Airbag And Belt Tensioner Wire Repair Information

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

In addition to the general repairs on wiring harnesses, the following methods and instructions must be observed for repairs on wiring harnesses for airbag systems and belt tensioners:

WARNING:

The airbag system and belt tensioner can fail.
Faulty repairs performed on airbag and seat belt tensioner system can lead to malfunction in passenger protection.
When performing repairs on airbag and seat belt tensioner wiring harness, use only terminals, connectors and wires designated for it .

Wires from the airbag and seat belt tensioner wiring harness may only be repaired using the Wiring Harness Repair Set VAS 1978/Wiring Harness Repair Set VAS 1978A/Wiring Harness Repair Set VAS 1978B.
Pay attention to stickers on vehicle designating high voltage components. When performing repairs, residual voltage must be discharged, refer to WARNINGS AND SAFETY PRECAUTIONS .
A maximum of 2 repairs may be performed when repairing wires of airbag- and seat belt tensioner system. Repairs increase the electrical resistance in the wire and may trigger malfunctions in the system On Board Diagnostic (OBD).

Fig 1: Airbag & Seat Belt Tensioner Wire Repairs (Max. 2)
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
When repairing airbag or safety belt tensioner wiring, crimp connectors must be shrunk to prevent corrosion.
Wiring harness repairs may only be performed using yellow wires.
Do not wrap the repair point again into the vehicle-specific wiring harness and mark the repair point very visibly with yellow insulating tape.
Repairs in the area of the airbag or seat belt tensioner should be performed a maximum of 30 cm from the next connector housing. Together with the identification via yellow insulating tape, this procedure makes it possible to obtain a quick overview of previously performed repairs.

Fig 2: Identifying Distance From Terminal Housing For Repairs
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Wires to the deploying units (airbags) have a wire-twisting with a length of lay of 20 mm ± 5 mm in series production. This length of lay is guaranteed via the norm part numbers for wire pairs in series production and must be observed strictly for the repair lengths of twisted wires.
During repair work, wires to deploying units (airbags) must have the same length. When twisting together wires -1- and -2-, length of lay of A = 20 mm ± 5 mm must be strictly observed.

Fig 3: Identifying Repair In Twisted Wire Pairs
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
While doing this, no section of the wire also in area of crimp connectors -arrow-, may be greater than B = 100 mm without twisting of the wires.