Installing Wire Harness For Airbag
Installing Wire Harness For Airbag
Tools
Technical values
Preliminary work
Preliminary work for wire harness for passenger's airbag unit
1. Disconnect battery.
2. Remove cover of console at the left and right.
3. Remove centre console cover.
4. Remove centre console.
5. If installed, remove control unit for tilt sensor.
6. Remove glove compartment.
Preliminary work for wire harness for left seat-belt tensioner
1. Disconnect battery.
2. Remove cover of console at the left and right.
3. Remove centre console cover.
4. Remove centre console.
5. If installed, remove control unit for tilt sensor.
6. Remove trim panel under dashboard on left.
7. Remove front side section trim.
8. Remove front seat.
9. Remove the rear side-panel lining.
10. Remove sill.
11. Remove sill support.
Preliminary work for wire harness for right seat-belt tensioner
1. Disconnect battery.
2. Remove cover of console at the left and right.
3. Remove centre console cover.
4. Remove centre console.
5. If installed, remove control unit for tilt sensor.
6. Remove glove compartment.
7. Remove front side section trim.
8. Remove front seat.
9. Remove the rear side-panel lining.
10. Remove sill.
11. Remove sill support.
Preliminary work for wire harness for left head airbag (triggering unit to A-pillar connection point)
1. Disconnect battery.
2. Remove cover of console at the left and right.
3. Remove centre console cover.
4. Remove centre console.
5. If installed, remove control unit for tilt sensor.
6. Remove trim panel under dashboard on left.
7. Remove front side section trim.
Preliminary work for wire harness for right head airbag (triggering unit to A-pillar connection point)
1. Disconnect battery.
2. Remove cover of console at the left and right.
3. Remove centre console cover.
4. Remove centre console.
5. If installed, remove control unit for tilt sensor.
6. Remove glove compartment.
7. Remove front side section trim.
Preliminary work for head airbag wire harness (head airbag to A-pillar connection point)
1. Remove front side section trim.
2. Remove door trim panel.
Tools and materials
Tools
Commercially available tool for pulling electric wires through.
Installing wire harness for airbag
Installing components for airbag from triggering unit to passenger's airbag unit or seat-belt pretensioner
WARNING:
Danger of injury and material damage if airbag units are not handled correctly.
- Always observe the safety regulations for handling airbag units
- Remove ignition key. Disconnect battery. Route or isolate the ground strap so that all contact with a ground carrier (e.g. body, seat frame) is avoided.
- After the battery is disconnected, always wait for 1 minute before disconnecting the airbag plugs.
1. Release connector on triggering unit for airbag -10- and fold open the locking lever.
2. Remove connector from the relevant component.
2.1. Connectors for stage 1 and stage 2 of passenger's airbag unit -1 and 2-
Release and remove connectors for stage 1 and stage 2 of passenger's airbag unit
2.2. Connector for seat-belt pretensioner, left -7- and right -8-
Release and remove connector on seat-belt pretensioner.
Remove rubber sleeves -9-.
2.3. Cut off the connector of the damaged wire harness, isolate it and secure it to the main wire harness with tie-wraps.
3. Using a small screwdriver, lever the seal out of the connector housing.
4. Cut and remove tie-wrap for fixing the wire harness to the connector housing.
5. Release connector housing with a small screwdriver, lift upwards and remove from connector.
6. Lift connector guide and remove from connector.
INFORMATION: Allocation of lines - see wiring diagram.
7. Release contact of the damaged line using the press-out tool 1575 1P of the press-out and unlocking tools for flat and round plug connections of all sizes NR.155 (-arrow a-) and pull out of the contact strip.
8. Connect connector for the new wire harness on the relevant component until it engages securely.
8.1. Connectors for stage 1 and stage 2 of passenger's airbag unit -1 and 2-
Push on connectors for stage 1 and stage 2 of passenger's airbag unit until they engage securely.
8.2. Connector for seat-belt pretensioner, left -7- and right -8-
Push on connector for the seat-belt pretensioner until it engages securely.
Fit rubber sleeve -9-.
9. Route the new wire harness along the main wire harness, guide it through existing cable ducts and tie it to the main wire harness using tie-wraps.
INFORMATION: Allocation of lines - see wiring diagram.
10. Plug new line into the contact strip until the contact engages securely.
11. Push connector guide onto the connector until it engages securely.
12. Push connector housing onto the connector
12.1. Before fitting the connector housing, check for signs of damage, and replace if necessary.
12.2. Push connector housing onto the connector until it engages securely.
13. Fasten wire harness with a new tie-wrap -arrow- to the connector housing.
14. Insert seal into the connector.
14.1. Before inserting the seal, check for signs of damage, and replace if necessary.
14.2. Insert seal into the connector and press down as far as it will go. Check seal is seated properly.
15. Push on connector on triggering unit for airbag -10- until it engages securely and lock it.
Installing wire harness for airbag from the triggering unit to the A-pillar connection point
WARNING:
Danger of injury and material damage if airbag units are not handled correctly.
- Always observe the safety regulations for handling airbag units
- Remove ignition key. Disconnect battery. Route or isolate the ground strap so that all contact with a ground carrier (e.g. body, seat frame) is avoided.
- After the battery is disconnected, always wait for 1 minute before disconnecting the airbag plugs.
INFORMATION: Allocation of lines - see wiring diagram.
1. Release and disconnect plug connection for main wire harness to wire harness for door -3 and 4-.
2. Cut and remove tie-wrap for fixing the wire harness to the connector housing.
3. Release cap on both sides -arrow a- and remove from the connector housing.
4. Release locking mechanism on connector housing with a small screwdriver -arrow A- and remove -arrow B-.
5. Remove connector from connector housing -arrow C-.
6. Release connector guide on both sides -arrow a- and remove from the contact strip.
INFORMATION: Allocation of lines - see wiring diagram.
7. Release contacts of the damaged lines using the press-out tool 1575-1P of the press-out and unlocking tools for flat and round plug connections of all sizes NR.155 -arrow a- and pull out of the contact strip.
8. Cut off the contacts of the damaged lines, isolate them and secure them to the main wire harness with tiewraps.
9. Release connector on triggering unit for airbag -10- and fold open the locking lever.
10. Using a small screwdriver, lever the seal out of the connector housing.
11. Cut and remove tie-wrap for fixing the wire harness to the connector housing.
12. Release connector housing with a small screwdriver, lift upwards and remove from connector.
13. Lift connector guide and remove from connector.
INFORMATION: Allocation of lines - see wiring diagram.
14. Release contact of the damaged line using the press-out tool 1575-1P of the press-out and unlocking tools for flat and round plug connections of all sizes NR.155 -arrow a- and pull out of the contact strip.
15. Cut off the contacts of the damaged lines, isolate them and secure them to the main wire harness with tiewraps.
INFORMATION: Allocation of lines - see wiring diagram.
16. Push new lines into the contact strip until the contacts are felt to engage.
17. Push connector guide onto the contact strip until it is felt to engage.
18. Insert connector into the connector housing -arrow A-.
19. Insert locking mechanism into the connector housing and press in -arrow B- until it is felt to engage.
20. Press cap onto the connector housing until it is felt to engage.
21. Secure wire harness with a new tie-wrap -arrow- to the connector housing.
22. Route the new wire harness along the main wire harness, guide it through existing cable ducts and tie it to the main wire harness using tie-wraps.
INFORMATION: Allocation of lines - see wiring diagram.
23. Plug new line into the contact strip until the contact is felt to engage.
24. Push connector guide onto the connector until it is felt to engage.
25. Push connector housing onto the connector
25.1. Before fitting the connector housing, check for signs of damage, and replace if necessary.
25.2. Push connector housing onto the connector until it is felt to engage.
26. Fasten wire harness with a new tie-wrap -arrow- to the connector housing.
27. Insert seal into the connector.
27.1. Before inserting the seal, check for signs of damage, and replace if necessary.
27.2. Insert seal into the connector and press down as far as it will go. Check seal is seated properly.
28. Push on connector of triggering unit for airbag -10- until it is felt to engage, and lock it.
Installing wire harness for airbag from the A-pillar connection point to the head airbag
WARNING:
Incorrect handling of airbag units
- Triggering of airbag unit
- System faults can occur
- Switch off ignition and remove ignition key.
- Disconnect the battery and insulate the ground strap so that all contact with a ground carrier is avoided.
- Wait 1 minute after disconnecting the battery.
- Only pull off connector on the triggering unit after the waiting time has elapsed.
- Make sure that no foreign objects are located in front of the airbag unit during installation.
- Replace damaged parts during removal.
- Always position the airbag unit in such a way that the airbag opening is facing upwards.
- If removed for an extended period, the airbag unit must be stored in a safe place.
- Airbag units must not come into contact with grease, oil, detergents, liquids, or similar substances.
- Do not expose airbag units to temperatures above - Temperature: 90°C.
- Do not remove the short-circuit spring on the plug-in contacts.
- Ignition and preparations may only be carried out by skilled staff, supervised by a second responsible person.
- Before disposal, the airbag unit must be rendered harmless by electrical ignition performed in accordance with all precautionary measures, thereby preventing it from being used incorrectly.
1. Release and disconnect plug connection for main wire harness to wire harness for door -3 and 4-.
2. Release and pull off connector on head airbag at the left -5- and right -6-.
3. Cut off the head airbag connector on the damaged wire harness, insulate it and secure it to the door wire harness with tie-wraps.
4. Remove rubber sleeve -A- and carefully pull it and the door wire harness out of the A-pillar.
5. Slide the rubber sleeve back slightly -arrow-, remove adhesive tape and pull off the foil hose -A-.
6. Cut and remove tie-wraps for fixing the wire harness to the connector housing.
7. Release cap on both sides -arrow a- and remove it from the connector housing.
8. Release the locking mechanism on the connector housing using a small screwdriver -arrow A- and remove it -arrow B-.
9. Pull the connector out of the connector housing -arrow C-.
10. Release the connector guide on both sides -arrow a- and push it down off the contact strip.
INFORMATION: Allocation of lines - see wiring diagram.
11. Release contacts of the damaged lines using the press-out tool 1575 1P of the press-out and unlocking tools for flat and round plug connections of all sizes Nr.155 (-arrow a-) and pull out of the contact strip.
12. Cut off the contacts of the damaged lines, insulate them and secure them to the main wire harness with tie-wraps.
13. Insert wire puller -1- with the flexible end on the right side -arrow- into the rubber sleeve -2-. Coat the wire puller -1- with soapy water and slide it through the rubber sleeve -2- (-arrow A-).
INFORMATION:
- Two different wire harnesses are available as spare parts, depending on the model year. Up to model year 05, the wire harness -A- comes with insulation as standard. From model year 2006 onwards, the wire harness -B- no longer has this insulation.
- Observe wrapping direction of adhesive tape. To keep the resistance as low as possible when pulling the new wire harness through, always start wrapping the tape around at the new wire harness and end at the wire puller.
14. Slide new lines -2- through the eyelet in the rear part of the wire puller -1- (-arrow A-) wrap them around and secure with adhesive tape -3- (-arrow B-).
15. Coat the new wire harness -2- with soapy water and use the wire puller -1- to pull it through the rubber sleeve -3- (-arrow A-). Carefully push on the new wire harness again at the same time in order to make it easier to slide the wire harness through.
16. Remove adhesive tape -3- (-arrow A-) and carefully pull the lines -2- out of the eyelet on the wire puller -1- (-arrow B-). Make sure not to damage the insulation on the new lines.
17. Route new wire harness along the door wire harness and secure at the standard attachment points on the door sub-frame.
18. Plug in connector for the new wire harness on the head airbag at the left -5- and right -6- until it engages securely.
INFORMATION: Allocation of lines - see wiring diagram.
19. Push new lines into the contact strip until the contacts engage securely.
20. Push connector guide onto the contact strip until it engages securely.
21. Insert connector into the connector housing -arrow A-.
22. Insert locking mechanism into the connector housing and press it in -arrow B- until it engages securely.
23. Press cap onto the connector housing until it engages securely.
24. Secure wire harness to the connector housing using a new tie-wrap -arrow-.
25. Slide the rubber sleeve back slightly -arrow-, then pull the foil hose (500 mm length) up to the rubber sleeve over the door wire harness and secure at this position with insulating tape.
Pull foil hose tight and wrap it tightly on the entire length from the rubber sleeve up to the connector -A- of the door wire harness with insulating tape.
INFORMATION: Route the door wire harness carefully through the A-pillar in the vehicle interior, so that the foil hose and the door wire harness are not damaged.
26. Carefully slide the door wire harness through the A-pillar and fit the rubber sleeve -A-. Check that the rubber sleeve is installed at the correct position.
Subsequent work
Subsequent work for wire harness for passenger's airbag unit
1. Install glove compartment.
2. If required, install control unit for tilt sensor.
3. Connect the battery.
4. Install centre console.
5. Install centre console cover.
6. Install cover of console at the left and right.
Subsequent work for wire harness for left seat-belt tensioner
1. Install support under the sill.
2. Install sill.
3. Install the rear side-panel lining.
4. Installing front seat.
5. Install front side section trim.
6. Install trim panel under dashboard on the left.
7. If required, install control unit for tilt sensor.
8. Connect battery.
9. Install centre console.
10. Install centre console cover.
11. Install cover of console at the left and right.
Subsequent work for wire harness for right seat-belt tensioner
1. Install support under the sill.
2. Install sill.
3. Install the rear side-panel lining.
4. Install front seat.
5. Install front side section trim.
6. Install glove compartment.
7. If required, install control unit for tilt sensor.
8. Connect the battery.
9. Install centre console.
10. Install centre console cover.
11. Install cover of console at the left and right.
Subsequent work for wire harness for left head airbag (triggering unit to A-pillar connection point)
1. Install front side section trim.
2. Install trim panel under dashboard on the left.
3. If required, install control unit for tilt sensor.
4. Connect the battery.
5. Install centre console.
6. Install centre console cover.
7. Install cover of console at the left and right.
Subsequent work for head airbag wire harness (head airbag to A-pillar connection point)
1. Install door trim panel.
2. Install front side section trim.