Air Bag: Service and Repair
AIR BAG (INFLATOR) MODULE AND SEAT BELT PRETENSIONER DISPOSALWARNING: Failure to follow proper air bag (inflator) module and seat belt pretensioner disposal procedures can result in air bag deployment and pretensioner activation which may cause personal injury. Undeployed air bag (inflator) module/inactivated seat belt pretensioner must not be disposed of through normal refuse channels.
The undeployed air bag (inflator) module and inactivated seat belt pretensioner contain substances that can cause severe illness or personal injury if the sealed container is damaged during disposal.
Do not dispose of the live (undeployed) air bag (inflator) modules and seat belt pretensioners.
The method employed depends upon the final disposition of the particular vehicle, as noted in "DEPLOYMENT/ACTIVATION OUTSIDE VEHICLE" and "DEPLOYMENT/ACTIVATION INSIDE VEHICLE".
Deployment/Activation Outside Vehicle:
Follow this procedure when disposing of the air bag (inflator) module(s) and seat belt pretensioner(s) only (i.e., the vehicle itself will be used again).
Deployment/Activation Inside Vehicle:
Follow this procedure when scrapping the entire vehicle including the air bag (inflator) modules and seat belt pretensioners.
WARNING: Following precautions must be observed for this work. Failure to observe any of them may result in personal injury.
- The procedure should be followed strictly as described here.
- Be sure to read "SERVICE PRECAUTIONS" beforehand.
- To avoid an accidental deployment, this work should be performed by no more than one person.
- Since the smoke is produced when air bag is deployed and pretensioner is activated, select a well ventilated area.
- The air bag (inflator) module and seat belt pretensioner will immediately deploy/activate when a power source is connected to it. Wear safety glasses throughout this entire deployment/activation and disposal procedure.
- Wear suitable ear protection when deploying air bag activating pretensioner. Also, advise those who are in the area close to deployment/activation site to wear suitable ear protection.
- Do not deploy/activate two or more air bag system components (air bag (inflator) modules and seat belt pretensioners) at the same time.
- Never connect deployment harness to any power source before connecting deployment harness to the air bag (inflator) module and seat belt pretensioner. Deployment harness shall remain shorted and not be connected to a power source until the air bag is to be deployed and the pretensioner is to be activated.
DEPLOYMENT/ACTIVATION OUTSIDE VEHICLE
Use this procedure when the vehicle itself is used again (only the air bag (inflator) module(s) and seat belt pretensioner(s) are disposed).
1. Turn ignition switch to "LOCK", position remove key and put on safety glasses.
2. Check that there is no open, short or damage in special tool (deployment harness). If any faulty is found, do not use it and be sure to use new deployment harness.
3. Short (1) the two deployment harness leads together by fully seating one banana plug into the other.
4. Remove air bag (inflator) module(s) and seat belt pretensioner(s) from vehicle.
WARNING:
- Always carry live air bag (inflator) module with trim cover away from you.
- When storing a live air bag (inflator) module or when leaving a live air bag (inflator) module unattended on a bench or other surface, always face the bag and trim cover up and away from the surface. As the live passenger air bag (inflator) module must be placed with its bag (trim cover) facing up, place it on the workbench with a slit (1) or use the workbench vise (2) to hold it securely at its lower mounting bracket (3). 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.
WARNING:
- For handing and storage of a live seat belt pretensioner, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from electric noise.
- Never carry the seat belt pretensioner by the wire or connector of the pretensioner.
- When placing a live seat belt pretensioner on the workbench or other surface, be sure not to lay it with its exhaust hole provided side facing down. It is also prohibited to put something on its face with an exhaust hole or to put a seat belt pretensioner on top of another.
Otherwise, personal injury may result.
5. Set air bag (inflator) module or seat belt pretensioner as follows.
[In case of driver air bag (inflator) module]
a. Clear a space on the ground about 185 (6 ft) (3) in diameter where the driver air bag (inflator) module (1) 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.
b. Place the driver air bag (inflator) module (1), with its vinyl trim cover facing up (2), on the ground in the space just cleared.
[In case of passenger air bag (inflator) module]
a. Clear a space on the ground about 185 (6 ft) (2) in diameter where the fixture (special tool) with attached air bag (inflator) module (1) 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 there is no activity and sufficient ventilation is recommended. Ensure that no loose or flammable objects are within the deployment area.
b. Place special tool (passenger air bag (inflator) module deployment fixture) on the ground in the space cleared in step a), if it has not already been placed there.
c. Fill plastic reservoir in fixture (special tool) with water or sand. This is necessary to provide sufficient stabilization of the fixture during deployment.
d. Attach the passenger air bag (inflator) module in the fixture (special tool) using mounting attachment, hold-down bolts and nuts and M8 bolts and nuts (1).
CAUTION: Be sure to use the following bolt and nut for fixing passenger air bag (inflator) module to mounting attachment.
Size : M8, Strength : 7T
Securely hand-tighten all fastener prior to deployment.
[In case of seat belt pretensioner]
a. Pull out the webbing (2) fully as shown in the figure and cut it at the root of the pretensioner (retractor assembly) (1) as shown in the figure.
WARNING: As the drum (3) of the retractor assembly (1) turns very quickly as soon as the webbing (2) is cut, fix the retractor assembly (1) with a vise on the workbench and keep your hands and fingers away from it when cutting the webbing (2).
b. Clear a space on the ground about 185 cm (6 ft) diameter where the seat belt pretensioner (retractor assembly) (1) is to be activated. 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 activation area.
c. Place the seat belt pretensioner (retractor assembly) (1) as shown in the figure on the ground in the space just cleared.
6. Stretch the deployment harness from the driver or passenger air bag (inflator) module to its full length 10 m (33 ft)).
7. Place a power source (3) near the shorted end of the deployment harness. Recommended application: 12 Volts minimum, 2 amps minimum. A vehicle battery is suggested.
8. Verify that the area around the air bag (inflator) module or seat belt pretensioner is clear of all people and loose or flammable objects.
9. Verify setting condition of air bag (inflator) module or pretensioner as follows.
[In case of driver air bag (inflator) module]
Verify that the driver air bag (inflator) module is resting with its vinyl trim cover facing up.
[In case of passenger air bag (inflator) module] Verify that the passenger air bag (inflator) module is firmly and properly secured in passenger air bag (inflator) module deployment fixture (special tool).
[In case of seat belt pretensioner]
Verify that the seat belt pretensioner, is placed as shown in the figure on the ground in the space just cleared.
10. Connect (2) the air bag (inflator) module or seat belt pretensioner to the deployment harness connector and lock connector with lock lever.
11. Notify all people in the immediate area that you intend to deploy/activate the air bag (inflator) module or seat belt pretensioner.
NOTE:
- When the air bag deploys and the pretensioner activates, the rapid gas expansion will create a substantial report. Wear suitable ear protection. Notify all people in the immediate area that you intend to deploy the air bag (inflator) module or activate the seat belt pretensioner and suitable ear protection should be worn.
- When the driver air bag deploys and the pretensioner activates, driver air bag (inflator) module and pretensioner (retractor assembly) may jump about 30 cm (1 ft) vertically. This is a normal reaction of them to the force of the rapid gas expansion inside the air bag and pretensioner.
- After the air bag (inflator) module 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.
WARNING:
- After deployment/activation, the metal surfaces of the air bag (inflator) module and the seat belt pretensioner will be very hot. Do not touch the metal areas of them for about 30 minutes after deployment/activation.
- Do not place the deployed air bag (inflator) module and the activated seat belt pretensioner near any flammable objects.
- Do not apply water, oil, etc. to deployed air bag (inflator) module and activated seat belt pretensioner.
- If the deployed air bag (inflator) module and the activated seat belt pretensioner must be moved before it is cool, wear gloves and handle it by using nonmetal material such as the air bag, webbing and vinyl trim.
Failure to follow procedures may result in fire or personal injury.
12. Separate (1) the two banana plugs on the deployment harness.
13. Connect the deployment harness to the power source (12 V vehicle battery) (2) to immediately deploy/activate the air bag or seat belt pretensioner.
14. Disconnect the deployment harness from power source (12 V vehicle battery) (2) and short (3) the two deployment harness leads together by fully seating one banana plug into the other.
15. In the unlikely event that the air bag (inflator) module or seat belt pretensioner did not deploy/activate after following these procedures, proceed immediately with Steps 20) through 23). If the air bag (inflator) module or the seat belt pretensioner did deploy/activate, proceed with Steps 16) through 19).
16. Put on a pair of shop gloves to protect your hands from possible irritation and heat when handling the deployed air bag (inflator) module and the activated seat belt pretensioner.
17. Disconnect the deployment harness from the air bag (inflator) module and the seat belt pretensioner as soon after deployment/activation as possible.
This will prevent damage to the deployment harness due to possible contact with the hot air bag (inflator) module and seat belt pretensioner. The deployment harness are designed to be reused. They should, however, be inspected for damage after each deployment/activation and replaced it if necessary.
18. Dispose of the deployed air bag (inflator) module and the activated seat belt pretensioner through normal refuse channels after it has cooled for at least 10 minutes and tightly seal the air bag (inflator) module and the seat belt pretensioner in a strong vinyl bag. (Refer to "DEPLOYED AIR BAG (INFLATOR) MODULE AND ACTIVATED SEAT BELT PRETENSIONER DISPOSAL" in detail.)
19. 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 (inflator) module did not deploy or the seat belt pretensioner did not activate after following these procedures.
20. Ensure that the 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.
21. Disconnect the deployment harness from the air bag (inflator) module and the seat belt pretensioner.
22. Temporarily store air bag (inflator) module or seat belt pretensioner.
[For driver air bag (inflator) module]
Temporarily store the air bag (inflator) module with its vinyl trim cover facing up, away from the surface upon which it rests. Refer to "SERVICE PRECAUTIONS" for details.
[For seat belt pretensioner]
When temporarily strong the seat belt pretensioner, be sure NOT to face its exhaust hole provided side down. It must face up. Refer to "SERVICE PRECAUTIONS" for details.
23. Contact your local distributor for further assistance.
DEPLOYMENT/ACTIVATION INSIDE VEHICLE
Use this procedure when scrapping the entire vehicle including the air bag (inflator) modules and seat belt pretensioners.
CAUTION: When vehicle itself will be used again, deploy/activate the air bag and pretensioner outside vehicle according to "DEPLOYMENT/ACTIVATION OUTSIDE VEHICLE", for deploying/activating it inside will cause the instrument panel, glove box and their vicinity to be deformed. Failure to observe this CAUTION may require unneeded vehicle inspection and repair.
1. Turn ignition switch to "LOCK" position, remove key and put on safety glasses.
2. Remove all loose objects from front seats and instrument panel.
3. [For driver air bag (inflator) module]
Disconnect contact coil connector (1) located near the base of the steering column.
[For passenger air bag (inflator) module] Remove glove box from instrument panel and disconnect passenger air bag (inflator) module connector (2). [For seat belt pretensioner]
Remove both side (driver and passenger side) front pillar lower trim and disconnect seat belt pretensioner connectors (3).
4. Confirm that each air bag (inflator) module is securely mounted.
5. Check that there is no open, short or damage in special tool (deployment harness). If any faulty condition is found, do not use it and be sure to use new deployment harness.
6. Short (1) the two deployment harness leads together by fully seating one banana plug into the other.
WARNING: Deployment harness shall remain shorted and not be connected to a power source until the air bag is to be and seat belt pretensioner is to be activated.
7. Connect deployment harness connector to air bag (inflator) module (driver or passenger) or seat belt pretensioner (driver or passenger) and lock connector with lock lever.
a. Connect connector.
b. Lock connector with lock lever.
8. Route deployment harness out the vehicle.
9. Verify that the inside of the vehicle and the area surrounding the vehicle are clear of all people and loose or flammable objects.
10. Stretch the deployment harness to its full length 10 m (33 ft)
11. Place a power source near the shorted end (3) of the deployment harness. Recommended application: 12 Volts minimum, 2 amps minimum. A vehicle battery is suggested.
12. Completely cover windshield area and front door window openings with a drop cloth, blanket to similar item (2). This reduces the possibility of injury due to possible fragmentation of the vehicle's glass or interior.
13. Notify all people in the immediate area that you intend to deploy the air bag (inflator) module or activate the seat belt pretensioner.
NOTE:
- When the air bag deploys and the pretensioner activates, the rapid gas expansion will create a substantial report. Wear suitable ear protection. Notify all people in the immediate area that you intend to deploy the air bag (inflator) module or to activate the seat belt pretensioner and suitable ear protection should be worn.
- After the air bag (inflator) module 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.
WARNING:
- After deployment/activation, the metal surfaces of the air bag (inflator) module and the seat belt pretensioner will be very hot. Do not touch the metal areas of them for about 30 minutes after deployment/activation.
- Do not apply water, oil, etc. to deployed air bag (inflator) module and activated seat belt pretensioner. Failure to follow procedures may result in fire or personal injury.
14. Separate the two banana plugs on the deployment harness.
15. Connect (1) the deployment harness to the power source (12 V vehicle battery) (2) to immediately deploy/activate the air bag or the pretensioner.
16. Disconnect the deployment harness from the power source (12 V vehicle battery) (2) and short (4) the two deployment harness leads together by fully seating one banana plug into the other.
17. Put on a pair of shop gloves to protect your hands from possible irritation and heat when handling the deployed air bag (inflator) module and the activated seat belt pretensioner.
18. Disconnect the deployment harness from the air bag (inflator) module and the seat belt pretensioner as soon after deployment/activation as possible.
This will prevent damage to the deployment harness due to possible contact with the hot air bag (inflator) module and seat belt pretensioner. The deployment harness are designed to be reused. They should, however, be inspected for damage after each deployment/activation and replaced it if necessary.
19. Carefully remove drop cloth (3) from vehicle and clean off any fragments or discard it entirely.
20. Repeat Steps 2) through 19) to deploy/activate air bag (inflator) modules and seat belt pretensioners which has not been deployed/activated, if any.
21. In the unlikely event that the air bag (inflator) module and the seat belt pretensioner proceed immediately with Steps 23) through 25). If the air bag (inflator) module and the seat belt pretensioner did deploy/activate, proceed with Steps 22).
22. With air bags deployed and pretensioners activated the vehicle may be scrapped in the same manner as a non-air bag system equipped vehicle.
23. Remove the undeployed air bag (inflator) module(s) and the inactivated seat belt pretensioner(s) from the vehicle. For driver air bag (inflator) module, refer, passenger air bag (inflator) module refer to "ON-VEHICLE SERVICE", for seat belt pretensioner.
24. For air bag (inflator) module]
Temporarily store the air bag (inflator) module with its vinyl trim cover facing up, away from the surface upon which it rests. Refer to "SERVICE PRECAUTIONS" for details.
[For seat belt pretensioner]
When temporarily strong the seat belt pretensioner, be sure NOT to face its exhaust hole provided side down. It must face up. Refer to "SERVICE PRECAUTIONS" for details.
25. Contact your local distributor for further assistance.
DEPLOYED AIR BAG (INFLATOR) MODULE AND ACTIVATED SEAT BELT PRETENSIONER DISPOSAL
WARNING: Failure to follow proper air bag (inflator) module and seat belt pretensioner disposal procedures can result in air bag deployment and pretensioner activation which may cause personal injury. The undeployed air bag (inflator) module and the inactivated seat belt pretensioner must not be disposed of through normal refuse channels.
The undeployed air bag (inflator) module and the inactivated seat belt pretensioner contains substances that can cause severe illness or personal injury if the sealed container is damaged during disposal.
Deployed air bag (inflator) module and the activated seat belt pretensioner can be disposed of through normal refuse channels just like any other parts. For their disposal, however, following points should be noted.
- The air bag (inflator) module and the seat belt pretensioner immediately after deployment/activation is very hot. Wait for 30 minutes to cool it off before handling it.
- Never apply water, oil, etc. to deployed air bag (inflator) module and the activated seat belt pretensioner to cool it off and be careful so that water, oil etc. does not get on the deployed air bag (inflator) module and the activated seat belt pretensioner.
- After the air bag (inflator) module 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. As with many service procedures, you should wear gloves and safety glasses.
- When disposing of the deployed air bag (inflator) module and the activated seat belt pretensioner, be sure to seal it in a vinyl bag.
- When air bag (inflator) module and seat belt pretensioner have been deployed/activated inside the vehicle which is going to be scrapped, leave them as installed to the vehicle.
- Be sure to wash your hands with mild soap and water after handling it.