Airbag. Special tools. VAS 5094 Airbag adapter

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1 69-26 Airbag Special tools VAS 5094 Airbag adapter

2 69-27 Airbag system component locations (Jetta) 1 - Airbag unit driver's side (with Airbag igniter, driver's side -N95) Removing Page Airbag Malfunction Indicator Lamp (MIL) -K Airbag unit passenger's side (with Airbag igniter 1, passenger's side -N131) Removing Page Side airbag, front passenger's side (with Side airbag igniter, passenger's side -N200) Removing Page 69-71

3 Rear side airbag crash sensor, passenger's side Removing Page Side curtain protection, driver's and passenger sides Removing Page Side airbag crash sensor, passenger's side -G180 Removing Page Side airbag crash sensor, driver's side -G179 Removing Page Rear side airbag crash sensor, driver's side Removing Page 69-73

4 Side airbag, front driver's side (with Side airbag igniter, driver's side -N199) Removing Page Airbag Control Module -J234 Removing Page Data Link Connector (DLC)

5 69-30 Airbag system component locations (Golf) 1 - Airbag unit driver's side (with Airbag igniter, driver's side -N95-) Removing Page Airbag Malfunction Indicator Lamp (MIL) -K Airbag unit passenger's side (with Airbag igniter 1, passenger's side -N131-) Removing Page Side curtain protection, driver's and passenger sides Removing Page Rear side airbag crash sensor, driver's side Removing Page 69-73

6 Side airbag, front passenger's side (with Side airbag igniter, passenger's side -N200-) Removing Page Side airbag crash sensor, passenger's side -G180- Removing Page Side airbag crash sensor, driver's side -G179- Removing Page Rear side airbag crash sensor, passenger side Removing Page Side airbag, front driver's side (with Side airbag igniter, driver's side -N199-) Removing Page Airbag Control Module -J234- Removing Page Data Link Connector (DLC)

7 69-32 Safety precautions when working on airbags Testing, removing, installing and repair work may only be performed by qualified technicians. When working on airbag system, battery ground (GND) strap must be disconnected. No waiting time is necessary after disconnecting the battery. When connecting airbag system to a voltage source no person can be present inside the vehicle. Technicians must electrostatically discharge themselves by touching a suitable metal part, for example, a water pipe, heater pipe or metal frame, before picking up (touching) airbag unit. Airbag units should be installed immediately after removing them from their packaging. If work is interrupted, airbag unit should again be placed in its packaging. Do not leave airbag unit unattended.

8 69-33 Airbag units which have been removed should be stored so that upholstered side is facing up. Airbag units which have dropped onto a hard surface or show signs of damage must not be installed in the vehicle. Airbag units which have not been activated should be marked and returned to manufacturer for disposal in original airbag unit transport containers. Storage and transportation of airbags must comply with the Explosives Act. Only install original seat covers that have been authorized for use with side airbags (recognizable by airbag label). Use of commercially-available loose-fitting covers is not permissible. When installing backrest cover ensure that cover seam is straight in area of side airbag. Always replace all cover clips. Only use original clips.

9 Always replace cover if damaged in area of side airbag - torn, burn holes etc.- for safety reasons.

10 69-34 Supplemental side airbag protection safety precautions Do not repair damaged pillar trim panels; they must be replaced. Side curtain protection must not be buckled or warped. After body repair in area around side curtain protection, look over vehicle body for weld splatter, deformities and abrasions, and use other side of vehicle for comparison. Replacing airbag units following accidents Accident involving activation of airbag Always replace the following: All triggered airbag units with control units and sensors Support for front passenger module Coil connector with slip ring All seat belts with triggered belt tensioners

11 In addition, the following must also be replaced if necessary (visual check): All damaged components

12 69-35 Accident not involving activation of airbag If Airbag Malfunction Indicator (MIL) -K 75 does not indicate a fault, it is not necessary to replace airbag components. Seat belts should be checked separately. After replacing airbag units or the control unit, affix stickers (only tear-off strips) to registration card and return registration card to relevant dealer or to Importer for registration. The registration card must be ordered separately.

13 69-36 Driver's airbag unit, removing and installing Vehicles with four spoke steering wheel Four spoke steering wheels are supplied by two vendors. Airbags supplied by Petri mount with rectangular retaining studs -1-. Airbags supplied by TRW mount with stepped pins -2-. Because of the differing engaging mechanisms, only steering wheels and airbag units from same supplier can be installed. Replacement parts must be from same supplier.

14 Steering wheel Removing Page Connector 3 - Locking lug Release from rear of steering wheel 4 - Airbag unit (with Airbag igniter, driver's side -N95) Because of differing engaging mechanisms, only steering wheels and airbag units from the same supplier can be installed Removing Page Installing Page 69-41

15 Multi-point socket head bolt 55 Nm ( ft lb) Equipped with locking compound Can be used up to 5 times Mark using center punch after each assembly 6 - Securing plate 7 - Coil spring for airbag/return spring with slip ring -F138 Removing Page Trim 9 - Clip

16 69-39 Removing - Disconnect battery ground (GND) strap. - Release steering column height adjustment. - Turn steering wheel until steering wheel spokes are vertical. Pull out steering column completely and press down to lowest position. - Secure steering column adjustment. - Insert screwdriver (approx. 175 mm or 6.8 in. long) from reverse side into hole of steering wheel hub (insert screwdriver approx. 45 mm or 1.8 in.).

17 Press screwdriver in direction of arrow so that clip -10- is pressed back and locking lug of airbag unit is released. - Turn steering wheel back 180 and release second locking lug on opposite side. - Turn steering wheel -1- to center position (road wheels in straight-ahead position). - Pull connector off airbag unit.

18 69-41 Installing Note: Only steering wheels and airbag units from the same supplier can be installed. - Connect electrical connector -2- to back of airbag unit Press in airbag unit until tabs -3- are locked. - Switch on ignition. - Connect battery ground strap. WARNING! No persons may be inside vehicle during this step. Note: If engine Electronic Control Module (ECM) is subject to low voltage with ignition on, DTC memory and Readiness code must be checked Repair Manual, On Board Diagnostic Fuel Injection & Ignition, Repair Group 01

19 69-42 Vehicles with three spoke steering wheel 1 - Steering wheel Removing Page Connector 3 - Locking lug Release from rear of steering wheel 4 - Airbag unit Removing Page Installing Page 69-46

20 Multi-point socket head bolt 55 Nm ( ft lb) Equipped with locking compound Can be used up to 5 times Mark using center punch after each assembly 6 - Securing plate 7 - Airbag spiral spring/return spring with slip ring -F138 Removing Page Trim 9 - Clip

21 69-44 Removing - Disconnect battery ground (GND) strap. - Release steering column height adjustment. - Turn steering wheel - 1 -, until steering wheel spoke is vertical. Pull out steering column completely and press up to upper position. - Secure steering column adjustment. - Insert screwdriver (approx. 175 mm or 6.8 in. long) from reverse side into hole of steering wheel hub (insert screwdriver approx. 45 mm or 1.8 in.).

22 Press screwdriver in direction of arrow to press back clip -10- and release locking lug of airbag unit. - Turn steering wheel back 180 and release second locking lug on opposite side. - Turn steering wheel -1- to center position (road wheels in straight-ahead position). - Pull connector off airbag unit.

23 69-46 Installing - Connect electrical connector -2- to back of airbag unit Press in airbag unit until tabs -3- are locked. - Switch on ignition. - Connect battery ground (GND) strap. WARNING! No persons may be inside vehicle during this step. Note: If engine Electronic Control Module (ECM) is subject to low voltage with ignition on, DTC memory and Readiness code must be checked Repair Manual, On Board Diagnostic (OBD) Fuel Injection & Ignition, Repair Group 01

24 69-47 Steering wheel, removing and installing 1 - Steering wheel Removing Page Multi-point socket head bolt 55 Nm ( ft lb) Equipped with locking compound Can be used up to 5 times Mark using center punch after each assembly 3 - Torx screw 5 Nm (44 in. lb)

25 Airbag unit with driver's side airbag igniter -N95 Because of differing engaging mechanisms, only steering wheels and airbag units from same supplier can be installed 5 - Connector 6 - Securing plate

26 69-49 Removing Driver airbag removed. - Turn steering wheel to center position (road wheels in straight-ahead position). - Remove multi-point socket head bolt and pull steering wheel off steering column.

27 69-50 Airbag spiral spring/return spring with slip ring, removing and installing Notes: Steering must be in center position (road wheels in straight-ahead position) when coil connector and slip ring are removed and installed. Replacement slip ring -F138 is secured as a new part in center position with cable tie. Removing Driver airbag unit and steering wheel removed. - Remove two screws -arrows-. - Remove upper steering column switch trim -1-.

28 Remove three screws -arrows-. - Release steering wheel height adjustment Take off lower steering column switch trim Separate connection Release locking lugs -arrows- and pull airbag spiral spring/return spring with slip ring - F138 off steering column switch. Notes: Steering must be in center position (road wheels in straight-ahead position) when coil connector and slip ring are removed and installed. Replacement slip ring is secured as a new part in center position with cable tie. Installing - Install in reverse order of removal.

29 69-52 Front passenger's airbag unit, removing and installing Instrument panel with airbag seams 1 - Passenger's airbag unit with airbag igniter 1, passenger's side -N Connector 3 - Nut 4 - Cover 4 Nm (35 in lb) 5 - Support 6 - Bolt 7 - Bolt Must be replaced if airbag has triggered 2.5 Nm (22 in lb) 2.5 Nm (22 in lb)

30 Disconnect battery ground (GND) strap. - Pull cover for front passenger's airbag off dash panel to rear (cover is pushed flush into dash panel). - If airbag has been triggered and cover has been deformed, swing coverup and remove nuts CAUTION! The airbag harness is very short. To keep from damaging the connector remove the glove box Page Remove nuts - 6 -, take airbag unit off supports and separate connector

31 69-54 Installation - Connect electrical connector -2- to back of airbag unit Install airbag unit on supports Install cover Press in cover until flush with dash. - Switch on ignition. - Connect battery ground (GND) strap. WARNING! No persons may be inside vehicle during this step. Note: If engine Electronic Control Module (ECM) is subject to low voltage with ignition on, DTC memory and Readiness code must be checked Repair Manual, Fuel Injection & Ignition, Repair Group 01

32 69-55 Instrument panel without airbag seams 1 - Airbag unit, passenger side 2 - Connector 3 - Center tube 4 - Support must be replaced if airbag has deployed 5 - Socket-head screw 2.5 Nm (22 in lb) 6 - Torx-head screw 2.5 Nm (22 in lb)

33 69-56 Removing CAUTION! Before working on electronic components, disconnect the battery ground (GND) strap. - Remove center console Page Remove glove box Page Remove four Torx-head screws Press airbag unit -1- along with supports -4- up and out of mounting elbow on central tube -3-.

34 Push airbag unit to side and remove downward. - Disconnect electrical connection Installation - Install in reverse order of removal. - Switch on ignition. - Close doors. - Connect battery ground (GND) strap. WARNING! No persons may be inside vehicle during this step. Note: If engine Electronic Control Module (ECM) is subject to low voltage with ignition on, DTC memory and Readiness code must be checked Repair Manual, Fuel Injection & Ignition, Repair Group 01

35 69-58 Airbag control module -J 234-, removing and installing Note: Disconnect battery ground (GND) strap before removing airbag control module. - Remove footwell trim Move bar -2- in opposite direction of arrow and pull connector -3- out of the control unit Remove nuts -4- and pull control unit off studs (nut -4- = 9 Nm or 80 in. lb.). - Install in reverse order of removal. Note: If engine Electronic Control Module (ECM) is subject to low voltage with ignition on, DTC memory and Readiness code must be checked Repair Manual, Fuel Injection & Ignition, Repair Group 01

36 69-59 Side curtain protection, driver's and passenger sides, removing and installing (Jetta) CAUTION! Before working on electronic components, disconnect the battery ground (GND) strap. Assembly overview 1 - Side curtain protection 2 - Detent notch 3 - Side curtain guide snapped in 4 - Screws seven pieces 5 Nm (44 in lb) 5 - Connector

37 69-60 Removing Notes: Before disconnecting battery cables, take all notes into account regarding coding in radio operating instructions. After reconnecting the battery cables, check vehicle equipment, such as radio, clock and window regulator as shown in the repair manual and/or the owner's manual. Technicians must electrostatically discharge themselves by touching door lock or vehicle body briefly before separating igniter and ground (GND) wires.

38 Remove the upper trim panals of the A pillars Page Remove the upper trim panals of the B pillars Page Remove the upper trim panals of the C pillars Page Remove inside roof lining Page Disconnect the battery ground strap. - Detach connection Remove screw -4- and pull side curtain protection downward out of the angle brackets (latches -2- install the side curtain in retaining brackets).

39 Pull gas alternator -1- out of the bracket Take side curtain protection out the vehicle without kinking. Installing Install in reverse order of removal. - Switch on ignition. - Close all doors. - Connect battery ground (GND) strap. WARNING! No persons may be inside vehicle during this step.

40 69-63 Side curtain protection, driver's and passenger sides, removing and installing (Golf) WARNING! Before working on electronic components, disconnect the battery ground (GND) strap. Assembly overview 1 - Side curtain 2 - Detent notch 3 - Connector 4 - Screws six 5 Nm (44 in lb) 5 - Gas alternator 6 - Bracket

41 69-64 Removing Notes: Before disconnecting battery cables, take all notes into account regarding coding in radio operating instructions. After reconnecting the battery cables, check vehicle equipment, such as radio, clock and window regulator as shown in the repair manual and/or the owner's manual. Technicians must electrostatically discharge themselves by touching door lock or vehicle body briefly before separating igniter and ground (GND) wires. The procedure for removing side curtain protection is the same for 2-door and 4-door vehicles.

42 Remove upper trim panels of the A-pillars Page Remove the upper trim panels of the B-pillars Page Remove the upper trim panels of the C-pillars Page Remove inside roof lining Page Disconnect the battery ground strap. - Detach connection Remove screws -4- and pull side curtain protection downward out of the angle brackets (latches -2- fit the side curtain in the brackets).

43 Pull gas alternator -5- out of the bracket Remove side curtain protection without kinking. Installing Install in reverse order of removal. - Switch on ignition. - Close all doors. - Connect battery ground (GND) strap. WARNING! No persons may be inside vehicle during this step.

44 69-67 Crash sensor for rear side airbag, driver's and passenger sides, removing and installing In certain accident situations, the "rear crash sensor for side airbag" can initiate deployment of side curtain protection and side airbag. The "rear crash sensor for side airbag, driver's and passenger sides" is known as "electronic control unit side curtain protection" in case of replacement part.

45 69-68 Removing WARNING! Before working on electronic components, disconnect the battery ground (GND) strap. Notes: Before disconnecting battery cables, take all notes into account regarding coding in radio operating instructions. After reconnecting the battery cables, check vehicle equipment, such as radio, clock and window regulator as shown in the repair manual and/or the owner's manual.

46 Remove wheel house trim (Golf) Page Remove wheel house trim (Jetta) Page Disconnect battery ground (GND) strap. - Detach connection Remove screws -3- and -4-.

47 69-70 Installing - Attach crash sensor -1- with screws -3- and Attach connector -2- to the connector housing of crash sensor Switch on ignition. - Close all doors. - Connect battery ground (GND) strap. WARNING! No persons may be inside vehicle during this step.

48 69-71 Driver's/front passenger's side airbags, removing and installing 1 - Side airbag, driver's with igniter for side airbag -N199- /front passenger's with igniter for side airbag -N Bolt 7 Nm (62 in lb) 3 - Connector 4 - Backrest frame - Disconnect battery ground strap. - Remove driver's or front passenger's seat (Airbag - use adapter VAG 5094) Page Remove backrest frame Page 72-6 and release backrest cover in area of airbag Remove screws

49 Pull connector off airbag unit Pull airbag unit off backrest frame Installation - Install in reverse order of removal. - Reassemble seat. - Switch on ignition. - Close doors. - Connect battery ground (GND) strap. WARNING! No persons may be inside vehicle during this step. Note: If engine Electronic Control Module (ECM) is subject to low voltage with ignition on, DTC memory and Readiness code must be checked Repair Manual, Fuel Injection & Ignition, Repair Group 01

50 69-73 Driver's/front passenger's side airbag crash sensor, removing and installing 1 - Side airbag crash sensor, driver's -G179-/front passenger's -G Connector 3 - Bolt 6 Nm 4 - Carpet - Disconnect battery ground (GND) strap. - Remove driver's or front passenger's seat (Airbag - use adapter VAG 5061) Page Release carpet and insulation mat in area of sensor. - Disconnect connector and remove screws

51 69-74 Installation - Install in reverse order of removal. - Reassemble carpet. - Install seat and connect connectors. - Switch on ignition. - Close doors. - Connect battery ground (GND) strap. WARNING! No persons may be inside vehicle during this step. Note: If engine Electronic Control Module (ECM) is subject to low voltage with ignition on, DTC memory and Readiness code must be checked Repair Manual, Fuel Injection & Ignition, Repair Group 01

52 69-75 Airbag units, deploying (disposal) WARNING! DO NOT ignite airbag units in vehicles. According to regulations, airbag units must be rendered unusable by igniting them electrically before scrapping the vehicle. This is necessary because the airbag unit is a pyrotechnic device that may cause injuries if activated in an improper manner (e.g. using a cutting torch). - Remove airbag unit Page Use J Deployment Fixture and refer to the Airbag & Pyrotechnic Deployment Device Instruction Booklet for proper deployment procedure.

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