SIR/SRS Wiring Repairs

SIR/SRS Wiring Repairs

Warning: Refer to SIR Service Precautions Technician Safety Information.


For European regions - Operations on restraint systems must only be performed by trained and qualified personnel.

Special Tools

EL-38125-10 - Splice Sleeve Crimping Tool

For equivalent regional tools, refer to Special Tools Tools and Equipment.

The DuraSeal splice sleeves have the following 2 critical features:

* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside.

* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits.

The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals.

SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)

Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.

The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits.

Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. Terminated leads can be used to replace damaged terminals when replacing the connector body.

SIR/SRS Component Wire Pigtail Repair

Note: Do not make wire, connector, or terminal repairs on components with wire pigtails.

A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component.

SIR/SRS Wire Repair

Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity.

Caution: Do not install more than 2 DuraSeal splice sleeves per SIR deployment loop. A deployment loop consists of both wires from the K36 Inflatable Restraint Sensing and Diagnostic Module to the deployable component. If more than 2 DuraSeal splice sleeves are required for any SIR deployment loop, the complete circuit of the loop must be replaced. More than 2 DuraSeal splice sleeves per deployment loop may increase the resistance in the circuit causing a DTC to be set.

If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves.

For connector position assurance (CPA), refer to Connector Position Assurance Locks Connector Position Assurance Locks.

For terminal position assurance (TPA), refer to Terminal Position Assurance Locks Terminal Position Assurance Locks.