pigtail
adapter from the air bag assembly to its full length.
10. Place a power source near the shorted end of the
SRS deployment harness. (Recommended
application: 12 volts minimum, 2 amps minimum. A
vehicle battery is suggested.)
11. Connect the air bag assembly to the pigtail adapter on
the SRS deployment harness. The SRS Deployment
Harness 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.
NOTE: Ensure that the pigtail adapter is firmly seated into
the air bag assembly connector. Failure to fully seat the
connectors may leave the shorting bar located in the air
bag assembly connector functioning (shorting the
deployment circuit) and may result in nondeployment of
the air bag assembly.
12. Verify that the area around the passenger air bag
assembly is clear of all people and loose or flammable
objects.13. Verify that the passenger air bag assembly is firmly
and properly in 5±8840±2420±0.
14. Notify all people in the immediate area of your
intention to deploy the passenger air bag assembly.
The deployment will be accompanied by a substantial
noise which may startle the uninformed.
15. Separate the two banana plugs on the SRS
deployment harness.
NOTE: When air bag deploys, the rapid gas expansion
will create a substantial noise. Notify all people in the
immediate area that you intend to deploy the air bag
assembly.
WARNING: D E P L O Y M E N T HARNESS 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 HARNESS TO
THE POWER SOURCE SHOULD ALWAYS BE THE
LAST STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
PROCEDURES IN THE ORDER LISTED MAY RESULT
IN PERSONAL INJURY.
16. Connect the SRS deployment harness wires to the
power source to immediately deploy the air bag
assembly. Recommended application : 12 volts
minimum, 2 amps minimum. A vehicle battery is
suggested.
17. Disconnect the SRS deployment harness from the
power source.
18. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other.
19. In the unlikely event that the passenger air bag
assembly did not deploy after following these
procedures, proceed immediately with Steps 24
through 26. If the passenger air bag assembly
deployed as intended, proceed with Steps 20 through
23.
20. Put on a pair of shop gloves and safety glasses to
protect your hands and eyes from possible irritation
and heat when handling the deployed air bag
assembly.
After the air bag assembly has been deployed, the
surface of the air bag may contain a powdery residue.
This powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by products of the
chemical reaction. Sodium hydroxide dust (similar to
lye soap) is produced as a by product of the
deployment reaction. The sodium hydroxide then
quickly reacts with atmospheric moisture and is
converted to sodium carbonate and sodium
bicarbonate (baking soda). Therefore, it is unlikely
that sodium hydroxide will be present after
deployment.
WARNING: S A F E T Y P R ECAUTIONS MUST BE
OBSERVED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE
METAL SURFACES OF THE AIR BAG ASSEMBLY
WILL BE HOT. ALLOW THE AIR BAG ASSEMBLY TO
Page 3454 of 3573
SUPPLEMENTAL RESTRAINT SYSTEM9J±17
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 FOR
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 air bag
assembly canister. The pigtail adapter and SRS
deployment harness are designed to be reused.
They should, however, be inspected for 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 at least
30 minutes.
23. Wash your hands with mild soap and water afterward.
NOTE: The remaining steps are to be followed in the
unlikely event that the air bag assembly did not deploy
after following the above procedures.
24. Ensure that the SRS deployment harness has been
disconnected from the power source and that 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: W H E N S T O R I N G A L I V E A I R B A G
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 Outside Vehicle (Fixing Air
Bag on Tire)
Read and understand the items of ªCAUTIONS ABOUT
AIR BAG DEPLOYMENT AND DISPOSAL
PROCEDURESº and ªUsage of Deployment Toolº for
safe deployment of air bag.
1. Remove air bag assembly from vehicle. Refer to air
bag assembly Removal ªin this sectionº.2. Inspect J±41434 Supplemental Restraint System
(SRS) Deployment Harness and appropriate pigtail
adapter for damage. If harness or pigtail is damaged,
discard and obtain a replacement.
3. Extend double pole extension cord to a position far
away 10 m (33 feet) from the air bag assembly.
4. Place a power source near the extended end of SRS
air bag deployment harness. (Use of 12V battery is
recommended).
827RW057
Legend
(A) 10 m (33 feet) or more
5. Insert one of the banana plugs into the other banana
plug to short the two SRS air bag deployment
harness. Do not the harness to a power source until
deployment.
827RW055
Page 3455 of 3573
SUPPLEMENTAL RESTRAINT SYSTEM 9J±18
6. Prepare four 15 inch or larger tires without wheel and
two same size tires with wheels.
827RW056
7. How to fix Driver air bag.
1. Fix the air bag with its trim cover up on a tire with a
wheel using an automobile use wire harness,
(core size: 0.05 inch) or a wire trebly at two or
more points.
2. Connect SRS air bag assembly to the double pole
extension cord of the air bag deployment
harness.
Do not connect the deployment harness to a pow-
er source until air bag deployment.
(If connected the SRS air bag assembly deploys
immediately)
NOTE: Ensure that the pigtail adapter is firmly seated into
the air bag assembly connector. Failure to fully seat the
connectors may leave the shorting bar located in the air
bag assembly connector functioning (shorting the
deployment circuit) and may result in non deployment of
the air bag assembly.
827RW054
3. Place three tires without wheel on the tire on
which air bag is fixed and a tire with a wheel on
top.
Bind the five tires with a rope so that the tires may
not collapse.
827RW053
Legend
(A) 10 m (33 feet) or more
8. How to fix Passenger air bag.
1. Fix the air bag with its trim cover side fixing the
center of a tire without a wheel using an
automobile use wire harness, (core size: 0.05
inch) or a wire trebly at two or more points.
901RX045
2. Connect Supplemental Restraint System (SRS)
air bag assembly to the deployment harness
double pole extension cord end. Be sure not to
connect the deployment harness to a power
source. (If connected the SRS air bag assembly
deploys immediately).
Page 3456 of 3573
SUPPLEMENTAL RESTRAINT SYSTEM9J±19
NOTE: Ensure that the pigtail adapter is firmly seated into
the air bag assembly connector. Failure to fully seat the
connectors may leave the shorting bar located in the air
bag assembly connector functioning (shorting the
deployment circuit) and may result in non deployment of
the air bag assembly.
827RW054
3. Put a tire without wheel on another, put the tire on
which the air bag is fixing, put a tire without a
wheel, and finally put a tire with a wheel on top.
Bind the tires with a rope so that the tires pile may
not collapse.
827RW050
Legend
(A) 10 m (33 feet) or more
9. Notify all people in the immediate area of your
intention to deploy the passenger air bag assembly.
The deployment will be accompanied by a substantial
noise which may startle the uninformed.
WARNING: DEPLOYED HARNESS 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 CONNECTING THE
DEPLOYMENT HARNESS TO THE POWER SOURCE
SHOULD ALWAYS BE THE LAST STEP IN THE AIR
BAG ASSEMBLY DEPLOYMENT PROCEDURE.
FAILURE TO FOLLOW PROCEDURES IN THE
ORDER LISTED MAY RESULT IN PERSONAL
INJURY.
10. Connect the Supplemental Restraint System (SRS)
deployment harness wires to the power source to
immediately deploy the air bag assembly.
Recommended application : 12 volts minimum, 2
amps minimum. A vehicle battery is suggested.
827LW011
WARNING: S A F E T Y P R ECAUTIONS MUST BE
OBSERVED WHEN HANDING A DEPLOYED AIR BAG
ASSEMBLY. AFTER DEPLOYMENT, THE METAL
SURFACES OF THE AIR BAG ASSEMBLY WILL BE
VERY 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 FOR
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 IT SELF.
11. 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 air bag
assembly canister. The pigtail adapter and SRS
deployment harness are designed to be reused. They
should, however, be inspected for damage after each
deployment and replaced if necessary.
12. Dispose of the deployed air bag assembly through
normal refuse channels after it has cooled for at least
30 minutes.
Page 3457 of 3573
SUPPLEMENTAL RESTRAINT SYSTEM 9J±20
13. Wash your hands with mild soap and water afterward.
NOTE: The remaining steps are to be followed in the
unlikely event that the air bag assembly did not deploy
after following the above procedures.
14. Ensure that the SRS deployment harness has been
disconnected from the power source and that its two
banana plugs have been shorted together by fully
seating one banana plug into the other.
827RW055
15. Disconnect the pigtail adapter from the air bag
assembly.
WARNING: W H E N S T O R I N G A L I V E A I R B A G
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.
16. Temporarily store the air bag assembly with the bag
facing up, away from the surface upon which it rests.
066RW030
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
BAG 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 MANNER INCONSISTENT WITH PROPER
PROCEDURES MAY BE A VIOLATION OF FEDERAL,
STATE AND/OR LOCAL LAWS.
1. Turn ignition switch to ªLOCK,º remove key and put
on safety glasses.
2. Remove all loose objects from front seats.
3. Disconnect driver air bag assembly, yellow 2±pin
connector located at the base of the steering column.
4. Cut the driver air bag assembly yellow 2±pin harness
connector from the vehicle leaving at least 15 cm (six
inches) of wire at the connector.
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 (18 gauge) or thicker multi±strand wire. These
wires will be used to fabricate the driver 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 air 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 AIR BAG WHEN A POWER SOURCE IS
CONNECTED TO IT. WEAR SAFETY GLASSES
Page 3458 of 3573
SUPPLEMENTAL RESTRAINT SYSTEM9J±21
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 deployment
wire.
12. Connect the deployment harness to the driver air bag
assembly, yellow 2±pin connector at the base of the
steering column. Route deployment harness out 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
POWER 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, yellow 2±pin
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 (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 air 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 AIR 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 passenger air
bag assembly, yellow 2±pin 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 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 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.
23. Verify that the inside of the vehicle and the area
surrounding the vehicle are clear of all people and
loose or flammable objects.
24. Stretch the driver and passenger deployment
harness to their full length.
25. Completely cover windshield area and front door
window openings with a drop cloth, blanket or similar
item. This reduces the possibility of injury due to
possible fragmentation of the vehicle's glass or
interior.
26. Notify all people in the immediate area that you intend
to deploy the air bags. The deployment will be
accompanied by a substantial noise which may
startle the uninformed.
27. Separate the two ends of the driver deployment
harness wires.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE AIR BAG IS 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 POWER 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.
NOTE: W h e n t h e a i r b a g deploys, the rapid gas
expansion will create a substantial noise. Notify all
people in the immediate area that you intend to deploy the
air bags.
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SUPPLEMENTAL RESTRAINT SYSTEM 9J±22
28. Connect the driver deployment harness wires to a
power source to immediately deploy the driver air bag
assembly. Recommended application: 12 volts
minimum, 2 amps minimum. A vehicle battery is
suggested.
29. Separate the two ends of the passenger deployment
harness wires.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE AIR BAG IS 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 POWER 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.
30. Connect the passenger deployment harness wires to
a power source to immediately deploy the passenger
air bag assembly. Recommended application: 12
volts minimum, 2 amps minimum. A vehicle battery is
suggested.(Driver air bag assembly) Put on a pair of
shop gloves and safety glasses to protect your hands
and eyes from possible irritation and heat when
handling the deployed air bag assembly. After the air
bag assembly has been deployed, the surface of the
air bag may contain solid particulate. This solid
particulate consists primarily of by products of the
chemical reaction, Potassium Chloride and copper
metal dust. Compounds of Potassium Borate,
Strontium Chloride, Copper Chloride, and
Ammonium Chloride may be found in amounts of
about 1 % (each) of the total particulate.
(Passenger air bag assembly)
Put on a pair of shop gloves and safety glasses to
protect your hands and eyes from possible irritation
and heat when handling the deployed air bag
assembly.
After the air bag assembly has been deployed, the
surface of the air bag may contain a powdery residue.
This powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by products of the
chemical reaction. Sodium hydroxide dust (similar to
lye soap) is produced as a by product of the
deployment reaction. The sodium hydroxide then
quickly reacts with atmospheric moisture and is
converted to sodium carbonate and sodium
bicarbonate (baking soda). Therefore, it is unlikely
that sodium hydroxide will be present after
deployment.
WARNING: S A F E T Y P R ECAUTIONS MUST BE
OBSERVED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE
METAL SURFACES OF THE AIR BAG ASSEMBLY
WILL BE VERY HOT. ALLOW THE AIR BAG
ASSEMBLY TO COOL BEFORE HANDLING ANY
METAL PORTION OF IT. DO NOT PLACE THE HOT
DEPLOYED AIR BAG ASSEMBLY NEAR ANY
FLAMMABLE OBJECTS. FAILURE TO FOLLOWPROCEDURES COULD 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 very hot. Do not touch the metal
areas of the air bag assembly for about 30 minutes
after deployment. If the deployed air bag assembly
must be moved before it is cool, wear gloves and
handle by the air bag or trim cover.
31. Short the driver deployment harness wires by twisting
together one end from each. Repeat this procedure
for the passenger deployment harness.
32. Carefully remove drop cloth from vehicle and clean off
any fragments or discard drop cloth entirely.
33. Disconnect driver deployment harness and
passenger deployment harness from vehicle and
discard.
34. In the unlikely event that either or both of the air bag
assemblies did not deploy after following these
procedures, proceed immediately with Steps 36
through 37. If the air bag assembly deployed, proceed
to step 35.
35. With both air bags deployed, the vehicle may be
scrapped in the same manner as a non±SRS
equipped vehicle.
NOTE: The remaining steps are to be followed in the
unlikely event that the air bag assembly did not deploy
after following these procedures.
36. Remove the undeployed air bag assembly (s) from
the vehicle. For driver air bag assembly refer to in the
ªPassenger Air Bag Assembly Removalº in this
manual.
WARNING: W H E N S T O R I N G A L I V E A I R B A G
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
ASSEMBLY UNATTENDED ON A BENCH OR OTHER
S U R FA C E , A LWAY S FA C E T H E B A G A N D T R I M
COVER UP, 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 COULD
RESULT IN PERSONAL INJURY.
37. Temporarily store the air bag assembly with the air
bag opening facing up, away from the surface upon
which it rests.
Deployed Air Bag Assembly Handling
Put on a pair of shop gloves and safety glasses to protect
your hands and eyes from possible irritation and heat
when handling the deployed air bag assembly.
After the air bag assembly has been deployed, the
surface of the air bag may contain a powdery residue.
(Passenger air bag assembly)
After the air bag assembly has been deployed, the
surface of the air bag may contain a powdery residue.
This powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by products of the
chemical reaction. Sodium hydroxide dust (similar to lye
soap) is produced as a by product of the deployment
reaction. The sodium hydroxide then quickly reacts with
atmospheric moisture and is converted to sodium
Page 3460 of 3573
SUPPLEMENTAL RESTRAINT SYSTEM9J±23
carbonate and sodium bicarbonate (baking soda).
Therefore, it is unlikely that sodium hydroxide will be
present after deployment.
(Driver air bag assembly)
After the air bag assembly has been deployed, the
surface of the air bag may contain solid particulate. This
solid particulate consists primarily of by products of the
chemical reaction, Potassium Chloride and copper metal
dust. Compounds of Potassium Borate, Strontium
Chloride, Copper Chloride, and Ammonium Chloride may
be found in amounts of about 1 % (each) of the total
particulate.
Deployment Outside Vehicle (Pretensioner
Seat Belt Assembly)
Deployment outside the vehicle is proper when the
vehicle is to be returned to service. This includes, for
example, situations in which the vehicle will be returned to
useful service after a functionally or cosmetically deficient
pretensioner seat belt assembly is replaced. Deployment
and disposal of a malfunctioning pretensioner seat belt
assembly is, of course, subject to any required retention
period.
For deployment of a live (undeployed) pretensioner seat
belt assembly outside the vehicle, the deployment
procedure must be followed exactly. Always wear gloves
and safety glasses during this deployment procedure until
a deployed pretensioner seat belt assembly is scrapped
or until an undeployed pretensioner seat belt assembly is
shipped. Before performing the procedures you should
be familiar with servicing the system and with proper
handling of the pretensioner seat belt assembly.
Procedures should be read fully before they are
performed.
The following procedure requires use of SRS deployment
harness with appropriate pigtail adapter. Do not attempt
procedure without adapter.
WARNING: FAILURE TO FOLLOW PROCEDURES IN
THE ORDER LISTED MAY RESULT IN PERSONAL
INJURY. NEVER CONNECT DEPLOYMENT
HARNESS TO ANY POWER SOURCE BEFORE
CONNECTING DEPLOYMENT HARNESS TO THE
PRETENSIONER SEAT BELT ASSEMBLY.
DEPLOYMENT HARNESS SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE PRETENSIONER SEAT BELT IS
TO BE DEPLOYED. THE PRETENSIONER SEAT
BELT ASSEMBLY WILL IMMEDIATELY DEPLOY THE
PRETENSIONER SEAT BELT WHEN A POWER
SOURCE IS CONNECTED TO IT. WEAR GLOVES
AND SAFETY GLASSES THROUGHOUT THIS
ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
1. Turn ignition switch to ªLOCKº, remove key.
2. Remove the pretensioner seat belt assembly from
vehicle. Refer to ªPretensioner Seat Belt Removalº in
this manual.
3. Prepare SRS deployment harness.
901HV009
4. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other. SRS deployment harness shall remain shorted
and not be connected to a power source until the
pretensioner seat belt is to be deployed.
5. Place the pretensioner seat belt assembly on a work
bench or other surface away from all loose or
flammable objects.
WARNING: W H E N F I X I N G T H E D E P L O Y M E N T
DEVICE OF PRETENSIONER SEAT BELT, THE
DEPLOYMENT DEVICE SHOULD BE FIXED AWAY
FROM OTHER PERSON
6. Clear a space on the ground about 183 cm (six feet) in
diameter where the pretensioner seat belt assembly
is to be deployed. A paved, outdoor location where
there is no activity is preferred. If an outdoor location
is not available, a space on the shop floor where there
is no activity and sufficient ventilation is
recommended. Ensure no loose or flammable
objects are within the deployment area.
7. Stretch the SRS deployment harness and pigtail
adapter from the pretensioner seat belt assembly to
its full length.
8. Place a power source near the shorted end of the
SRS deployment harness. Recommended
application: 12 volts minimum, 2 amps minimum. A
vehicle battery is suggested.
9. Deployment harness shall remain shorted and not be
connected to a power source until the pretensioner
seat belt is to be deployed. The pretensioner seat belt
assembly will immediately deploy the pretensioner
seat belt when a power source is connected to it.
10. Verify that the area around the pretensioner seat belt
assembly is clear of all people and loose or flammable
objects.
11. Notify all people in the immediate area that you intend
to deploy the driver air bag. The deployment will be
accompanied by a substantial noise which may
startle the uninformed.
12. Connect the pretensioner seat belt to the pigtail
adapter on the SRS deployment harness.