Airbag And Belt TENSIONER Wires, Repairing

WARNING: This page is about a different car, the 2023 Volkswagen Arteon. 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 airbag- and seat belt tensioner wires:

WARNING:

The airbag and seat belt tensioner system 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. Refer to the appropriate Electronic Parts Information.

NOTE:

Air bag wires and the safety belt tensioner wiring harness may repaired only with the Wiring Harness Repair Set:VAS 1978 B and previous versions.

Observe general notes for repairs on the vehicle electrical system. Refer to VEHICLE ELECTRICAL SYSTEM, GENERAL REPAIR INFORMATION .

Pay attention to decals designating high-voltage components. When performing repairs, the residual voltage must be discharged. Refer to OVERVIEW - PEDESTRIAN PROTECTION .

A maximum of two 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 wiring harness of airbag- and seat belt tensioner system, the crimp connectors must always be heat-shrunk to prevent corrosion.

Do not wrap the repair point again into the vehicle-specific wiring harness and mark the repair point quite 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 contact 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 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, for example, in area of crimp connectors -arrow-, may be greater than B = 100 mm without twisting of the wires.

Pay attention to the following when repairing the airbag and seat belt tensioner unit connectors:

The different connectors are only available with connected wires.

The repair connectors with wires always have the same wire colors. Pin 1 is black, pin 2 is yellow and, if equipped, pin 3 is brown.

The correct allocation of the wires is determined in the wiring diagram. Refer to the appropriate Wiring Diagram.