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Deployment/Activation Outside of Vehicle

When you intend to return the vehicle to service, deploy the air bag (inflator) module(s) or activate seat belt pretensioner(s) outside of the vehicle.

  1. Turn ignition switch to LOCK position and remove key.
  2. Wear safety glasses during this deployment/activation procedure.
  3. Check that there is no open, short or damage in special tools (deployment harness (A) and adapter cable (B)). If any faulty is found, do not use it and be sure to use new special tool.

    Special Tool 

    1. 09932-75031 
    2. 09932-76510 
  4. Short two deployment harness leads (1) together by fully seating one banana plug into the other.
    WARNING: Deployment harness (A) shall remain shorted and not be connected to 12 volts vehicle battery till you are ready to deploy air bag module or activate seat belt pretensioner.
    Fig 1: Identifying Deployment Harness Leads
    G04809698Courtesy of SUZUKI OF AMERICA CORP.
  5. Remove air bag (inflator) module(s) or seat belt pretensioner(s) from vehicle referring to DRIVER AIR BAG (INFLATOR) MODULE REMOVAL AND INSTALLATION:EXCEPT ADVANCED AIR BAG , PASSENGER AIR BAG (INFLATOR) MODULE REMOVAL AND INSTALLATION:EXCEPT ADVANCED AIR BAG , SIDE-AIR BAG (INFLATOR) MODULE REMOVAL AND INSTALLATION:EXCEPT ADVANCED AIR BAG , SIDE CURTAIN-AIR BAG (INFLATOR) MODULE REMOVAL AND INSTALLATION:EXCEPT ADVANCED AIR BAG  or Front Seat Belt Removal and Installation  .
    WARNING:
    • For handing and storage of live air bag (inflator) module, select place where ambient temperature below 65 °C (150 °F), without high humidity and away from electric noise.
    • Always carry live air bag (inflator) module with trim cover away from you.
    • When storing live air bag (inflator) module or when leaving live air bag (inflator) module unattended on bench or other surface, always face trim cover up and away from surface. It is also prohibited to place anything on top of the trim cover and stack air bag (inflator) modules. This is necessary so that free space is provided to allow air bag (inflator) module to expand in the unlikely event of accidental deployment.

      Failure to follow procedures may result in personal injury.

      Fig 2: Removing Procedure Of Air Bag (Inflator) Module Or Seat Belt Pretensioner From Vehicle
      G04809699Courtesy of SUZUKI OF AMERICA CORP.
    WARNING:
    • For handling and storage of seat belt pretensioner, select place where ambient temperature is below 65 °C (150 °F), without high humidity and away from electric noise.
    • Never carry seat belt pretensioner by webbing.
    • When placing seat belt pretensioner on workbench or other surface, be sure to lay it with its exhaust hole (1) side facing up. It is also prohibited to put something on seat belt pretensioner.

      Otherwise, personal injury may result.

      Fig 3: Identifying Seat Belt Pretensioner Exhaust Hole
      G04809700Courtesy of SUZUKI OF AMERICA CORP.
  6. Set air bag (inflator) module or seat belt pretensioner as follows.
    • For driver air bag (inflator) module
      1. Clear space (3) on ground about 185 cm (6 ft) in diameter where driver air bag (inflator) module (1) is set for deployment. Paved, outdoor location where there is no activity is preferred. If outdoor location is not available, use space on shop floor where there is no activity and sufficient ventilation is provided. Ensure no loose or flammable object exists within deployment area.
      2. Place driver air bag (inflator) module (1) with its vinyl trim cover facing up (2) on ground in step  a.
        Fig 4: Identifying Driver Air Bag (Inflator) Module
        G04809701Courtesy of SUZUKI OF AMERICA CORP.
    • For passenger air bag (inflator) module
      1. Clear space (3) on ground about 185 cm (6 ft) in diameter where passenger air bag (inflator) module (1) is set for deployment. Paved, outdoor location where there is no activity is preferred. If outdoor location is not available, use space on shop floor where there is no activity and sufficient ventilation is provided. Ensure no loose or flammable object exists within deployment area.
      2. Place deployment fixture (A) on ground in step  a.

        Special Tool 

        1. 09932-75041 
      3. Fill plastic reservoir in deployment fixture (A) with water or sand. This is necessary to provide sufficient stabilization of fixture during deployment.
      4. Attach passenger air bag (inflator) module (1) in deployment fixture (A) securely using M8 bolt (2).
        CAUTION: Be sure to use M8 size and 7T strength bolt for fixing passenger air bag (inflator) module (1) to deployment fixture (A).
        Fig 5: Identifying Deployment Fixture
        G04809702Courtesy of SUZUKI OF AMERICA CORP.
    • For side-air bag (inflator) module
      1. Remove sleeve (1) and sleeve lock nut (2), if equipped.
        Fig 6: Identifying Sleeve And Sleeve Lock Nut
        G04809703Courtesy of SUZUKI OF AMERICA CORP.
      2. Clear space (3) on ground about 185 cm (6 ft) in diameter where side-air bag (inflator) module for deployment. Paved, outdoor location where there is no activity is preferred. If outdoor location is not available, space on shop floor where there is no activity and provide sufficient ventilation. Ensure no loose or flammable objects are within deployment area.
      3. Place deployment fixture (A) on ground.

        Special Tool 

        1. 09932-75041 
      4. Fill plastic reservoir in deployment fixture (A) with water or sand. This is necessary to provide sufficient stabilization of fixture during deployment.
      5. Attach side-air bag (inflator) module (1) in deployment fixture using mounting attachment, sleeve lock nut and washer (2).
        NOTE: Make sure that deploying direction faces as shown in the figure against mounting attachment.
        Fig 7: Identifying Side-Air Bag (Inflator) Module
        G04809704Courtesy of SUZUKI OF AMERICA CORP.
    • For side curtain-air bag (inflator) module
      1. Loosen nut (1) and remove bag (2) of side curtain-air bag (inflator) module.
        Fig 8: Identifying Bag Of Side Curtain-Air Bag (Inflator) Module
        G04809705Courtesy of SUZUKI OF AMERICA CORP.
      2. Tie side curtain-air bag inflator (1) to tire (3) with wire harness (2) as shown.

        Wire harness specifications 

        Stripped wire harness section 1.25 mm 2  (0.0019 in. 2  ) or more (Stripped wire harness diameter 1.25 mm (0.05 in). or more) 

        CAUTION: Make sure that wire harness is tight. It is very dangerous if looseness in wire harness results in side curtain-air bag inflator flying off due to shock from inflator deploying.
        NOTE: Wind wire harness (2) around at least 3 times.
      3. Clear space (5) on ground about 185 cm (6 ft) in diameter where side curtain-air bag (inflator) module (1) is set for deployment. Paved, outdoor location where there is no activity is preferred. If outdoor location is not available, use space on shop floor where there is no activity and sufficient ventilation is provided. Ensure no loose or flammable object exists within activation area.
      4. Pile tire with side curtain-air bag (inflator) module on tire (4).
        Fig 9: Pile Tire With Side Curtain-Air Bag (Inflator) Module On Tire
        G04809706Courtesy of SUZUKI OF AMERICA CORP.
    • For seat belt pretensioner
      1. Cut webbing (1) at tongue plate stopper (3) of seat belt pretensioner (2) side as shown.
        NOTE: Hold seat belt pretensioner (2) vertically in the same condition as it is installed. Otherwise, webbing can't be pulled out.
      2. Remove tongue plate (4) and shoulder anchor (5) from webbing.
      3. Tie webbing (1) tightly at 10 cm (3.9 in). from cutting edge as shown.
        Fig 10: Cutting Webbing At Tongue Plate Stopper Of Seat Belt Pretensioner
        G04809707Courtesy of SUZUKI OF AMERICA CORP.
        Fig 11: Tying Webbing Tightly At 10 cm (3.9 in). From Cutting Edge
        G04809708Courtesy of SUZUKI OF AMERICA CORP.
      4. Tie seat belt pretensioner (2) with wire harness (3) to wheel-installed tire (4) as shown.

        Wire harness specifications 

        Stripped wire harness section 1.25 mm 2  (0.0019 in. 2  ) or more (Stripped wire harness diameter 1.25 mm (0.05 in). or more) 

        NOTE: Wind wire harness (3) around at least 3 times.
      5. Clear space (5) on ground about 185 cm (6 ft) in diameter where seat belt pretensioner (2) is to be activated. Paved, outdoor location where there is no activity is preferred. If outdoor location is not available, use space on shop floor where there is no activity and sufficient ventilation is provided. Ensure no loose or flammable object exists within activation area.
      6. Place wheel-installed tire (4) with seat belt pretensioner (2) on ground in step  e.
        Fig 12: Placing Wheel-Installed Tire With Seat Belt Pretensioner On Ground
        G04809709Courtesy of SUZUKI OF AMERICA CORP.
  7. Stretch deployment harness (A) from air bag (inflator) module or seat belt pretensioner to its full length 10 m (33 ft).

    Special Tool 

    1. 09932-75031 
  8. Place 12 volts vehicle battery (1) near the shorted end of deployment harness (A).
  9. Check that area around air bag (inflator) module or seat belt pretensioner is clear of all people and loose or flammable objects.
  10. Connect adapter cable (B) as follows.

    Special Tool 

    (B): 09932-76510 

    • For driver air bag (inflator) module [A]

      Check that driver air bag (inflator) module is placed with its vinyl trim cover facing up, and connect adapter cable (B) to driver air bag (inflator) module.

    • For passenger air bag (inflator) module [B]

      Check that passenger air bag (inflator) module is firmly and properly secured on deployment fixture (special tool), and connect adapter cable (B) to passenger air bag (inflator) module.

    • For side-air bag (inflator) module [C]

      Verify that side-air bag (inflator) module is firmly and properly on deployment fixture (special tool), and connect adapter cable (B) to side-air bag (inflator) module.

    • For side curtain-air bag (inflator) module [D]
      1. Connect adapter cable (B) to side curtain-air bag (inflator) module.
      2. Pile 2 tires (2) and wheel-installed tire (3) on top of tire with side curtain-air bag (inflator) (4), and tie them with wire harness (5) as shown.

        Wire harness specifications 

        Stripped wire harness section 1.25 mm 2  (0.0019 in. 2  ) or more (Stripped wire harness diameter 1.25 mm (0.05 in). or more) 

        NOTE: Wind wire harness (5) around at least 2 times.
    • For seat belt pretensioner [E]
      1. Connect adapter cable (B) to seat belt pretensioner.
      2. Pile 2 wheel-installed tires (3) on top of tire with seat belt pretensioner (6), and tie them with wire harness (5) as shown.

        Wire harness specifications 

        Stripped wire harness section 1.25 mm 2  (0.0019 in. 2  ) or more (Stripped wire harness diameter 1.25 mm (0.05 in). or more) 

        NOTE: Wind wire harness (5) around at least 2 times.
      3. Drape blanket (7) over those tires.
  11. Connect adapter cable (B) to deployment harness (A) connector and lock connectors with lock lever.
    Fig 13: Connecting Adapter Cable To Deployment Harness Connector And Lock Connectors With Lock Lever
    G04809710Courtesy of SUZUKI OF AMERICA CORP.
  12. Notify all people in immediate area that you intend to deploy/activate air bag (inflator) module or seat belt pretensioner.
    NOTE:
    • When air bag (inflator) module deploys and seat belt pretensioner activates, rapid gas expansion will create substantial report. Wear suitable ear protection. Notify all people in immediate area that you intend to deploy air bag (inflator) module or activate seat belt pretensioner and suitable ear protection should be worn.
    • When driver air bag (inflator) module deploys, driver air bag (inflator) module may jump about 30 cm (1 ft) vertically. This is normal reaction to force of rapid gas expansion inside of drive airbag (inflator) module.
    • After air bag (inflator) module has been deployed, surface of air bag (inflator) may contain powdery residue. This powder consists primarily of cornstarch (used to lubricate bag (inflator) as it inflates) and by-products of chemical reaction.
    WARNING:
    • Do not place deployed air bag (inflator) module and 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.
    • Wait for about 30 minutes before touching any metal surface of air bag (inflater) module or seat belt pretensioner module. Disregarding these precautions may cause fire or personal injury.

      Failure to follow procedures may result in fire or personal injury.

  13. Separate two banana plugs (1) on deployment harness.
  14. Connect deployment harness to 12 volts vehicle battery (2). This will immediately deploy or activate air bag (inflator) module or seat belt pretensioner.
  15. Disconnect deployment harness from 12 volts vehicle battery (2) and short two deployment harness leads together by fully seating one banana plug into the other.
    Fig 14: Disconnecting Deployment Harness From 12 Volts Vehicle Battery
    G04809711Courtesy of SUZUKI OF AMERICA CORP.
  16. In the unlikely event that air bag (inflator) module or seat belt pretensioner did not deploy/activate after following these procedures, proceed immediately with Step  22 through  25. If air bag (inflator) module or seat belt pretensioner did deploy or activate, proceed with Steps  18 through  21.
  17. Put on pair of shop gloves to protect your hands from possible irritation and heat when handling deployed air bag (inflator) module or activated seat belt pretensioner.
  18. Disconnect adapter cable (special tool) from air bag (inflator) module or seat belt pretensioner as soon as possible. This will prevent adapter cable (special tool) from damage due to possible contact with hot air bag (inflator) module or hot seat belt pretensioner.
  19. Check adapter cable as follows.
    • For air bag (inflator) module

      Be sure to check air bag (inflator) module adapter cable (special tool) for damage after deployment and replace it with new adapter cable (special tool), if it is damaged.

    • For seat belt pretensioner

      Be sure to check seat belt pretensioner adapter cable (special tool) for damage after seat belt pretensioner is activated. Replace it with spare connector (special tool) or new adapter, if necessary.

  20. Dispose of deployed air bag (inflator) module (1) or activated seat belt pretensioner (2) through normal refuse channels after it has cooled for at least 30 minutes and tightly seal air bag (inflator) module (1) or seat belt pretensioner (2) in strong vinyl bag. Refer to DEPLOYED AIR BAG (INFLATOR) MODULE AND ACTIVATED SEAT BELT PRETENSIONER DISPOSAL:EXCEPT ADVANCED AIR BAG  for details.
    Fig 15: Sealing Air Bag (Inflator) Module Or Seat Belt Pretensioner In Strong Vinyl Bag
    G04809712Courtesy of SUZUKI OF AMERICA CORP.
  21. Wash your hands with mild soap and water afterward.
    NOTE: Remaining steps are to be followed in the unlikely event that air bag (inflator) module did not deploy or seat belt pretensioner did not activate.
  22. Ensure that deployment harness has been disconnected from 12 volts vehicle battery and that its two banana plugs have been shorted together by fully seating one banana plug into the other.
  23. Disconnect deployment harness and adapter cable from air bag (inflator) module or seat belt pretensioner.
  24. Temporarily store undeployed air bag (inflator) module referring to PRECAUTIONS ON HANDLING AND STORAGE OF AIR BAG SYSTEM COMPONENTS:EXCEPT ADVANCED AIR BAG  for details.
  25. Contact your local distributor for further assistance.
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