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Deployment Outside Vehicle for Seat Belt Pretensioners

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.

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

    Fig 1: Proper Transportation of Seat Belt Pretensioner
    GM1225155Courtesy of GENERAL MOTORS CORP.
    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 OFF position.
  2. Remove the ignition key.
  3. Put on safety glasses.
  4. Remove the seat belt pretensioner from the vehicle. Refer to Seat Belt Retractor Pretensioner Replacement - Left Front (Buick)  or Seat Belt Retractor Pretensioner Replacement - Right Front (Buick) .
  5. When carrying a pretensioner to the deployment area keep the open end of pretensioner pointed away from the body.
    6. Fig 2: Illustrating Proper Space For Deployment Of Pretensioner
    GM1225166Courtesy of GENERAL MOTORS CORP.
  6. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the pretensioner. 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.
  7. Make sure no loose or flammable objects are in the area.
  8. Place J 39401-B  in the center of the cleared area. See Special Tools and Equipment .
  9. Fill the fixture plastic reservoir with water or sand.
    10. Fig 3: Seat Belt Pretensioner And SIR Deployment Fixture
    GM1225176Courtesy of GENERAL MOTORS CORP.
  10. Mount the module (1) in the SIR deployment fixture (3) with the open end facing up using the following mounting method.
    • Adjust and secure the arms (4) of J 39401-B  to the deployment fixture (3). See Special Tools and Equipment .
    • To mount, use the proper size bolt (2) and nut (5) with washers in order to secure the pretensioner (1) to the deployment fixture brackets (4).
    • Securely tighten all fasteners prior to deployment.
    11. Fig 4: Identifying SIR Deployment Harness & Adapter
    GM68645Courtesy of GENERAL MOTORS CORP.
  11. Inspect the J 38826  SIR Deployment Harness and the appropriate pigtail adapter for damage. See Special Tools and Equipment . Replace as needed.
  12. Short the 2 SIR deployment harness (1) leads together using one banana plug seated into the other.
  13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1).
    14. Fig 5: Identifying Seat Belt Pretensioner Connector, Adapter & Deployment Harness
    GM1225179Courtesy of GENERAL MOTORS CORP.
  14. Extend the SIR deployment harness and adapter to full length from the deployment fixture.
  15. Connect the pretensioner (1) to the adapter (2) on the deployment harness (3).
    16. 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.
  16. Clear the area of people.
    17. Fig 6: Separating Banana Plugs
    GM39382Courtesy of GENERAL MOTORS CORP.
    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.
  17. Separate the 2 banana plugs on the SIR deployment harness.
    18. Fig 7: Deploying Seat Belt Pretensioner
    GM1225186Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When the seat belt pretensioner deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of the seat belt pretensioner due to the force of the rapid expansion of gas inside the pretensioner.
  18. Place a 12-volt minimum/2-amp minimum power source, such as a vehicle battery, near the shorted end of the harness.
  19. Connect the SIR deployment harness wires to the power source. Pretensioner deployment will occur when contact is made.
  20. Disconnect the SIR deployment harness from the power source after the pretensioner deploys.
    21. Fig 8: View Of Deployment Harness Leads
    GM9581Courtesy of GENERAL MOTORS CORP.
  21. Seat 1 banana plug into the other in order to short the deployment harness leads.
  22. If the pretensioner did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps.
  23. Put on a pair of shop gloves.
  24. Disconnect the pigtail adapter from the pretensioner as soon as possible.
  25. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed.
  26. Dispose of the deployed pretensioner through normal refuse channels.
  27. Wash your hands with a mild soap.
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