Deployment Inside Vehicle - Vehicle Scrapping Procedure

Deploy the inflator modules inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes, but is not limited to, the following situations:

• The vehicle has completed all useful life.
• Irreparable damage occurred to the vehicle in a non-deployment type accident.
• Irreparable damage occurred to the vehicle during a theft.
• The vehicle is being salvaged for parts to be used on a vehicle with a different VIN, as opposed to rebuilding as the same VIN.

1. Lower the driver and passenger windows.
2. Turn the ignition switch to the OFF position and remove the ignition key.
3. Check that all inflator modules which will be deployed are mounted securely.
   • Driver inflator module is secured to steering wheel.
   • Passenger inflator module is secured to instrument panel.
   • Left roof rail inflator module is secured to left roof rail.
   • Right roof rail inflator module is secured to right roof rail.
4. Put on safety glasses.
5. Remove all loose objects from the front seats.
   WARNING: A deployed dual stage inflator module will look the same whether one or both stages were used, always assume a deployed dual stage inflator module has an active stage 2. Improper handling or servicing can activate the inflator module and cause personal injury.
   Fig 1: Identifying Steering Wheel Module Connector From Vehicle Harness Connector

   Courtesy of SUZUKI OF AMERICA CORP.
6. Disconnect the steering wheel module yellow connector (1) from vehicle harness yellow connector (3).
   Fig 2: Identifying Strip Dimension

   Courtesy of SUZUKI OF AMERICA CORP.
   NOTE: If the vehicle is equipped with dual stage air bags the steering wheel module and I/P module will each have 4 wires. Refer to SIR CONNECTOR END VIEWS  for determining high and low circuits.
7. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
8. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
   Fig 3: Identifying Thicker Multi-Strand Wire Dimension

   Courtesy of SUZUKI OF AMERICA CORP.
9. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. Use these wires to fabricate the driver deployment harness.
10. Strip 13 mm (0.5 in) of insulation from both ends of the wires.
11. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the inflator module.
    Fig 4: Identifying Connector Wire Leads From High Circuits

    Courtesy of SUZUKI OF AMERICA CORP.
12. Twist together the 2 connector wire leads from the high circuits from both stages of the steering wheel module, to one set of deployment wires. Refer to SIR CONNECTOR END VIEWS  in order to determine the correct circuits.
13. Inspect that the 3-wire connection is secure.
    Fig 5: Bending Flat Twisted Connection

    Courtesy of SUZUKI OF AMERICA CORP.
14. Bend flat the twisted connection.
    Fig 6: Identifying Wire Connection To Harness Electrical Tape

    Courtesy of SUZUKI OF AMERICA CORP.
15. Secure and insulate the 3-wire connection to the deployment harness using electrical tape.
    Fig 7: Identifying Connector Wire Leads From Low Circuits

    Courtesy of SUZUKI OF AMERICA CORP.
16. Twist together the 2 connector wire leads from the low circuits from both stages of the steering wheel module, to one set of deployment wires. Refer to SIR CONNECTOR END VIEWS  in order to determine the correct circuits.
17. Inspect that the 3-wire connection is secure.
    Fig 8: Bending Flat Twisted Connection

    Courtesy of SUZUKI OF AMERICA CORP.
18. Bend flat the twisted connection.
    Fig 9: Identifying Wire Connection To Deployment Harness With Electrical Tape

    Courtesy of SUZUKI OF AMERICA CORP.
19. Secure and insulate the 3-wire connection to the deployment harness using electrical tape.
20. Connect the deployment harness to the connector on the steering wheel module.
    Fig 10: Identifying Harness Of Driver Side Of Vehicle

    Courtesy of SUZUKI OF AMERICA CORP.
21. Route the deployment harness out of the driver side of the vehicle.
    Fig 11: Identifying Left Roof Rail Harness Connector From Vehicle Harness Connector

    Courtesy of SUZUKI OF AMERICA CORP.
22. Disconnect the yellow left roof rail harness connector from the vehicle harness connector.
    Fig 12: Leaving Least Of Wire Connector

    Courtesy of SUZUKI OF AMERICA CORP.
23. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
24. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
    Fig 13: Identifying Deployment Wires Thicker Multi-Strand Wire

    Courtesy of SUZUKI OF AMERICA CORP.
25. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. These wires will be used to fabricate the roof rail air bag deployment harness.
26. Strip 13 mm (0.5 in) of insulation from both ends of the wires.
27. Twist together one end from each of the wires in order to short the wires.
    Fig 14: Identifying Connector Wire Lead

    Courtesy of SUZUKI OF AMERICA CORP.
28. Twist together one connector wire lead to one deployment wire.
    Fig 15: Insulating Twisted Connection

    Courtesy of SUZUKI OF AMERICA CORP.
29. Bend flat the twisted connection.
30. Secure and insulate the connection using electrical tape.
    Fig 16: Identifying Harness Connector Of Roof Rail Module

    Courtesy of SUZUKI OF AMERICA CORP.
31. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
32. Connect the deployment harness to the yellow connector of the roof rail module.
    Fig 17: Identifying Deployment Harness Driver Side Of Vehicle

    Courtesy of SUZUKI OF AMERICA CORP.
33. Route the deployment harness out of the driver side of the vehicle.
    Fig 18: Identifying I/P Module Harness Connector From Vehicle Harness Connector

    Courtesy of SUZUKI OF AMERICA CORP.
34. Disconnect the I/P module yellow harness connector (1) from the vehicle harness connector (2).
    Fig 19: Identifying Strip Dimension

    Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: If the vehicle is equipped with dual stage air bags the steering wheel module and I/P module will each have 4 wires. Refer to SIR CONNECTOR END VIEWS  for determining high and low circuits.
35. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
36. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
    Fig 20: Identifying Deployment Wires From Thicker Multi-Strand Wire

    Courtesy of SUZUKI OF AMERICA CORP.
37. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. These wires will be used to fabricate the passenger deployment harness.
38. Strip 13 mm (0.5 in) of insulation from both ends of the wires.
39. Twist together one end from each of the wires in order to short the wires.
    Fig 21: Identifying Connector Wire Leads From High Circuits

    Courtesy of SUZUKI OF AMERICA CORP.
40. Twist together the 2 connector wire leads from the high circuits from both stages of the I/P module to one set of deployment wires. Refer to SIR CONNECTOR END VIEWS  in order to determine the correct circuits.
41. Inspect that the 3-wire connection is secure.
    Fig 22: Identifying Bend Flat Twisted Connection

    Courtesy of SUZUKI OF AMERICA CORP.
42. Bend flat the twisted connection.
    Fig 23: Identifying Wire Connection To Harness With Electrical Tape

    Courtesy of SUZUKI OF AMERICA CORP.
43. Secure and insulate the 3-wire connection to the deployment harness using electrical tape.
    Fig 24: Identifying Connector Wire Leads From Low Circuits

    Courtesy of SUZUKI OF AMERICA CORP.
44. Twist together the 2 connector wire leads from the low circuits from both stages of the I/P module to one set of deployment wires. Refer to SIR CONNECTOR END VIEWS  in order to determine the correct circuits.
45. Inspect that the 3-wire connection is secure.
    Fig 25: Bending Flat Twisted Connection

    Courtesy of SUZUKI OF AMERICA CORP.
46. Bend flat the twisted connection.
    Fig 26: Identifying Wire Connection To Harness

    Courtesy of SUZUKI OF AMERICA CORP.
47. Secure and insulate the 3-wire connection to the deployment harness using electrical tape.
48. Connect the deployment harness to the I/P module in-line connector.
    Fig 27: Identifying Deployment Harness Out Of Passenger Side Of Vehicle

    Courtesy of SUZUKI OF AMERICA CORP.
49. Route the deployment harness out of the passenger side of the vehicle.
    Fig 28: Identifying Right Roof Rail Air Bag From Vehicle Harness Connector

    Courtesy of SUZUKI OF AMERICA CORP.
50. Disconnect the yellow harness connector to the right roof rail air bag from the vehicle harness connector.
    Fig 29: Identifying Wire Connector Length

    Courtesy of SUZUKI OF AMERICA CORP.
51. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector.
52. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
    Fig 30: Identifying Multi-Strand Wire Dimension

    Courtesy of SUZUKI OF AMERICA CORP.
53. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used to fabricate the roof rail air bag deployment harness.
54. Strip 13 mm (0.5 in) of insulation from both ends of the wires.
55. Twist together one end from each of the wires in order to short the wires.
    Fig 31: Identifying Connector Wire Lead To Deployment Wire

    Courtesy of SUZUKI OF AMERICA CORP.
56. Twist together one connector wire lead to one deployment wire.
    Fig 32: Insulating Twisted Connection

    Courtesy of SUZUKI OF AMERICA CORP.
57. Bend flat the twisted connection.
58. Secure and insulate the connection using electrical tape.
    Fig 33: Identifying Connector Wire Lead To Deployment Wire

    Courtesy of SUZUKI OF AMERICA CORP.
59. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire.
    Fig 34: Identifying Harness To Roof Rail Module Connector

    Courtesy of SUZUKI OF AMERICA CORP.
60. Connect the deployment harness to the roof rail module yellow connector.
    Fig 35: Identifying Deployment Harness Of Passenger Side Of Vehicle

    Courtesy of SUZUKI OF AMERICA CORP.
61. Route the deployment harness out of the passenger side of the vehicle.
62. Completely cover the windshield and the front door window openings with a drop cloth.
63. Stretch to the full length all of the deployment harness wires on the right side of the vehicle.
64. Deploy each deployment loop one at a time.
65. Place a power source, 12 V minimum / 2 A minimum, such as a vehicle battery, near the shorted end of the harnesses.
66. Separate one set of wires and touch the wire ends to the power source in order to deploy the selected inflator module.
67. Disconnect the deployment harness from the power source and twist the wire ends together.
68. Continue the same process with the remaining deployment harnesses.
    Fig 36: Identifying Deployment Harness Wires On Left Side Of Vehicle

    Courtesy of SUZUKI OF AMERICA CORP.
69. Stretch to the full length all of the deployment harness wires on the left side of the vehicle.
70. Deploy each deployment loop one at a time.
71. Place a power source, 12 V minimum / 2 A minimum, such as a vehicle battery, near the shorted end of the harnesses.
72. Separate one set of wires and touch the wires ends to the power source in order to deploy the selected inflator modules.
73. Disconnect the deployment harness from the power source and twist the wire ends together.
74. Continue the same process with the remaining deployment harnesses.
75. Remove the drop cloth from the vehicle.
76. Disconnect all harnesses from the vehicle.
77. Discard the harnesses.
78. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
79. If one or all of the inflator modules did not deploy, remove the undeployed modules from the vehicle.