Pyrotechnic Components Safety Precautions

• Airbag units
• Belt tensioner
• Belt force limiter (depending on equipment)
• Battery cut-off components (depending on equipment)

General 

• Testing, assembly, and repair work may only be performed by qualified personnel.
• There is no change interval for airbag units.
• Never test with a test light, volt meter or ohm meter.
• The pyrotechnic components may be check only when they are installed and with a Volkswagen approved vehicle diagnosis, testing and information system.
• When working on the Airbag System (pyrotechnic components, Airbag Control Module -J234- , wiring), the battery Ground (GND) cable must be disconnected WITH THE IGNITION SWITCHED ON. Then cover the negative terminal.
• Wait for 10 seconds after disconnecting the battery.
• The ignition must be SWITCHED ON when connecting the battery. Nobody should be inside the vehicle with doing this. Exception: Vehicles with a battery inside the passenger compartment.
• If the ignition is not switched on after the battery is reattached - the warning lamps on the instrument cluster do not light up - then place the ignition (button) on the driver seat, which should be reclined back to its furthest position.
• Follow the steps after connecting the battery, refer to BATTERY .
• Before handling pyrotechnic components of the restraint system, for example, before disconnecting the electrical harness connector, the relevant person must discharge static electricity. Touching GND metal parts, for example, touching the door striker, will discharge the static electricity.
• Wash hands after touching ignited restraint system pyrotechnic components.
• Pyrotechnic components may not be opened nor repaired; always use new parts (risk of injury).
• Pyrotechnic components that have fallen onto a hard surface or show signs of damage must not be installed in vehicle.
• Pyrotechnic components should be installed immediately upon removal from shipping package.
• If the work must be stopped for awhile, put the pyrotechnic component back into its shipping package.
• Do not leave the pyrotechnic component out unattended.
• When connecting restraint system pyrotechnic components, only the person performing the work should be in the vehicle.
• Do not use any grease or cleaning solutions on pyrotechnic components.
• Replace the airbag unit if any contaminants such as oil, grease, paint, dye or cleaning solution have penetrated the fabric.
• Pyrotechnic components must not be exposed to temperatures over 100 °C (212 °F), even for a short time.

Special information regarding the driver and front passenger airbags 

• Store the driver and front passenger airbag units in the uninstalled state so that the cushioned side faces upward.

When replacing airbag units, following sequence must be followed exactly: 

1. Remove the old airbag unit and store with the upholstered side facing up.
2. Remove the new airbag unit from the transport container and store it with the upholstered side facing up.
3. Place the old airbag unit in the transport container immediately.
4. Install the new airbag unit in the vehicle.

Belt Tensioner Special Instructions 

• Use extreme care when removing and installing belt tensioners. Handling belt tensioner units improperly is very dangerous and could result in serious personal injury.
• Belt tensioners that are mechanically damaged (dents, cracks) must always be replaced.
• The open end of the belt tensioner should never be pointed at anyone.
• When connecting a belt tensioner, all mechanical parts, including those in the three-point seat belt, must be secured correctly. If it is not possible to connect the belt tensioner because of insufficient space, the seat belt must be rolled up completely prior to connection. In this case there is no increased safety risk, if all other safety instructions are followed. In particular, this includes the notes regarding the disconnection of the battery and the static discharging of the technician prior to connection of the belt tensioner.
• Even after a crash, it is possible that the belt tensioner ignited, but the belt force limiter did NOT. Treat these components as if they had not ignited!