CAUTION: When you are carrying an undeployed seat belt pretensioner:

Shipping Procedures

Refer to the latest service bulletins for proper shipping procedures.

Scrapping Procedure

During the course of a vehicle's useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) pretensioner. The following information covers the proper procedures for the disposing of a live pretensioner. Deploy the pretensioner before disposal. Do not dispose of a live pretensioner through normal disposal channels.

CAUTION: In order to prevent accidental deployment of the pretensioner which could cause personal injury, do not dispose of an undeployed pretensioner as normal shop waste. The undeployed pretensioner 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 pretensioner. Failure to dispose of a pretensioner as instructed may be a violation of federal, state, or local laws.

Do not deploy a pretensioner in the following situations:

Deployment Procedures

The pretensioner 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 Inside the Vehicle

Refer to Inflator Module Handling, Shipping, and Scrapping Deployment Inside Vehicle (Vehicle Scrapping Procedure) for deploying the pretensioners inside the vehicle.

Deployment of the Seat Belt Pretensioners

Deploy the seat belt pretensioners outside of the vehicle when the vehicle will be returned to service. Situations that require deployment oustide of the vehicle include the following:

Deployment and disposal of a malfunctioning seat belt pretensioner is subject to any required retention period.

CAUTION: In order to prevent accidental deployment of the pretensioner which could cause personal injury, do not dispose of an undeployed pretensioner as normal shop waste. The undeployed pretensioner 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 pretensioner. Failure to dispose of a pretensioner as instructed may be a violation of federal, state, or local laws.

Tools Required

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

1. Turn the ignition switch to the LOCK position.
2. Remove the ignition key.
3. Put on safety glasses.
4. Inspect the J 38826 J 38826 and the appropriate pigtail adapter for damage. Replace as needed.
5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other.
6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1).




CAUTION: When you are carrying an undeployed seat belt pretensioner:

•	Do not carry the seat belt pretensioner by the wires or connector on the pretensioner.

•	Do not touch the seat belt pretensioner in the area of the cable (1).

•	Do not cover the tube opening with your hand.

•	Keep the open end of the tube pointed away from you. Do not point the open end of the tube at another person.

•	When the pretensioner deploys the cable retracts. This shortens the pretensioner between the buckle and the mounting bolt. Grasp the pretensioner by the piston tube (2).

Disregarding these precautions may result in personal injury or unnecessary SIR system repairs.
7. Remove the seat belt pretensioner from the vehicle. Refer to Seats.



8. Clear a space around a bench vice about 1.85 M (6 ft) in diameter for deployment of the seat belt pretensioner. Use a space free of activity. Make sure you have sufficient ventilation.
9. Make sure no loose or flammable objects are in the area.



10. Clamp the pretensioner, near the attachment bolt hole, in the vice.



11. Extend the SIR deployment harness and adapter to full length from the seat belt pretensioner.
12. Place a 12V minimum/2A minimum power source (i.e., vehicle battery) near the shorted end of the harness.



13. Connect the seat belt pretensioner (1) to the adapter (2) on the SIR deployment harness (3).
14. Firmly seat the adapter into the seat belt pretensioner connector.
15. Clear the area of people.




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

16. Separate the two banana plugs on the SIR deployment harness.




Important: The rapid gas expansion involved with deploying a pretensioner is very loud. Notify all the people in the immediate area that you intend to deploy the seat belt pretensioner.

17. Connect the SIR deployment harness wires to the power source.



18. Disconnect the SIR deployment harness from the power source after the pretensioner deploys.
19. Seat one banana plug into the other in order to short the deployment harness leads.
20. If the pretensioner did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps.
21. Put on a pair of shop gloves.
22. Disconnect the pigtail adapter from the seat belt pretensioner as soon as possible.
23. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed.
24. Dispose of the deployed seat belt pretensioner through normal refuse channels.
25. Wash hands with a mild soap.

Pretensioner Deployment Inside Vehicle (Vehicle Scrapping Procedure)

Deploy the inflator modules outside of the vehicle and deploy the pretensioners 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:

1. Turn the ignition switch to the LOCK position.
2. Remove the ignition key.
3. Put on safety glasses.
4. Remove all loose objects from the front seats.
5. Remove the inflator modules from the vehicle.
6. Deploy the inflator modules outside the vehicle. Refer to Deploying the Inflator Modules Outside the Vehicle.
7. Disconnect the LH pretensioner 2-way connector.



8. Cut the two pretensioner wires leading to the 2-way harness connector, leaving at least 16 cm (6 in) of wire at the connector.



9. Strip 13 mm (0.5 in) of insulation from each of the pretensioner connector wire leads.



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 pretensioner.



13. Twist together one connector wire lead to one deployment wire.
14. Inspect that the previous connection is secure.



15. Bend flat the twisted connection.
16. Secure and insulate the connection using electrical tape.



17. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
18. Connect the deployment harness to the LH pretensioner 2-way connector.



19. Route the deployment harness out of the LH side of the vehicle.



20. Disconnect the RH pretensioner 2-way connector.



21. Cut the two pretensioner wires leading to the 2-way harness connector, leaving at least 16 cm (6 in) of wire at the connector.



22. Strip 13 mm (0.5 in) of insulation from each of the pretensioner connector wire leads.



23. 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.
24. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
25. 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 pretensioner.



26. Twist together one connector wire lead to one deployment wire.
27. Inspect that the previous connection is secure.



28. Bend flat the twisted connection.
29. Secure and insulate the connection using electrical tape.



30. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.



31. Connect the deployment harness to the RH pretensioner 2-way connector.



32. Route the deployment harness out of the RH side of the vehicle.
33. Stretch the LH pretensioner harness to full length.
34. Stretch the RH pretensioner harness to full length.
35. Place a power source, 12V minimum/2A minimum (i.e., a vehicle battery) near the shorted end of the harnesses.



36. Separate the two ends of the LH seat belt pretensioner deployment harness wires.
37. Connect the LH seat belt pretensioner deployment harness wires to the power source in order to deploy the LH seat belt pretensioner.
38. Disconnect the LH seat belt pretensioner deployment harness wires from the power source.
39. Twist together one end of each wire on the LH pretensioner deployment harness in order to short the wires.



40. Separate the two ends of the RH seat belt pretensioner deployment harness wires.
41. Connect the RH seat belt pretensioner deployment harness wires to the power source in order to deploy the RH seat belt pretensioner.
42. Disconnect the RH seat belt pretensioner deployment harness wires from the power source.



43. Twist together one end of each wire on the RH pretensioner deployment harness in order to short the wires.
44. Disconnect the harnesses from the vehicle.
45. Discard the harnesses.
46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
47. If one or both of the pretensioners did not deploy, perform the following steps:

47.1.

Remove the undeployed pretensioners from the vehicle. Refer to Seat Belt Buckle Pretensioner Replacement - LH , and Seat Belt Side Buckle Pretensioner Replacement - Pass. .

CAUTION: When you are carrying an undeployed seat belt pretensioner:

•	Do not carry the seat belt pretensioner by the wires or connector on the pretensioner.

•	Do not touch the seat belt pretensioner in the area of the cable (1).

•	Do not cover the tube opening with your hand.

•	Keep the open end of the tube pointed away from you. Do not point the open end of the tube at another person.

•	When the pretensioner deploys the cable retracts. This shortens the pretensioner between the buckle and the mounting bolt. Grasp the pretensioner by the piston tube (2).

Disregarding these precautions may result in personal injury or unnecessary SIR system repairs.

47.2.

Temporarily store the pretensioner(s).

47.3.

Call the Technical Assistance Group for further assistance.

Some gas will be visible after deployment. Exposure to this gas is not a health concern. The pretensioner can be handled immediately after deployment.