Air Bag Systems: Service and Repair

It is essential to have Isuzu tool kit No. J-38125-A, or equivalent, when repairing air bag system wiring or connectors. The tool kit contains a special crimping tool, a heat torch, special sealed splices and an instruction manual.

The terminals in the air bag system are made of a special metal to provide the necessary contact integrity for sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the connector repair packs.

If any individual terminals are damaged on the DERM connector, they should be repaired using the DERM terminal repair pack. If any individual connector terminals are damaged for any other air bag system component, except pigtails, the entire connection should be replaced using the appropriate connector repair pack. If the connector cannot be repaired, the entire wiring harness should be replaced.

If the wiring pigtail (wire or wires attached directly to a component) is damaged, the entire component must be replaced. Some components with pigtail connectors are the passenger air bag inflator module, discriminating sensor and SIR coil assembly. No wiring or terminal repairs should be performed on these components.

If any wire is damaged, except the pigtail, it can be repaired by splicing in a new section of wire of the same gauge. To splice in a new wire, use the following procedure:

1. Remove tape covering the wiring harness. Use a sewing seam ripper to remove tape to avoid damage to wire insulation. A sewing seam ripper is available from a sewing supply outlet.
2. Cut as little wire off the harness as possible. Extra wire may be needed to adjust splice location.
3. To add a length of wire to existing harness, strip approximately 5/16 inch of insulation from each wire to be spliced. Use care not to nick or cut any strands of wire. Remove any existing wire that has cut or nicked strands.
4. Select the proper sealed splice sleeve from the repair kit.
5. Using splice crimp tool provided with repair kit, position splice sleeve in the correct color nets of the crimp tool. Place splice sleeve so that crimp falls midway between end of barrel and stop.
6. Close hand crimper handles slightly to hold splice sleeve firmly in the correct nest of the tool.
7. Insert wire into splice sleeve until it hits the barrel stop.
8. Close handles of crimp tool tightly. The crimp tool will not open until the proper amount of pressure has been applied to the splice sleeve.
9. Repeat procedure at other end of splice.
10. Using the torch, apply heat where barrel of sleeve is crimped. Gradually move heat barrel to open end of tubing, shrinking the tubing completely as heat moves along insulation. A small amount of sealant will come out end of tubing when sufficient shrinking has been achieved.