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Volkswagen Golf Service & Repair Manual: Safety measures when working with pyrotechnic components

Volkswagen Golf Service & Repair Manual / General body repairs, interior / Technical data / Safety information / Safety measures when working with pyrotechnic components

Safety measures when working with pyrotechnic components
The following are pyrotechnic components:
  •   Airbag units
  •   Belt tensioner
  •   Belt force limiters (depending on vehicle equipment level)
  •   Battery isolation elements (depending on vehicle equipment level)
General information
  •   Testing, removing, installing and repair work may only be performed by qualified personnel.
  •   There are no replacement intervals for airbag units.
  •   Under no circumstances should checks be carried out with a test lamp, voltmeter or ohmmeter.
  •   Pyrotechnic components may only be checked in installed state and with vehicle diagnosis, testing and information systems approved by the manufacturer.
  •   When working on pyrotechnic components and airbag control unit -J234-, battery earth strap must be disconnected with ignition switched ON. Then cover negative terminal.
  •   A waiting time of 10 seconds is necessary after disconnecting the battery.
  •   The battery must be connected with the ignition SWITCHED ON. When doing this, there should be no-one inside the vehicle.
  •   If the ignition has not yet been switched on after the battery has been reconnected “warning lamps in dash panel insert are off”, the ignition (key or button) must only be switched on while sitting on the driver seat and with the seat set to rearmost position.
  •   Observe required procedures after connecting battery
  •   Before handling pyrotechnic components of the restraint system, for example before separating an electrical connection, the mechanic must electrostatically discharge himself/herself. Electrostatic discharge is achieved by touching earthed metallic parts, such as the door striker plate.
  •   Wash hands after coming into contact with triggered pyrotechnic components of restraint system.
  •   Pyrotechnic components must not be opened or repaired; always use new parts (risk of injury).
  •   Pyrotechnic components that have been dropped onto a hard surface or show signs of damage must not be installed in a vehicle.
  •   Pyrotechnic components must be installed immediately after they have been removed from their packaging.
  •   If work is interrupted, the pyrotechnic component must be stored back in its packaging.
  •   Leaving the pyrotechnic component unattended is prohibited.
  •   When connecting pyrotechnic components of the restraint system, only the person carrying out the work may be inside the vehicle.
  •   Pyrotechnic components must not come into contact with grease, cleaning solution or similar.
  •   The airbag unit must be renewed if any contamination such as oil, grease, paint or solvent penetrates the fabric.
  •   Pyrotechnic components must not be subjected to temperatures above 100°C even for short periods.
Special instructions for driver and front passenger airbags
  • Removed driver and front passenger airbag units must be stored with padded side upwards.
It is essential to carry out work in the following sequence when renewing airbag units:
1 -  Remove old airbag unit and place to one side with padded side upwards.
2 -  Remove new airbag unit from transport packaging and place to one side with padded side upwards.
3 -  Immediately place old airbag unit in transport packaging.
4 -  Install new airbag unit in vehicle.
Special instructions for belt tensioners
  •   Belt tensioner units must be handled with extreme caution during removal and installation. If handled incorrectly, there is a high risk of injury and damage in relation to the belt tensioner units.
  •   Belt tensioner units which are mechanically damaged (dents, fractures) always must be renewed.
  •   Never point open end of belt tensioner at another person.
  •   When connecting the belt tensioner unit, all mechanical parts (including those of the 3-point seat belt) must be properly attached. If connection of the belt tensioner unit is hindered due to tight conditions, the belt strap must be rolled up completely before connecting. In this case there is no heightened risk of safety as long as the additional safety instructions are heeded. Essentially this is aimed at battery disconnection and electrostatic discharge of the fitter prior to connection of the belt tensioner unit.
  •   Depending on the crash intensity, it is possible that the belt tensioner was triggered but the belt force limiter did NOT ignite. These parts are to be treated as unignited components!
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