SECTION 12M1 - AIRBAG
Service Precaution
General Description
SRS Component And Wiring Location View
Component Description
Definitions
Diagnosis
SRS Connector Body Face Views
Repairs And Inspections Required After An
Accident
On–Vehicle Service
Air Bag Assembly Handling / Shipping
/ Scrapping
Special Tools
Service Precautions for SRS Component
Service
SRS Connectors
Sensing And Diagnostic Module (SDM)
Service Precautions
Removal
Installation
Driver Air Bag Assembly
Service Precautions
Removal
Installation
Steering Wheel
Service Precautions
Removal
Installation
SRS Coil Assembly
Service Precautions
Removal
Installation
Steering Column
Service Precautions
Removal
Installation
Passenger Air Bag Assembly
Service Precautions
Removal
Installation
Main Data and Specifications
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, REFER
TO THE SRS SE RVICE INFORMATION. FAIL URE 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, or
other corrosion inhibitors) on threade d fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping f or ce, and may dama ge the fastener . Wh en
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 a t the same location from which they
were removed. If a fastener needs to be replaced,
use the correct part number fastener for that
application. If the correct part number 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.
Restrain t Devices
827LX00005
EndOFCallout
The Supplemental Restraint System (SRS) helps
supplement the protection offered b y the driver and front
passenger seat belts by deploying an air bag from the
center of the steering wheel and from the top of the right
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
instr umen t panel for both the dri ver and passenger, and
the steering column is collapsible.
827RW005
Legend
(1) Deployed Air Bag
(2) Knee Bolster
(3) Seat Belt
Syst em Description
The SRS consists of the Sensing and Diagnostic
Module (SDM), the driver air bag assembly, the SRS coil
assembly, the passenger air bag assembly and the “AIR
BA G" warning lamp in the instrument cluster . The SDM,
SRS coil assembly (driver side only), driver air bag
assembly, passenger air bag assembly and connector
wire make up the deployment loops. The function of the
deployment loops is to supply current through air bag
assembly, which will cause deplo yment of the air bags in
the event of a frontal crash of sufficient force, up to 30
degrees off the centerline of the vehicle. The air bag
assemblies are only supplied enough current to deploy
when the SDM detects vehicle velocity cha nges severe
enough to warrant deployment.
The SDM contains a sensing device which converts
vehicle velocity change to an electrical signal. The
electrical signal generated is processed by the SDM
and then compa red to a value stored in me mory. When
the generated signal exceeds the stored value, the SDM
will cause current to flow through the air bag assembly
deploying the air bags.
D09LX00001
SRS Component And Wiring Location View
810LX00014
EndOFCallout
Component Description
SDM (Sensing and Diagnostic Module)
WARNING: DURING SERVICE PROCEDURES, BE
VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR
JAR THE SDM. NEVER POWER UP TH E SRS WHE N
THE SDM IS NOT RIGIDLY ATTACHED TO THEVEHICLE. ALL SDM AND MOUNTING BRACKET
FASTENERS MUS T BE CAREFULLY TORQUED AND
THE ARROW MUST BE POINTED TOWARD THE
FRONT OF THE VEHICLE TO ENSURE PROPER
OPERATION OF THE SRS. THE SDM COULD BE
ACTIVATED WHEN POWERED WHILE NOT RIGIDLY
ATTACHED TO THE VEHICLE WHICH COULD
CAUSE DEPLOYMENT AND RESULT IN PERSONAL
INJURY.
The Sen si ng and Di agn os tic M odu le (SDM) i s des ig ned
to perform the following functions in the SRS:
Legend
(1) Battery
(2) Relay & Fuse Box
(3) Passenger Air Bag Assembly
(4) SDM
(5) Meter Assembly
(6)SRS Coil Assembly
(7) Driver Air Bag Assembly
(8) Starter Switch
(9) Fuse Box, C–21
(10) SRS Body Earth
(11) Body Harness Connector
(12) Instrument Harness Connector
(13) Engine Haness Connector
1.Energy Reserve — The SDM maintains 24–Volt
Loop Reserve (24VLR) energy supply to provide
deployment energy when ignition voltage is lost in a
frontal crash.
2.Frontal Crash Detection — The SDM monitors
vehicle velocity changes to detect frontal crashes
which are severe enough to warrant deployment.
3.Air Bag Deployment — When a frontal crash of
sufficient force is detected, the SDM will cause
enough current to flow through the air bag assembly
to deploy the air bag.
4.Malfunction Detection — The SDM performs
diagnostic monitoring of SRS electrical components
and sets a diagnostic trouble code when a
malfunction is detected.
5.Frontal Crash Recording — The SDM records
information regarding SRS status during frontal
crash.
6.Malfunction Diagnosis — The SDM displays SRS
diagnostic trouble codes and system status
information through the use of a scan tool.
7.Driver Notification — The SDM warns the vehicle
driver of SRS malfunctions by controlling the “Air
Bag" warning lamp.
The SDM is connected to the SRS wiring harness by a
24–pin connector. This harness connector uses a
shorting clip across certain terminals in the contact
area. This shorting clip connects the “AIR BAG"
warning lamp to ground when the SDM harness
connector is disconnected or CPA (Connector Position
Assurance) is not inserted even if completely
connected. This will cause the “AIR BAG" warning lamp
to come “ON" steady whenever the ignition switch is at
the ON or START positions with the SDM disconnected.
827RW026
EndOFCallout
“Air Bag" Warning Lamp
Ignition voltage is applied to the “AIR BAG" warning
lamp when the ignition switch is at the ON or START
positions. The SDM controls the lamp by providing
ground with a lamp driver. The “AIR BAG" warning
lamp is used in the SRS to do the following:
1.Verify lamp and SDM operation by flashing SEVEN
(7) times when the ignition switch is first turned
“ON".
2.Warn the vehicle driver of SRS electrical system
malfunctions which could potentially affect the
operation of the SRS. These malfunctions could
result in nondeployment in case of a frontal crash or
deployment for conditions less severe than
intended.
The “AIR BAG " warning lamp is the key to driver
notification of SRS malfunctions. For proper lamp
operation, refer to the “SRS Diagnostic System Check"
in this section.
821LY011
SRS Coil Assembly
The SRS c oil assem bly c onsists of two current ca rr ying
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
dr iver air bag asse mbly.
There is a shorting clip on the yellow 2–pin 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 2–pin 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.
Legend
(1) SDM
(2) SRS Harn ess
(3) Connector Positi on Assurance
825LX00017
Air Bag Assemblies
The air bag assembly consist of an inflatable air bag
assembly and an inflator (a canister of gas–generating
material and an initiating device). When the vehicle is
in a frontal crash of sufficient force.
The SDM 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
connecto r which connects the SRS coil assembly. Th e
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 shor ted in
this way to he lp prevent un wanted de ployment of t he a ir
bag when servicing the driver air bag assembly, the
steering column or other SRS components.
827RS008
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.
827RV012
Steering Column
The steering colum n abs or bs en er gy and is design ed to
compress in a frontal crash to decrease the chance of
injury to the driver.
431RS006
Knee Bolster
The knee bol sters are used to abs orb energy to prot ect
knees and control the f orward mov ement of the vehicle's
front seat occupants during a frontal crash, by limiting
leg movement.
Definitions
Air Bag
An inflata ble cloth c us hi on de si gne d to deploy in cert ain
frontal crashes. It supplements the protection off ered 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 th e tim e of the indicate d measuremen t. Wit h
the key “ON" and the engine not running, the system
v oltage will likely be between 12 and 12.5 volts. At idle,
the voltage may be 14 to 16 volts. The v oltage could be
as low as 10 volts during engine cranking.
Bulb Check
The SDM 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.
“Continuous Monitoring"
Tests performed by the SDM on the SRS every 100
milliseconds while “Ignition 1" voltage is in the normal
operating voltage range at the SDM.
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 (D TC)
Formerly “Code", a numerical designator used by the
SDM to indicate specific SRS malfunctions.
Driver Current Source
An output of the SDM which applies current into the
driver air bag assembly circuit during the “Initiator
Assem bly Resistance Test".
Driver Air Bag Assembly
An assembly located in the steering wheel hub
consisting of an inflatable bag, an inflator and an
initiator.
EEPROM
Electrically Erasable Programmable Read Only
Memory. Memory which retains its contents when
power is removed from the SDM.
Ignition Cycle
The voltage at the SDM “I gnition 1" in puts, with ignit ion
switch “ON", is within the normal operating voltage
range for at least ten seconds before turning ignition
switch “OFF".
Ignition 1
A battery voltage (B+) circuit which is only powered with
the ignition s witch in the ON, or START positions.
Initiator
The electrical component inside the air bag assembly
which, when sufficient current flows, sets off the
chemical reaction that inflates the air bag.
“Initiator Assembly Resistance Test"
Tests performed once each ignition cycle when no
malfunctions are detected during “Turn–ON" or
“Continuous Monitoring". This test checks f or the correct
SDM configuration for the vehicle, shor ts to “Ignition 1"
in the deployment loops, high resistance or opens in the
“Driver Side High", “Driver Side Low", “Passenger Side
High" a nd “Passe nger Side Low" c ircuits and me asures
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 SDM “Ignition 1"
terminals and “Ground" terminals is between 9 and 16
volts.
Passenger Current Source
An output of the SDM 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 right side of the instrument
panel consisting o f an inflatable bag, an inflato r and an
initiator.
Scan Tool
An external computer used to read diagnostic
information from on–board computers via the data link
connector.
SDM
Sensi ng and Diagn ostic Module which provid es 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 SDM performs on the SRS once during
each ignition cycle immediately after “Ignition 1" voltage
is applied to the SDM and before “Continuous
Monitoring".
Diagnosis
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS, DO NOT USE
ELECTRICAL TEST EQUIPMENT SUCH AS A
BATTERY–POWERED OR AC–POWERED
VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN THAT
SPECIFIED IN THIS MANUAL. DO NOT USE A
NONPOWERED PROBE–TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
Diagnostic Trouble Codes
The “SRS Diagnostic System Check" must always be
the starting point of any SRS diagnosis. The “SRS
Diagnostic System Check" checks for proper “AIR BAG"
warni ng lamp operation and checks for SRS diagnostic
trouble codes using the scan tool.
1. Curr en t di a gno st ic trouble codes – Ma l fu n ct i ons t h at
are presently being detected. Current diagnostic
trouble codes are stored in RAM (Random Access
Memory).
2. History diagnostic trouble codes – All malfunctions
detected since the last time the history memory was
cleared. History diagnostic trouble codes are stored
in EEPROM.
Scan Tool Diagnostics
A scan tool is used to read current and history
diagnostic trouble codes and to clear all diagnostic
trouble codes after a repair is completed. The scan tool
must be update d to co mmunicat e with th e SRS t hroug h
a replaceable cartridge before it can be used for SRS
diagnosti c s. To use the scan to ol , c onn ec t i t to the data
link connector and turn the ignition switch “ON". The
scan tool reads serial data from the SDM “Serial Data"
line terminal “24" to the data link connector terminal “9".
Use Of Special Tools
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS, DO NOT USE
ELECTRICAL TEST EQUIPMENT SUCH AS A
BATTERY–POWERED OR AC–POWERED
VOLTMETER, OHMMETER, ETC, OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN THAT
SPECIFIED IN THIS MANUAL. DO NOT USE A NON
POWERED PROBE–TYPE TESTER. INSTRUCTIONS
IN THIS MANUAL MUST BE FOLLOWED
CAREFULLY, OTHERWISE PERSONAL INJURY MAY
RESULT. YOU SHOULD BE FAMILIAR WITH THE
TOOLS LISTED IN THIS SECTION UNDER THE
HANDLING SRS SPECIAL TOOLS.
You should be able to measure voltage and resista nce.
You should be familiar with proper use of a scan tool
such as the Tech 2 Diagnostic Computer, SRS Driver/
Passenger Load Tool 5–8840–2421–0, Connector Test
Adapter Kit 5–8840–0385–0, and the DVM (Digital
Multimeter) 5–8840–0285–0.
SRS Connector Body Face Views
D09RW003
EndOFCallout
Repairs And Inspections Required
After An Accident
NOTE: 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 for SRS
repairs.
• Do not attempt to service the SDM, 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
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, replaceme nt of the SDM, air
bag assembly and dimensional inspection of the
steering column. Any visible damage to the SDM
mounting bracket (s) requires replacement, and the
steering column must be dimensionally inspected,
whether 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
•SDM
Legend
(1) SDM
(2) Driver Air Bag Assembl y
(3) Passenger Air Bag Assembly
(4) “Air Bag" Warni ng Lamp
(5) SRS Coil Assembly
(6) DLC Connector
CAUTION: Refer to “SDM Replacement Guidelines"
below for important information on SDM
replacement in both deployment and non
deployment crashes.
•SRS coil assembly — Inspect wiring and connector
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 for any
distortion, bending, cracking, or other damage.
•I/P steering column reinforcement plate — Inspect for
any distortion, bending, cracking, or other 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.
SDM Replacement Guidelines
SDM replacement policy requires replacement of SDM,
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.
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 SDM 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 SDM
is removed.
Many of the service procedures require removal of the
“SRS 2" 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 2, from left dash side lower
fuse block or disconnect battery.
2.Disconnect yellow 2–pin connector at the base of
steering column.
3.Remove glove box assembly, refer to “Passenger Air
Bag Assembly Replacement" in this manual.
4.Disconnect yellow 2–pin connector behind the glove
box assembly.
CAUTION: With the “SRS 2" 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
Trooper which is being repaired.
Turn ignition switch to “LOCK" and remove key.
1.Connect yellow 2–pin connector passenger air bag
assembly.
2.Install glove box assembly. Refer to “Passenger air
bag assembly replacement" in this manual.
3.Connect yellow 2–pin connector at the base of
steering column.
4.Install “AIR BAG" fuse SRS 2 to left dash side lower
fuse block or 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 (150°F).
2. Air bag assembly, and SDM should not be used if
they have been dropped from a height of 100
centimeters (3.28 feet) or more.
3.When a SDM 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 SDM to be
located flat on the mounting surface, parallel to the
vehicle datum line. It is important that the SDM
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 may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacement.
Air Bag Assembly Handling /
Shipping / Scrapping
Live (Undeployed) Air Bag Assembly
Special care is necessary when handling and storing a
live (undeployed) air bag assembly. The rapid gas
generation produced during deployment of the air bag
could cause the air bag assembly, or an object in front of
the air bag assembly, to be thrown through the air in the
unlikely event of an accidental deployment.
827RV004
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG OPENING IS
POINTED AWAY FROM YOU. IN CASE OF AN
ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN
DEPLOY WITH MINIMAL CHANCE OF INJURY.
NEVER CARRY THE AIR BAG ASSEMBLY BY THE
WIRES OR CONNECTOR ON THE UNDERSIDE OF
THE MODULE.
827RS044
Air Bag Assembly Shipping Procedure For
Live (Undeployed) Air Bag Assemblies
Service personnel should refer to the latest Service
Bulletins for proper SRS air bag assembly shipping
procedures.
Deployed Air Bag Assembly (Driver Side)
You should wear gloves and safety glasses. After the air
bag as sembly has be en depl oyed, the s urface 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
react ion. Sodium hydroxi de 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.
Air Bag Assembly Scrapping Procedure
During the course of a vehicle's useful life, certain
situations may arise which will necessitate t he disposal
of a live (undeployed) air bag assembly. This
informa tion covers proper procedure s for di sposing of a
live air bag assembly.
Before a live air bag assembly can be disposed of, it
must be deployed. A live air bag assembly must not be
disposed of through normal refuse channels.
WARNING: FAILURE TO FOLLOW PROPER
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR
BAG ASSEMBLY DISPOSAL PROCEDURES CAN
RESULT IN AIR BAG DEPLOYMENT WHICH MAY
CAUSE PERSONAL INJURY. AN UNDPLOYED AIR
BAG ASSEMBLY 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 LAW.
In situations which require deployment of a live air bag
assembly, deployment may be accomplished inside or
outside the vehicle. The method employed depends
upon the final disposition of the particular vehicle, as
noted in “Deployment Outside Vehicle" and
“Deployment Inside Vehicle" in this section.
Deployment Outside Vehicle (Driver Air
Bag 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 air bag assembly is replaced. Deployment and
disposal of a malfunctioning air bag assembly is, of
course, subject to any required retention period.
For deployment of a live (undeployed) air bag assembly
outside the vehicle, the deployment procedure must be
followed exactly. Always wear safety glasses during
this deployment procedure until a deployed air bag
assembly is scrapped or until an undeployed air bag
assembly is shipped. Before performing the procedures
you should be familiar with servicing the SRS 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 appropriate pigtail
adapter. Do not attempt procedure without 5–8840–
2468–0 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
DRIVER 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 driver air bag
assembly . Refer to “Deployment Outside Vehicle
(Passenger Air Bag assembly)" in this section for
information on passenger air bag assembly scrapping.
1.Turn ignition switch to “LOCK", 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 adapter 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. SRS deployment harness shall remain
shorted and not be connected to a power source
until the air bag is to be deployed.
827RS004
4.Connect the appropriate pigtail adapter to the SRS
deployment harness.
5.Remove the driver air bag assembly from vehicle.
Refer to “Inflator Module Removal" in this manual.
WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
ASSEMBLY UNATTEN DED ON A B ENCH OR OTHER
SURFACE, ALWAYS FACE THE AIR BAG AND TRIM
COVER UP AND AWAY FROM THE SURFACE. THIS
IS NECESSARY SO THAT A FREE SPACE IS
PROV IDED TO ALLOW THE AIR BAG TO EX PAND IN
THE UNLIKELY EVENT OF ACCIDENTAL
DEPLOYMENT. FAILURE TO FOLLOW
PROCEDURES MAY RESULT IN PERSONAL INJURY.
6.Place the driver air bag assembly on a work bench
or other surface away from all loose or flammable
objects with its trim cover facing up, away from the
surface.
827RV003
7.Clear a space on the ground about 183 cm (six feet)
in diameter where the driver air bag 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.
827RV005
8.Place the driver air bag assembly, with its trim cover
facing up, on the ground in the space just cleared.
9.Stretch the SRS deployment harness and pigtail
adapter from the driver 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 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 30 cm (one foot) vertically.
This is a normal reaction of the driver air bag to the
force of the rapid gas expansion inside the air bag.
NOTE: When the 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 driver air bag.
WARNING: DEPLOYMENT HARNESS SHALL
REMAIN SHORTED AND NO T 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 T O 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. Reco mmended ap pli cati on: 1 2 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 power 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 the 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: SAFETY PRECAUTIONS 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: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE INFLATOR
MODULE UNATTENDED ON A BENCH OR OTHER
SURFACE, ALWAYS FACE THE BAG AND TRIM
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. 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 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
5.Remove passenger air bag assembly from vehicle.
Refer to “Passenger Air Bag Assembly Removal ".
6.Clear a space on the ground approximately 183 cm
(six feet) in diameter 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
sufficien t ventilat ion is r e com me nded . En sur e tha t
no loose or flammable objects are within the
deployment area.
7. Place the 5–8840–242 0–0 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: 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.
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.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. Post deployment products are
relatively pH neutral. Disposing the inflator by
burying it in a landfill will not produce any hazardous
products. As with any dusty environment, safety
goggles, dust mask and gloves should be worn.
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 air bag
assembly as soon after deployment as possible to
avoid damage to the pigtail adapter or SRS
deployment har ne ss fro m con tactin g the hot ai r 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. E nsure that the SR S deployme nt harn ess 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: 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 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 “LOCK," 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
mm2 (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
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 A ND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED.
THE AIR BAG ASSEMBLY WILL IMMEDIATELY
DEPLOY THE AIR B AG 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 f ollo w pr ocedures in the or der 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. S tr ip 13 mm (1/2 i nch) of insul ation from blue–white
and pink–blue wire lead of the connector.
16. Cu t two 900 cm (30 feet) deployment wires from 0.8
mm2 (18 gauge) or thick er 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 en ds
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 A ND 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 B AG 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: When the 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 bags.
28. Connect the driver deployment harness wires to a
power source to immediately deploy the driver air
bag assem bly. Recom me nded appl ic ati on: 12 volts
minimum, 2 amps minimum. A vehicle battery is
suggested.
29. Separate the two ends of the passenger deployment
harness w ires.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED A ND 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 B AG 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 an air bag
assembly has been depl oyed, the su rface 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 h ydroxide 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.(Passenger air bag assembly) The
passenger inflator requires no special precaution
after deployment. 95% of the particulate emission
are potassium chloride (KLC), which is commonly
sold as an edible salt-substitutes. even if water is
applied. Post deployment products are relatively pH
neutral. Disposing the inflator by burying it in a
landfill will not products any hazardous products. As
with any dusty environment, safety goggles, dust
mask and gloves should be worn.
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 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 FOLLOW
PROCEDURES 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 “Passenger Air Bag Assembly Removal" in this
manual.
WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
ASSEMBLY UNATTENDED ON A BENC H OR OTHER
SURFACE, ALWAYS FACE THE BAG AND TRIM
COVER UP, AWAY FROM THE SURFACE. THIS IS
NECESS ARY SO THAT A FREE SPA CE IS PR OVIDED
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 ope ning 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
protec t your hands and eyes from pos sible irri tation 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.
Special Tools
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS, DO NOT USE
ELECTRICAL TEST EQUIPMENT SUCH AS A
BATTERY–POWERED OR AC–POWERED
VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN THAT
SPECIFIED IN THIS MANUAL. DO NOT USE A
NONPOWERED PROBE–TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
5–8840–2421–0 SRS Driver/Passenger
Load Tool
901RS146
The SRS Driver/Passenger Load Tool 5–8840–2421–0
is used only when called for in this section. It is used
as a diagnostic aid and safety device to prevent
inadvertent air bag assembly deployment.
The load tool has three y ellow connectors attached to its
case.
The three small connectors are electrically functional
and serve as resistive load substitutions.
No more than two connectors are used at any time.
One of the small connectors is used to substitute for the
load of the driver air bag ass em bly when it is co nnec te d
at the top of the column to the SRS coil assembly.
Another small connector is used to substitute for the
load of the driver air bag assembly and the SRS coil
assembly when it is connected at the base of the
column to the SRS wiring harness. The third small
connector is used to substitute for the load of the
passenger air bag assembly when connected to the
passenger air bag assembly harness connector.
By substituting the resistance of the load tool when
called for, a determination can be made as to whether
an inflator circuit component is causing system
malfunction and which component is causing the
malfunction. The load tool should be used only when
specifically called for in the diagnostic procedures.
5–8840–0285–0 DVM
901RS153
The 5–8 840–0285–0 DVM is the pr eferred DVM for use
in SRS diag nosis a nd rep air. However, 5–884 0–0366–
0 may be used if 5–8840– 0285–0 is not available. No
other DVMs are approved for SRS diagnosis and repair.
Scan Tool
901RW176
The Tech 2 is used to read and clear SRS Diagnostic
Trouble Codes (DTCs). Refer to the Tech 2 Operators,
Manual for specific infor mation on how to use the Tech
2.
5–8840–0385–0 Connector Test Adapter Kit
901RS151
The 5–8840–0385–0 Connector Test Adapter Kit must
be used whenever a diagnostic procedure requests
checking or probing a terminal. Using the appropriate
adapter will ensure that no damage to the terminal will
occur from the DVM prove, such as spreading or
bending. The adapter will also give an ide a of whet her
contact tension is sufficient, helping to find an open or
intermittent open due to poor terminal contact.
5–8840–2468–0 SRS Deployment Harness
901RW106
The 5–8840–2468–0 SRS Deployment Tool must be
used for deployment of the undeployed air bag.
5–8840–2420–0 SRS Deployment Fixture
901RW199
The 5–8840–2420–0 SRS Deployment Fixture must be
used for deployment of the undeployed passenger side
air bag.
5–8840–2469–0 SRS Adapter for Load Tool.
901RW107
The 5–8840–2469–0 SRS Adapter for Load Tool must
be used with 5–8840–2421–0 SRS Driver/Passenger
Load Tool.
Tech 2 Scan Tool
From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2
scan tool user guide.
901RW200
EndOFCallout
Getting Started
• Before operating the Isuzu PCMCIA card with the
Tech 2, the following steps must be performed:
1. Insert the Isuzu 98 System PCMCIA card (1) into
the Tech 2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC
cable (4).
3. Connect the DLC cable to the Tech 2 (5)
4. Make sure of the vehicle ignition is of f.
5. Connect the Tech 2 SAE 16/19 adapter to the
vehicle DLC connector.
740LX00007
6. Turn on the vehicle ignition switch.
7. Verify the Tech 2 power up display.
060RW009
NO TE: The RS232 Loop back connector is only used to
diagnosis Tech 2. Refer to user guide of the Tech 2.
Legend
(1) PCMCIA Card
(2) RS 232 Loop Back Connector
(3) SAE 16/19 Adaptor
(4) DLC Cable
(5) Tech–2
Service Precautions for SRS
Component Service
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 for that
application. If the correct part number 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.
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 SDM 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 SDM
is removed.
Many of the service procedures require removal of the
“SRS 2" 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 “OFF" and turn the steering
wheel so that the vehicle's wheels are pointing straight
ahead.
1.Remove SRS fuse “SRS 2" from left dash side lower
fuse block or disconnect battery.
2.Disconnect yellow 2–pin connector at the base of
steering column.
3.Remove glove box assembly; Refer to “Passenger
air bag assembly replacement" in this section.
4.Disconnect passenger air bag assembly yellow 2–
pin connector behind the glove box assembly.
CAUTION: With the “SRS 2" 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
Turn ignition switch to “LOCK" and remove key.
1.Connect yellow 2–pin connector passenger air bag
assembly.
2.Install glove box assembly. Refer to “Passenger Air
Bag Assembly Replacement" in this section.
3.Connect yellow 2–pin connector at the base of the
steering column.
4.Install “AIR BAG" fuse “SRS 2" to left dash side
lower fuse block or 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 section.
Handling / Installation / Diagnosis
1.Air bag assembly should not be subjected to
temperatures above 65°C (150°F).
2.Air bag assembly, and SDM should not be used if
they have been dropped from a height of 100
centimeters (3.28 feet) or more.
3.When a SDM is replaced, it must be oriented with
the arrow on the SDM pointing toward the front of
the vehicle. It is very important for the SDM to be
located flat on the mounting surface, parallel to the
vehicle datum line. It is important that the SDM
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.
Bypas si ng the se proc ed ur es may resu lt in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacements.
Inspections Required After An Accident
CAUTION: Certain SRS components must be
replaced after a frontal crash involving air bag
deployment.
In all types of accidents regardless of “Air Bag"
deployment, visually inspect all of the following
components and replace as required:
– Driver air bag assembly
– Passenger air bag assembly
– Steering wheel
– SRS coil assembly
– Steering column
– Knee bolster and instrument panel mounting
attachments
– Driver seat and belt
– Passenger seat and belt
–SDM
SDM always should be checked according to “SDM
Replacement Guidelines."
CAUTION: Refer to “SDM Replacement Guidelines"
below for important information on SDM
replacement in both deployment and non–
deployment crashes.
Inspect SRS coil assembly wiring and steering wheel for
any sign of scorching, melting, or damage due to
excessive heat. If coil assembly wire or steering wheel
is damaged, replace them. The steering column and
wheel must be dimensionally checked to determine if
they are damaged. Refer to Steering Wheel of in this
manual.
Never use SRS parts from another vehicle. This does
not include remanufactured parts purchased from an
authorized Isuzu Retailer; they may be used for SRS
repairs.
Do not attempt to repair the SDM, the SRS harness, the
SRS coil assembly, the air bag assembly, the steering
wheel, or the steering column. Service of these items is
replacement only. Verify replacement part numbers.
CAUTION: Proper operation of the SDM and
supplemental restraint system (SRS) requires that
any repairs to the vehicle structure return it to its
original pr oduction configuration.
SRS Connectors
CAUTION: The special yellow color connectors are
used for supplemental restraint system-air bag
circuit. When removing the oable harnese, do not
pull the cables otherwile, cable disconnection may
occur. When connect the SRS connector, inser t the
connector completely. Imperfect locking may cause
malfunction of SRS circuit.
Removal
To remove the connector, hold the cover insulator (1)
and pull it. The cover insulator slides and lock will be
released. Do not hold the socket insulator (2).
827RW028
Installation
To install the connector, hold the sock et insulator (1) and
insert it. The cover insulator slides and connector will be
locked. Do not hold the cover ins ulator (2).
827RW027
Sensing And Diagnostic Module (SDM)
Service Precautions
WARNING: DURING SERVICE PROCEDURES, BE
VERY CAREFUL WHEN HANDLING SDM. NEVER
STRIKE OR JAR SDM. UNDER SOME
CIRCUMSTANCES, IT COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL INJURY
OR IMPROPER OPERATION OF THE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . SDM
MOUNTING BRACKET BOLTS MUST BE
CAREFULLY TORQUED TO ASSURE PROPER
OPERATION. NEVER POWER UP THE SRS WHEN
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE.
THE SDM COULD BE ACTIVATED WHEN POWERED
WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE
WHICH COULD CAUSE DEPLOYMENT AND RESULT
IN PERSONAL INJURY.
WARNING: PROPER OPERATION OF THE SENSING
AND DIAGNOSTIC MODULE (SDM) REQUIRES THE
SDM TO BE RIGIDLY ATTACHED TO THE VEHICLE
STRUCTURE AND THAT THE ARROW ON THE
SENSOR BE POINTING TOWARD THE FRONT OF
THE VEHICLE.
SDM is specifically calibrated and is keyed to the SDM
location SRS wiring harness. Caution should be used
to ensure proper location of the SDM. The keying of the
SDM to its location and wiring harness connectors
should never be modified in the field.
Removal
1.Disable the SRS (Refer to “Disabling the SRS" in
this section) .
2. Remove the transmission knob (for M/T) and
transfer lever knob.
3. R emove the front con sole asse mbly and di sconn ect
wiring harness connector.
4. Pull CPA (Connector Position Assurance) out and
push connector lock down to disconnect the SDM
harness connector.
5. Remove the three SDM fixing bolts and remove
SDM.
827RW026
EndOFCallout
Installation
1. Install the SDM on bracket and fixing bolts and
tighten the fixing bolts to the specified torque.
Torque: 10 N·m (100 kg·cm/89 Ib in)
2. Co nnect the SD M har ne ss connec tor and afte r that,
put CPA into connector.
3. Install the front console.
4. Install the transmission knob (for M/T) and transfer
lever knob.
Legend
(1) SDM
(2) SRS Harness
(3) Connector Position Assurance
Driver Air Bag Assembly
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL
AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION, THAT
IS IRRITATING TO THE SKIN AND EYES. MOST OF
THE POWER ON THE AIR BAG ASSEMBLY IS
HARMLESS. AS A PRECAUTION, WEAR GLOVES
AND SAFETY GLASSES WHEN HANDLING A
DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR
HANDS WITH MILD SOAP AND WATER
AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE
OF INJURY. WHEN PLACING ALIVE AIR BAG
ASSEMBLY ON A BENCH OR OTHER SURFACE,
ALWAYS FACE BAG AND TRIM COVER UP, AWAY
FROM THE SURFACE. NEVER REST A STEERING
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD RESULT.
NOTE: In the event deployment has occurred, inspect
coil assembly wire for any signs of scorching, melting or
any other damage due to excessive heat. If the coil has
been damaged, replace it.
Removal
1.Disable the SRS (Refer to “Disabling the SRS" in
this section).
2.Loosen the air bag assembly fixing bolts from
behind the steering wheel assembly using a TORX®
driver or equivalent until the air bag assembly can
be released from steering wheel.
827LX00004
3.Disconnect the yellow 2–pin connector located
behind the air bag assembly and remove air bag
assembly. Refer to “SRS Connectors" in this section
for removal and installat ion .
827LX00003
Installation
1.Connect air bag to wiring harness connector.
NOTE: Pass the lead wire through the tabs on the
plastic cover (wire protector) of air bag to prevent lead
wire from being pinched.
827LX00003
2.Install air bag into steering wheel and tighten bolts
to specified sequence as shown in figure.
Torque: 8 N·m (81 kg·cm/69 Ib in)
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
which is being repaired.
827RW007
3.Enable the SRS (Refer to “Enabling the SRS" in this
section).
Steering Wheel
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL
AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION,
THAT IS IRRITATING TO THE SKIN AND EYES.
MOST OF THE POWER ON THE AIR BAG
ASSEMBLY IS HARMLESS. AS A PRECAUTION,
WEAR GLOVES AND SAFETY GLASSES WHEN
HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND
WASH YOUR HANDS WITH MILD SOAP AND WATER
AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE
OF INJURY. WHEN PLACING ALIVE AIR BAG
ASSEMBLY ON A BENCH OR OTHER SURFACE,
ALWAYS FACE BAG AND RIM COVER UP, AWAY
FROM THE SURFACE. NEVER REST A STEERING
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD RESULT.
NOTE: In the event deployment has occurred, inspect
coil assembly wire for any signs of scorching, melting or
any other damage due to excessive heat. If the coil has
been damaged, replace it.
Removal
1.Disable the SRS (Refer to “Disabling the SRS" in
this section).
2.Loosen the air bag assembly fixing bolts from
behind the steering wheel assembly using a TORX®
driver or equivalent until the air bag assembly can
be released from steering wheel.
827LX00004
3.Disconnect the yellow 2–pin connector located
behind the air bag assembly and remove air bag
assembly. Refer to “SRS Connectors" in this section
for removal and installat ion .
4. Disconnect horn lead.
827LX00003
5. Remove steering wheel attachment nut.
6. A pply a setting mar k across the steering whe el and
shaft so par ts can be reassembled in their original
position.
430RS004
7. Move the tires to the straight ahead position before
removing the steering wheel. Install steering wheel
puller onto steering wheel and remove steering
wheel with 5–8521–0016–0.
827LX00002
8. Feed wiring through the wheel and remove wheel.
CAUTION: Never apply force to the steering wheel
in direction of the shaft by using a hammer or other
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
Installation
1. Install the steering wheel and align the setting
marks.
430RS004
2. Tighten the steering wheel fixing nut to the specified
torque.
Torque : 34 N·m (3.5 kg·m/25 Ib ft)
3. Co nne ct horn lead.
4. Connect air bag to wiring harness connector.
NOTE: Pass the lead wire through the tabs on the
plastic cover (wire protector) of air bag to prevent lead
wire from being pinched.
827LX00003
5.Install air bag into steering wheel and tighten bolts
to specified sequence as show in figure.
Torque: 8 N·m (81 kg·cm/69 Ib in)
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
which is being repaired.
827LX00004
6.Enable the SRS (Refer to “Enabling the SRS" in this
section).
SRS Coil Assembly
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL
AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION, THAT
IS IRRITATING TO THE SKIN AND EYES. MOST OF
THE POWER ON THE AIR BAG ASSEMBLY IS
HARMLESS. AS A PRECAUTION, WEAR GLOVES
AND SAFETY GLASSES WHEN HANDLING A
DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR
HANDS WITH MILD SOAP AND WATER
AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE
OF INJURY. WHEN PLACING ALIVE AIR BAG
ASSEMBLY ON A BENCH OR OTHER SURFACE,
ALWAYS FACE BAG AND RIM COVER UP, AWAY
FROM THE SURFACE. NEVER REST A STEERING
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD RESULT.
NOTE: In the event deployment has occurred, inspect
coil assembly wire for any signs of scorching, melting or
any other damage due to excessive heat. If the coil has
been damaged, replace it.
Removal
1.Disable the SRS (Refer to “Disabling the SRS" in
this section).
2.Loosen the air bag assembly fixing bolts from
behind the steering wheel assembly using a TORX®
driver or equivalent until the air bag assembly can
be released from steering wheel.
827LX00004
3.Disconnect the yellow 2–pin connector located
behind the air bag assembly and remove air bag
assembly. Refer to “SRS Connectors" in this section
for removal and installat ion .
4. Disconnect horn lead connector.
827LX00003
5. Remove the steering wheel attachment nut.
6. A pply a setting mar k across the steering whe el and
shaft so par ts can be reassembled in their original
position.
430RS004
7. Move the tires to the straight ahead position before
removing the steering wheel and remove wheel with
5–8521–0016–0.
827LX00006
8. Feed wiring though the wheel and remove wheel.
9. Remove the steering lower cover and engine hood
opening lever.
10. Remove the driver knee bolster assembly.
11. Remove the steering column cover.
12. Remove air conditioning lower duct.
13. Disconnect the 2–pin wiring harness connectors
located at the base of steering column.
CAUTION: Never apply force to the steering wheel
in the direction of the shaft by using a hammer or
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as an
energy absorbing unit.
14. Remove the combination switch assembly with
SRS coil.
NOTE: SRS coil is a part of combination switch
assembly, which cannot be replaced separately.
Therefore, be sure not to remove t he SRS coil from the
combination switch assembly.
Installation
1. Install the combination switch assembly with SRS
coil.
2. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark (1).
CAUTION: When turning the SRS coil
counterclockwise to full, stop turning if resistance
is felt. For ced further turning may damage the cable
in the SRS coil.
826RW014
3. Connect the wiring harness connectors located at
the base of steering column.
4. Install the air conditioning lower duct.
5. Install the steering column cover.
CAUTION: When installing the steering column
cover, be sure to wire (through each harness) as
illustrated so that the harness starter switch,
combination switch and SRS coil may not catch
wiring.
825RS048
6.Install the driver knee bolster assembly.
7.Install the steering lower cover and engine hood
opening lever.
8.Install the steering wheel and align the setting
marks.
430RS004
9.Tighten the steering wheel fixing nut to the
specified torque.
Torque: 34 N·m (3.5 kg·m/25 Ib ft)
10.Connect horn lead.
11.Connect air bag to wiring harness connector.
NOTE: Pass the lead wire through the tabs on the
plastic cover (wire protector) of air to prevent lead wire
from being pinches.
827LX00003
12.Install air bag into steering wheel and tighten bolts
to specified sequence as shown in figure.
Torque: 8 N·m (81 kg·cm/69 Ib in)
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
which is being repaired.
827LX00004
13.Enable the SRS (Refer to “Enabling the SRS" in this
section).
Steering Column
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL
AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION, THAT
IS IRRITATING TO THE SKIN AND EYES. MOST OF
THE POWER ON THE AIR BAG ASSEMBLY IS
HARMLESS. AS A PRECAUTION, WEAR GLOVES
AND SAFETY GLASSES WHEN HANDLING A
DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR
HANDS WITH MILD SOAP AND WATER
AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE
OF INJURY. WHEN PLACING ALIVE AIR BAG
ASSEMBLY ON A BENCH OR OTHER SURFACE,
ALWAYS FACE BAG AND RIM COVER UP, AWAY
FROM THE SURFACE. NEVER REST A STEERING
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD RESULT.
NOTE: In the event deployment has occurred, inspect
coil assembly wire for any signs of scorching, melting or
any other damage due to excessive heat. If the coil has
been damaged, replace it.
Removal
1.Disable the SRS (Refer to “Disabling the SRS " in
this section).
2.Loosen the air bag assembly fixing bolts from
behind the steering wheel assembly using a TORX®
driver or equivalent until the air bag assembly can
be released from steering wheel.
827LX00004
3.Disconnect the yellow 2–pin connector located
behind the air bag assembly and remove air bag
assembly. Refer to “SRS Connectors" in this section
for removal and installat ion .
827LX00003
4. Disconnect horn lead connector.
5. Remove the steering wheel attachment nut.
6. A pply a setting mar k across the steering whe el and
shaft so par ts can be reassembled in their original
position.
430RS004
7. Move the tires to the straight ahead position before
removing the steering wheel and removing wheel
with 5–8521 –0016–0.
827LX00006
8. Feed wiring though the wheel and remove wheel.
9. Remove the steering lower cover and engine hood
opening lever.
10. Remove the driver knee bolster assembly.
11. Remove the steering column cov er.
12. Remove air conditioning lower duct.
13. Disconnect the wiring harness connectors located
at the base of steering column.
CAUTION: Never apply force to the steering wheel
in direction of the shaft by using a hammer or other
impact tools in an attempt to remove the steering
wheel. The steer ing shaft is designed as an ene rgy
absorbing unit.
14. Remove the combination switch assembly with
SRS coil.
NOTE: SRS coil is a part of combination switch
assembly, which cannot be replaced separately.
Therefore, be sure not to remove t he SRS coil from the
combination switch assembly.
15. Re move the snap ring.
16. Re move the cushion rubber.
17. Disconnect shift lock cab le (A/T only).
18. Disconnect the starter switch harness connector
located base of steering column.
19. Remove steering lock cylinder assembly.
20. Apply a setting mark across the universal joint and
steering shaft to reassemble the parts in their
original pos ition.
431RS013
21. Remove steering column assembly.
Installation
1. Install the steering column assembly and align the
setting marks on the universal joint and steering
shaft made during removal.
431RS013
2. Ti ght en the s teering c ol umn fixi ng bo lts ( da sh pa nel
side) to the specified torque.
Torque: 20 N·m (2.0 kg·m/14 Ib ft)
3. Tighten the steering column fixing bolts (Pedal
brac ket) to the specified torque.
Torque: 20 N·m (2.0 kg·m/14 Ib ft)
4. Tighten the universal joint to the specified torque.
Torque: 31 N·m (3.2 kg·m/23 Ib ft)
5. Install steering lock cylinder assembly.
6. Connect shift lock cable (For A/T)
7. Install cushion rubber.
8. Install snap ring.
9. Install the combination switch assembly with SRS
coil.
10. Connect the wiring harness connector located on
the base of steering column.
11. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark (1).
CAUTION: When turning the SRS coil
counterclockwise to full, stop turning if resistance
is felt. Forced further turning may damage to the
cable in the SRS coil.
826RW014
12. Install steering column cover.
CAUTION: When installing the steering column
cover, be sure to wire (through each harness) as
illustrated so that the harness starter switch,
combination switch and SRS coil may not catch
wiring.
825RS048
13.Install the steering wheel and align the setting
marks.
430RS004
14.Tighten the steering wheel fixing nut to the specified
torque.
Torque: 34 N·m (3.5 kg·m/25 Ib ft)
15.Connect horn lead.
16.Connect air bag wiring harness connector.
NOTE: Pass the lead wire through the tabs on the
plastic cover (wire protector) of air bag to prevent lead
wire from being pinched.
827LX00003
17.Install air bag into steering wheel and tighten bolts
to specified sequence as shown in figure.
Torque: 8 N·m (81 kg·cm/69 Ib in)
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
which is being repaired.
827LX00004
18.Enable the SRS (Refer to “Enabling the SRS" in this
section).
Passenger Air Bag Assembly
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL
AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION, THAT
IS IRRITATING TO THE SKIN AND EYES. MOST OF
THE POWER ON THE AIR BAG ASSEMBLY IS
HARMLESS. AS A PRECAUTION, WEAR GLOVES
AND SAFETY GLASSES WHEN HANDLING A
DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR
HANDS WITH MILD SOAP AND WATER
AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE
OF INJURY. WHEN PLACING ALIVE AIR BAG
ASSEMBLY ON A BENCH OR OTHER SURFACE,
ALWAYS FACE BAG AND RIM COVER UP, AWAY
FROM THE SURFACE. NEVER REST A STEERING
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD RESULT.
WARNING: In the event deployment has occurred,
inspect coil assembly wire for any signs of
scorching, melting or any other damage due to
excessive heat. If the coil has been damaged,
replace it.
Removal
827RV012
1.Disable the SRS (Refer to “Disabling the SRS " in
this section).
2. Remove gear con tr ol kn ob.
3. Remove front console assembly.
4. Remove rear console assembly and disconnect
harness connector.
5. Remove ECM and SDM cover.
6. Remove glove box assembly with lid.
7. Remove glove box cover.
8. Remove instrument panel assist side lower cover.
9. Disconnect engine hood opener lever.
10. Remove instrument panel door side lower cover.
11. Re move lower clust er with ashtray.
12. Remove meter cluster assembly and disconnect
harness connector.
13. Remove instrument panel lower center cover.
14. Disconnect passenger air bag assembly harness
connector.
15. Remove air bag assembly fixing bolts and nuts.
16. Remove passenger air bag assembly.
Installation
827RV012
1.Install passenger air bag assembly.
2.Install air bag assembly fixing nuts and tighten to
specified torque.
Torque: 6 N·m (61 kg·cm/52 Ib in)
3.Connect air bag assembly harness connector.
4.Install instrument panel lower center cover.
5.Install meter cluster assembly and connect harness
connector.
6.Install lower cluster with ashtray.
7.Install instrument panel door side lower cover.
8.Connect engine hood opener lever.
9.Install instrument panel assist side lower cover.
10.Install glove box cover.
11.Install glove box assembly with lid.
12.Install ECM and SDM cover.
13.Install rear console assembly and connect harness
connector.
14.Install front console assembly.
15.Install gear control knob.
16.Enable the SRS (Refer to “Enabling the SRS" in this
section).
Main Data and Specifications
Fastener Tightening Specification
Application N·m kg·m (kg·cm) Lb Ft (Lb in)
SDM 10 (100) (87)
Driver air bag fixing bolt 8 (81) (78)
Steering wheel fixing bolt 34 3.5 25
Steering column (dash panel side fixing bolts) 20 2.0 14
Steering column (Pedal bracket fixing bolt) 20 2.0 14
Steering column (Universal joint fixing bolt) 31 3.2 23
Passenger Air Bag fixing nuts 6 (61) (52)