Part 2

WM 976623 Installing wire harness for airbag

Information

Allocation of lines - see wiring diagram.

Connector overview for airbag wire harness, shown on the 911

Removing cap from 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-.

Removing connector from connector housing

5. Remove connector from connector housing -arrow C-.
6. Release connector guide on both sides -arrow a- and remove from the contact strip.

Pushing down connector guide 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.

Pressing out contacts from the contact strip

8. Cut off the contacts of the damaged lines, isolate them and secure them to the main wire harness with tie-wraps.
9. Release connector on triggering unit for airbag -10- and fold open the locking lever. -> 695319 Removing and installing triggering unit for airbag - section on "Removing" 69531900 Removing and installing triggering unit for airbag
10. Using a small screwdriver, lever the seal out of the connector housing.

Levering out seal from connector housing

11. Cut and remove tie-wrap for fixing the wire harness to the connector housing.

Removing tie-wrap at connector housing

12. Release connector housing with a small screwdriver, lift upwards and remove from connector.

Removing connector housing from connector

13. Lift connector guide and remove from connector.

Removing connector guide 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.

Pressing out the contacts

15. Cut off the contacts of the damaged lines, isolate them and secure them to the main wire harness with tie-wraps.

Information

Allocation of lines - see wiring diagram.

16. Push new lines into the contact strip until the contacts are felt to engage.

Pressing in contacts on the contact strip

17. Push connector guide onto the contact strip until it is felt to engage.

Pushing connector guide onto the contact strip

18. Insert connector into the connector housing -arrow A-.

Inserting connector into the connector housing

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.

Pressing cap onto the connector housing

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.

Securing wire harness to the main wire harness

Information

Allocation of lines - see wiring diagram.

23. Plug new line into the contact strip until the contact is felt to engage.

Pressing in the contacts

24. Push connector guide onto the connector until it is felt to engage.

Pushing connector guide onto the connector

25. Push connector housing onto the connector
25.1. Before fitting the connector housing, check for signs of damage, and replace if necessary. -> 976600 Airbag warning light activated: seal in plug connection of triggering unit defective
25.2. Push connector housing onto the connector until it is felt to engage.

Pushing connector housing onto the connector

26. Fasten wire harness with a new tie-wrap -arrow- to the connector housing.

Fitting tie-wrap at connector housing

27. Insert seal into the connector.
27.1. Before inserting the seal, check for signs of damage, and replace if necessary. -> 976600 Airbag warning light activated: seal in plug connection of triggering unit defective
27.2. Insert seal into the connector and press down as far as it will go. Check seal is seated properly.

Inserting seal of connector housing

28. Push on connector of triggering unit for airbag -10- until it is felt to engage, and lock it. -> 695319 Removing and installing triggering unit for airbag - section on "Installing" 69531900 Removing and installing triggering unit for airbag

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 or remote control (hand-held transmitter).
-> A voltage supply (e.g. battery charger) must not be connected to the external power supply/jump-lead starting terminals.
-> 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 detach 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 airbag units so that the blow-out opening is facing upwards, e.g. crest on driver's airbag.
-> Do not position anything on the airbag units.
-> If removed for an extended period, the airbag units 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 90°.
-> 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.

Connector overview for airbag wire harness, shown on the 911

1. Release and disconnect plug connection for main wire harness to wire harness for door -3 and 4-. -> 973219 Removing and installing wire harness for door - section on "Removing" 97321900 Removing and installing wiring harness for door
2. Release and pull off connector on head airbag at the left -5- and right -6-. -> 696619 Removing and installing head airbag - section on "Removing" 69661900 Removing and installing the head airbag unit
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.

Removing rubber sleeve

5. Slide the rubber sleeve back slightly -arrow- , remove adhesive tape and pull off the foil hose -A-.

Removing foil hose

6. Cut and remove tie-wraps for fixing the wire harness to the connector housing.

Removing cap from 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-.

Removing connector from connector housing

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.

Pushing down connector guide from 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.

Pressing out contacts from 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- ). -> 976623 Installing wire harness for airbag - section on "Tools and materials"

Sliding wire puller through the sleeve

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.

Wire harness spare part

Information

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- ).

Securing new lines on wire puller

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.

Pulling new wire harness through rubber sleeve

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.

Releasing new line on wire puller

17. Route new wire harness along the door wire harness and secure at the standard attachment points on the door sub-frame.

Securing line for head airbag at 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. -> 696619 Removing and installing head airbag - section on "Installing" 69661900 Removing and installing the head airbag unit

Information

Allocation of lines - see wiring diagram.

19. Push new lines into the contact strip until the contacts engage securely.

Pressing in contacts on the contact strip

20. Push connector guide onto the contact strip until it engages securely.

Pushing connector guide onto contact strip

21. Insert connector into the connector housing -arrow A-.

Inserting connector into connector housing

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.

Pressing cap onto connector housing

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.

Attaching foil hose

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.

Fitting rubber sleeve

Subsequent work

Subsequent work for wire harness for passenger's airbag unit

1. Install glove compartment. -> 681519 Removing and installing glove compartment - section on "Installing" 681519 Removing and installing glove compartment
2. If required, install control unit for tilt sensor. -> 966319 Removing and installing control unit for tilt sensor - section on "Installing" Service and Repair
3. Connect the battery. -> 271000 Work instructions after disconnecting the battery
4. Install centre console. -> 681719 Removing and installing centre console - section on "Installing" 681719 Removing and installing centre console
5. Install centre console cover. -> 681919 Removing and installing centre console cover - section on "Installing" 681919 Removing and installing cover for centre console
6. Install cover of console at the left and right. -> 681419 Removing and installing centre console cover - section on "Installing" 681419 Removing and installing centre console cover

Subsequent work for wire harness for left seat-belt tensioner

1. Install support under the sill. -> 695119 Removing and installing airbag sensor - section on "Installing" 69511900 Removing and installing airbag sensor
2. Install sill. -> 680519 Removing and installing inner sill
3. Install the rear side-panel lining. -> 707519 Removing and installing rear side-panel lining
4. Installing front seat. => Removing and installing front seat
5. Install front side section trim. -> 702419 Removing and installing front side section trim - section on "Installing" 702419 Removing and installing front side section trim
6. Install trim panel under dashboard on the left. -> 701919 Removing and installing trim panel under dashboard - section on "Installing" 701919 Removing and installing trim under dashboard
7. If required, install control unit for tilt sensor. -> 966319 Removing and installing control unit for tilt sensor - section on "Installing" Service and Repair
8. Connect battery. -> 271000 Work instructions after disconnecting the battery
9. Install centre console. -> 681719 Removing and installing centre console - section on "Installing" 681719 Removing and installing centre console
10. Install centre console cover. -> 681919 Removing and installing centre console cover - section on "Installing" 681919 Removing and installing cover for centre console
11. Install cover of console at the left and right. -> 681419 Removing and installing centre console cover - section on "Installing" 681419 Removing and installing centre console cover

Subsequent work for wire harness for right seat-belt tensioner

1. Install support under the sill. -> 695119 Removing and installing airbag sensor - section on "Installing" 69511900 Removing and installing airbag sensor
2. Install sill. -> 680519 Removing and installing inner sill
3. Install the rear side-panel lining. -> 707519 Removing and installing rear side-panel lining
4. Install front seat. => Removing and installing front seat
5. Install front side section trim. -> 702419 Removing and installing front side section trim - section on "Installing" 702419 Removing and installing front side section trim
6. Install glove compartment. -> 681519 Removing and installing glove compartment - section on "Installing" 681519 Removing and installing glove compartment
7. If required, install control unit for tilt sensor. -> 966319 Removing and installing control unit for tilt sensor - section on "Installing" Service and Repair
8. Connect the battery. -> 271000 Work instructions after disconnecting the battery
9. Install centre console. -> 681719 Removing and installing centre console - section on "Installing" 681719 Removing and installing centre console
10. Install centre console cover. -> 681919 Removing and installing centre console cover - section on "Installing" 681919 Removing and installing cover for centre console
11. Install cover of console at the left and right. -> 681419 Removing and installing centre console cover - section on "Installing" 681419 Removing and installing centre console cover

Subsequent work for wire harness for left head airbag (triggering unit to A-pillar connection point)

1. Install front side section trim. -> 702419 Removing and installing front side section trim - section on "Installing" 702419 Removing and installing front side section trim
2. Install trim panel under dashboard on the left. -> 701919 Removing and installing trim panel under dashboard - section on "Installing" 701919 Removing and installing trim under dashboard
3. If required, install control unit for tilt sensor. -> 966319 Removing and installing control unit for tilt sensor - section on "Installing" Service and Repair
4. Connect the battery. -> 271000 Work instructions after disconnecting the battery
5. Install centre console. -> 681719 Removing and installing centre console - section on "Installing" 681719 Removing and installing centre console
6. Install centre console cover. -> 681919 Removing and installing centre console cover - section on "Installing" 681919 Removing and installing cover for centre console
7. Install cover of console at the left and right. -> 681419 Removing and installing centre console cover - section on "Installing" 681419 Removing and installing centre console cover

Subsequent work for wire harness for right head airbag (triggering unit to A-pillar connection point)

1. Install front side section trim. -> 702419 Removing and installing front side section trim - section on "Installing" 702419 Removing and installing front side section trim
2. Install glove compartment. -> 681519 Removing and installing glove compartment - section on "Installing" 681519 Removing and installing glove compartment
3. If required, install control unit for tilt sensor. -> 966319 Removing and installing control unit for tilt sensor - section on "Installing" Service and Repair
4. Connect the battery. -> 271000 Work instructions after disconnecting the battery
5. Install centre console. -> 681719 Removing and installing centre console - section on "Installing" 681719 Removing and installing centre console
6. Install centre console cover. -> 681919 Removing and installing centre console cover - section on "Installing" 681919 Removing and installing cover for centre console
7. Install cover of console at the left and right. -> 681419 Removing and installing centre console cover - section on "Installing" 681419 Removing and installing centre console cover

Subsequent work for head airbag wire harness (head airbag to A-pillar connection point)

1. Install door trim panel. -> 705919 Removing and installing door trim panel - section on "Installing" 705919 Removing and installing door panel
2. Install front side section trim. -> 702419 Removing and installing front side section trim - section on "Installing" 702419 Removing and installing front side section trim