Safety Precautions When Working With Pyrotechnic Components

• Airbag units
• Belt tensioners
• Seat belt force limiter (depending on vehicle equipment)
• Battery cut-out elements (depending on vehicle 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 checked only when they are installed and with a vehicle diagnostic tester approved by the manufacturer.
• When working on the airbag system (pyrotechnic components, Airbag Control Module -J234-, wiring), the battery ground cable must be disconnected when the ignition is 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 when doing this. Exception: Vehicles with a battery inside the passenger compartment.
• If the ignition is not switched on after the battery is reconnected - the indicator lamps in the instrument cluster do not turn on - the ignition (key/button) may only be switched on while sitting in the driver seat with the seat all the way back.
• Follow the steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .
• The technician must discharge static electricity before handling pyrotechnic components for the restraint system, for example, before disconnecting the connector. Touching grounded metal parts will discharge the static electricity, for example by touching the door striker.
• 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 the vehicle.
• Pyrotechnic components should be installed immediately upon removal from shipping package.
• If the procedure must be stopped for awhile, put the pyrotechnic component back into its shipping package.
• It is not permitted to leave a 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, cleaning solutions or similar substance on pyrotechnic components.
• Replace the airbag unit if any contaminants such as oil, grease, paint, dye or solvents 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 driver and front passenger airbags

• Store dismounted driver and front passenger airbag units with the cushioned side facing up.

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

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

Special Information regarding Belt Tensioners

• Use extreme care when removing and installing belt tensioner units. Improper handling of belt tensioner units is very dangerous and could result in serious personal injury.
• Belt tensioner units 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 webbing must be rolled up completely prior to connection. In this case there is no increased safety risk, if all other safety precautions are followed. This particularly includes the notes regarding the disconnection of the battery and the static discharging of the technician prior to connecting the belt tensioner.
• Even after a crash, it is possible that the belt tensioner ignited, but the seat belt force limiter did NOT. Treat these components as if they had not ignited.