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Passenger Air Bag Assembly

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 of a live (undeployed) airbag assembly for disposal should not take place in the vehicle. This includes vehicles that needs replacement airbag assembly. Disposal of a malfunctioning air bag assembly is subject to a retention period.

Proper service procedures must be followed when performing live (undeployed) airbag deployment in the shop floor or open area live (undeployed) airbag deployment. Safety glasses and gloves must always be worn during live (undeployed) airbag deployment until the deployed airbag assembly has been properly disposed.

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 J-42986 SRS Deployment Harness with the appropriate pigtail adapter. The procedure also requires the use of J-41497 Passenger Side Supplemental Restraint System (SRS) Deployment Fixture. Do not attempt this procedure without J-42986 and fixture J-41497.

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. WEAR SAFETY 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 "Deployment Outside Vehicle" (Driver Air Bag Assembly) in this section.

1. Turn ignition switch to "LOCK" remove key, and put on safety glasses.
2. Inspect J-41434 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.




4. Connect the appropriate pigtail adapter to the SRS Deployment Harness
5. Remove passenger air bag assembly from vehicle. Refer to Passenger Air Bag Assembly Removal in this section.
6. Deploy a live (undeployed) airbag assembly in an open shop area allowing a radius of at least 183 cm (6 feet) attached to the J-41497 on the bench vise. Also make sure there is sufficient ventilation and no loose or flammable objects are within the area of deployment.
7. Attach the J-41497 securely on the bench vise to prevent injury during airbag deployment.
8. Attach the passenger air bag assembly in the J-41497. Air bag assembly must be mounted such that the bag will deploy upward. SECURELY HAND-TIGHTEN ALL FASTENERS PRIOR TO DEPLOYMENT.
9. The double pole extension cord must be at least 10 m (33 feet) away from the airbag assembly.




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 non deployment of the air bag assembly.

12. Keep the area clear of people and loose or flammable objects when deploying the passenger airbag to prevent injury.
13. Verify that the passenger air bag assembly is firmly and properly in J-41497.
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: DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND DISCONNECTED FROM 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 quickly reacts with the atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present for very long after deployment.

WARNING: SAFETY PRECAUTIONS 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 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 airbag assembly immediately after deployment to avoid damage to the pigtail adapter or SRS deployment harness from contacting the hot airbag assembly cannister. 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 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: 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.
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