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Service Training

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Reference Guide 810103

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Volkswagen Airbag and Safety Systems l purpos

Reference Guide

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 Volkswagen Group of America, Inc.
Volkswagen Academy
Printed in U.S.A.
Printed 11/2011

Course Number 810103

©2011 Volkswagen Group of America, Inc.

All rights reserved. All information contained in this manual

is based on the latest information available at the time of
. Volkswagen AG
a gen AG does
printing
olksand is subject to the copyright
w not and other intellectual
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property
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au ac
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to make changes at any time without notice. No part of this
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document may be reproduced, stored in a retrieval system,

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or transmitted in any form or by any means, electronic,

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mechanical, photocopying, recording or otherwise, nor

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may these materials be modiƂed or reposted to other sites

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without the prior expressed written permission of the

es, in part or in w

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publisher.

All requests for permission to copy and redistribute

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information should be referred to Volkswagen Group of

l purpos

America, Inc.
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Always check Technical Bulletins and the latest electronic

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repair information for information that may supersede any

n in
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information included in this booklet.

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 Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Airbag and Pyrotechnic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Working on the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ir se
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Special Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

an
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Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
hole

spec
es, in part or in w

t to the co
Repair Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

rrectness of i
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Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Note Important!

This Self-Study Program provides information This information will not be updated.
regarding the design and function of new For maintenance and repair procedures,
models. always refer to the latest electronic
This Self-Study Program is not a Repair Manual. service information.

iii
 AG. Volkswagen AG d
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 Introduction

Introduction to Volkswagen Airbag and Safety Systems

After completing this course you will be able to:

• Recognize that occupant safety is integrated throughout the vehicle, and practice caution when performing
repairs
• Identify the conditions that cause the airbag to deploy
• Handle airbags and pyrotechnic seat belts according to safety rules and precautions
• Recognize the special tools used with airbag and safety systems
• Recognize the special procedural steps for performing a repair involving an airbag

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1
Introduction

Safety Related Components

When it comes to safety, airbags and seatbelts aren’t the only components involved. Safety is integrated
throughout Volkswagen vehicles.

• Instrument panels are made with materials to reduce the risk of injury in a crash, such as soft textures and
padding
• Steering columns and the lower portions of instrument panels are designed to absorb energy and control the
position of occupants during a crash
• Door panels have special designs, materials, and crush elements that help reduce the chance of injury to the
occupant
• Seat cushions and head restraints are also engineered to position occupants and reduce injuries

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Rollover Protection
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Vehicle Body Design

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mer

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Accident Avoidance Features

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2
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Airbag and Pyrotechnic Systems

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Volkswagen has always been innovative with its occupant safety systems. It began offering seat belts in the early

es, in part or in w

t to the co
1960's.

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Today’s Volkswagen safety systems are much more advanced, including driver and passenger front airbags, side

l purpos
airbags, side curtain airbags and pyrotechnic safety belts.

nform
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As you proceed through this guide, you will learn about how these systems work, and the things you need to

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know to work safely with these components.

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3
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Airbag and Pyrotechnic Systems

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ACM Inputs

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Airbag and pyrotechnic devices deploy only in certain instances.

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The deployment of an airbag or pyrotechnic device depends on the vehicle deceleration, acceleration or pressure

ss
change caused by the crash and registered by the Airbag Control Module (ACM).

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If the measured value is below the reference value programmed into the ACM, the airbags or pyrotechnic devices

atio
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will not be deployed.

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Vehicle damage or lack of vehicle damage is not necessarily an indication of whether or not the airbag or a

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pyrotechnic device should or should not have been deployed.

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4
 Airbag and Pyrotechnic Systems
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There are sensors located in the vehicle that detect
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The ACM receives the sensor information and determines what type of crash it is.

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The ACM sends a signal to pre-tension the seat belts and then deploys the airbags that are needed for that

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5
Airbag and Pyrotechnic Systems

Front Crash Sequence

The time that passes between a braking vehicle going into a crash and the deployment of the airbags is very
short.

For example, a vehicle going 35 mph into a rigid wall has about 150 milliseconds to complete the activation of all
the safety features. That is about as long as it takes you to blink your eyes.

The driver doesn’t have any time to react. This is why it is called a “passive” restraint system. The ACM,
seatbelts, and airbags function on their own to protect the occupants.
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6
 Airbag and Pyrotechnic Systems

Passive Occupant Detection System

Now that you know about how a vehicle will activate an airbag, let’s look at how it knows when to turn it off.

It is a requirement that the front passenger airbag be turned off for an infant in a child seat.

In most Volkswagen vehicles, there is a mat under the seat cushion that sends ƃuid through a transfer hose to a
sensor. (The 2011 Jetta and 2012 Passat introduced an electromagnetic system).

The sensor converts the pressure

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The control module uses those signals to determine the weight of the occupant and sends a signal to the ACM

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Seat Occupied
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Connector
Beneath
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Seat Occupied
Seat Occupied Recognition Pressure
Recognition Control Sensor
Module

7
Airbag and Pyrotechnic Systems agen
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There are certain precautions that you should always take when working on an airbag system.

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Refer to the repair manual for the latest warnings and cautions as well as other important information on airbags and

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pyrotechnic devices.
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Empty pockets of pencils, pens, cigerettes, and other items that could fall out.
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Disconnect the battery ground (GND) strap before working on the airbag or pyrotechnic seat belts.

Wear O.S.H.A approved safety goggles with a minimum ANSI rating of ANSI Z87_1_1968 and ANSI Z87_1_1989. Flying
material released during an inadverent deployment can damage eyesight or cause blindness.

Electrostatically discharge yourself before handling an airbag or pyrotechnic safety belt. Do this by touching a suitable
metal part, such as a door jam striker pin or ground point.

8
 Working on the Vehicle
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There are quite a few things a Technician needs to know when working on vehicles with Airbags and pyrotechnic

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seatbelts.
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Never open or attempt to repair an airbag module or pyrotechnic safety belts.

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Do not install airbag components or pyrotechnic safety belts that have been dropped or py
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Never use a (nine volt) battery saver. Using a battery battery saver can cause an airbag or
safety belt pretensioner to deploy.

Never use a digital volt ohmeter or self powered test light when working on an airbag or
pyrotechnic safety belt system.

Using the wrong diagnostic tools can cause and airbag or safety belt pretensioner to deploy.

Use only approved Volkswagen diagnostic tools on airbag and pyrotechnic safety belt
systems.

9
Working on the Vehicle

Never use impact tools to remove or install pyrotechnic safety belts.

Do not hammer in the area of pyrotechnic safety belts, the airbag control module or crash
sensors.

See ElsaWeb for the location of sensors that trigger safety belts and airbags.

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Do notthuse
o grease, cleaning solutions, solvents or similar esubstances
or on safety belts or
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Do not appy stickers or badges to airbag covers.

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Do not use salvage parts when repairing a safety belt or airbag system.
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Never turn the ignition to the ON position while reaching through the steering wheel
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spokes. The airbag could deploy and cause serious injury.

10
 Working on the Vehicle
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Do not disable any safety systems on the vehicle

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Always wash your hands and face with mild soap and water after working on a vehicle in
which the airbags and other pyrotechnic deveices have been deployed, especially before
l purpos

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Do not let the particles and dust released from an airbag or pyrotechnic safety belt get into
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your eyes or into any cuts or scratches. If contact does occur, ƃush eyes with water and
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wash exposed skin with soap and water.

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On the following pages you will learn some of the special handling rules to follow for airbags and pyrotechnic
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seatbelts
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All airbags and pyrotechnic safety belts of a vehicle scheduled to be scrapped must be

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deployed using Airbag Deployment Device J-44210

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Always read the instruction booklet and view the supplemental video for Airbag

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Deployment Device J-44210 and heed all warnings before using the device.

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Undeployed airbags and pyrotechnic safety belts are considered hazardous material. When
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disposing of an undeployed airbag or pyrotechnic safety belt that is either defective or
expired, use the appropriate repair information and Airbag Deployment Device J-44210.

Never deploy airbags or pyrotechnic safety belts in the vehicle.

If airbag or pyrotechnic safety belt cannot be safely deployed or removed from the vehicle,
contact the Volkswagen Dealer Technician's Helpline (877) 299-0505.

Make sure your dealer complies with federal, state and local regulations for explosive
substances.

Deployed airbags and pyrotechnic safety belts can be disposed of as normal scrap.

12
 Special Handling

Shipment of active, undeployed airbag gas generators and pyrotechnic safety belt retractors
must be in accordance with the regulations published in the latest edition of the Code of
Federal Regulations #49 (49 CFR)

Shipment must be initiated and received by certiƂed individuals. lkswpenalties

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noncompliance are severe. Civil penalties range from olksw to $27,500 per violation,
$250 per
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day. Criminal penalties, for willfully violating the ed regulations, range from $250,000 for uara
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individuals and $500,000 tho for corporations eo
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13
Special Handling

Special Procedures
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Now that you have learned about safe handling,swlets dabout
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If airbags and pyrotechnic safety belts did not deploy, it's not necessary to replace and
hole

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component unless the MIL indicates a malfunction
es, in part or in w

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!
Register replacement of any airbag components with the Volkswagen Group of America,
LLC. Refer to ElsaWeb for the latest registration procedures.

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Report any triggered airbag incident, as soon as possible, to the Product Liaison OfƂce yi
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and the Volkswagen Group of America. The report should include: VIN, mileage, ht. C py
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14
 Special Handling

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Refer to the latest repair information in ElsaWeb to determine which components have
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to be replaced in the event of airbag and pyrotechnic safety belt deployment.
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! Inspect pyrotechnic safety belts even if the airbag(s) did not deploy.

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15
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Airbag Deployment Device J-44210
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State and federal law requires airbags and seat belt tensioners to be deployed before being discarding.

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The J-44210 Deployment Fixtures assists certiƂed technicians on the deployment of Volkswagen driver,

t to the co
passenger, side-impact airbags and seatbelt tensioners for the purpose of disposal.

rrectne
The Ƃxture functions as a platform to which airbags and tensioners can be attached for deployment. It
incorporates a plastic tank that must be Ƃlled with water prior to use. It also includes the necessary bolts and

ss
brackets to properly attach the airbag/tensioners.

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The instructions supplement the service procedures for airbag modules published by Volkswagen. It is important

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that the technician is familiar with these procedures.

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16
 Special Tools

VAS 5056
The VAS 5056 simulates the resistance of the airbag. It can also simulate a short circuit when the button on the
tester is pushed. The tester comes with adapter harnesses to Ƃt all airbag and pyrotechnic safety belt igniter
connectors.

For example, for the DTC Passenger’s side airbag igniter 1-N131-Too High, a technician can connect the VAS
5056 to the igniter wiring harness and monitor the value blocks on the VAS 5051 or 5052. When the technician
pushes the button on the tester, the value block should change from Too High to Too Low. If this happens the
technician has veriƂed the wiring harness to the airbag is not the cause of the DTC.

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17
Repair Steps
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Repair the Problem
Do not erase DTCs until after the repair.

Conduct a Quality Check Inspect and make sure all trim has been replaced correctly.

18
 AG. Volkswagen AG d
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concierge@volkswagenacademy.com

21
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Volkswagen Group of America

2200 Ferdinand Porsche Drive
Herndon, VA 20171
November 2011
 Cautions & Warnings

Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.

•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.

•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

•= Volkswagen is constantly improving its vehicles and sometimes

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are made applicable to earlier models. Therefore,Vpart
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•= Any time the battery has been disconnected
on an automatic transmission vehicle, it
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reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
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•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support

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a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a

wit
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vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.

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•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
es, in part or in w

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battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.

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•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
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starting the vehicle while you are under it.

nform
ercia

•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
m

others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
at
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being fully alert.

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•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
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•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
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goggles, gloves and other protective clothing whenever the job requires working with harmful substances. C py
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machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
AG.

injury could result.

•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.

Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
 AG. Volkswagen AG d
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Cautions & Warnings
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•= Illuminate the work
s au area adequately but safely. Use a portable
for working inside or under the vehicle. safety r a light
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Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled

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fuel or oil.

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•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
pe

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grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.

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Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
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•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be

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crushed by heavy parts.

•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the

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instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
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replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.

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•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
m

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might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
com

tion in
once, but do not store the oily rags, which can ignite and burn spontaneously.
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•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
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fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque

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Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
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•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.

•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.

•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.

•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.

•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).

•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.

Page 2 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
 Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.

•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.

•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.

•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.

I have read and I understand these Cautions and Warnings.

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Page 3 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0