Fiat barchetta Electrical equipment

-
Air bags and pretensioners
55.
fA) SAFETY PRECAUTIONS TO BE OBSERVED
EQUIPPED WITH AN AIR-BAG SYSTEM
WHEN WORKING ON VEHICLES

The following regulations MUST ABSOLUTELY BE OBSERVED during any operations

carried out on vehiclesfitted with an air bag.
INTERVENTIONSON VEHICLE
Note that air bag modules should be handled with caution. Their use, transport and storage are gov-
erned by legal regulations covering explosives applicable in the country where the vehicle is sold.
Before beginning to carry out:
- repairs to the body;
- welding work;
- work where it is necessary to remove the air bag modules or the control unit.
A Turn the ignition key to STOP and remove. Disconnect the battery, i.e. DISCONNECT TERMINALS
(- and +) from their respective poles and THOROUGHLY INSULATE using tape.
B Disconnect the control unit connector and wait for at least 10 minutes after removing the battery.
C If an air bag inflation device is removed, strictly observe the following procedure:

1. Wait for at least 10 minutes after discon-

necting the battery before beginning to re-
move the module.
2. Unscrew the retaining bolts.
3. Disconnect connector pin of inflation de-
'--
- _. -..:..

vices.
4. Replace the devices with the cover facing
up, in a locked steel cabinet. This cabinet
is designed solely for this purpose and
shou Id never be used to store other types
of materials, particularly if inflammable.
The cabinet must be designed to store py-
rotechnic charges (steel, impact-resistant
cabinet with grilles to allow natural venti-
lation inside). It must be marked in accor-
dance with current legislative require-
ments (DANGER EXPLOSIVES - DO ~
NOT USE NAKED FLAMES - NOT TO BE
P3WO91LO1
OPENED BY UNAUTHORIZED PER-
SONNEL).

NOTE All connectorswired to air bag modules contain a short-circuit clip. Theunit cannot be a;ctivat-
ed in any way until the air bag modulesare connectedto an appropriatepower sourceby means
of the proper connector.

If any systemcomponentis NO T activatedas a result of an accident ,it must be consideredstill

active. Componentswhich are unexplodeddue to faults, becausethey have reachedthe end of
their warranty term or becausethey require replacementfor other reasonsmust be returned to
the centre using the procedure describedbelow.
Safety system componentsmust be fitted and removed ONLY by skilled, authorised technical
personnel.
Thesystemcould be activated when not requiredand lead to personalinjury or unnecessaryre-
pairs to the systemif the following rules are not respected.
IT IS STRICTLYPROHIBITED TO DISMANTLE AIR BAG MODULES

Copyright Fiat Auto 87

Electrical equipment Fiat barchetta
Air bags and pretensioners

NOTE All system componentshave been designedspecifically to work on a car of a particular make
and type. Modules and pretensionerscannot thereforebe adapted,reusedor installed on other
cars,but only on the carsfor which they have been designedand built.
Any attempt to re-use, adapt or install on another type of vehicle may lead to injury to occu-
pants in the caseof an accident.

Replacing an Air Bag (due to defects or warranty expiry)

If an air bag module is replaced due to defects or expiry of the term of warranty, proceed as follows:

1. Remove the adhesive label from the new module, apply to a special file (charge/discharge register)
with the vehicle data (chassis no. registration date, model etc.) and add the old module serial num-
ber. The file with the registration data must be kept for the purposes of future checks.
2. Before the plate is stuck over the original plate, it must be perforated for the month and year ten years
after module installation date (e.g. the year 2006 when the module is fitted in 1996).
3. Connect the module to the connector which emerges from the steering wheel.
4. Fit the air bag module in its housing on the steering wheel and check that the connection lead is
properly arranged. Tighten retaining bolts to the specified torque.

Replacing control unit

The electronic control unit must ALWAYS be replacedin the caseof a crash involving total activation of
the safety system (air bag modules+pretensioners).

Never attempt to reuse the electronic control unit in any way.

If the control unit is replaced, remove the adhesive label from the control unit and stick in the appropriate
file as described above.
NOTE After working on the system, check operation by means of a FIA T/ LANCIA TESTER.

Action following an accident

If any component of the safety system is damagedfollowing an accident, it MUST be replaced.
Never attempt to repair the control unit, clock spring or air bag modules.

Accidents with or without activation of the air bag system

Some componentsof the safety system should be inspected if the system has been activated, if the sys-
tem has been only partly activated or if the system has not be activated at all.
These components are as follows:
- steering column;
- steering column mounts;
- electronic control unit and module anchorage area;
- clock spring contact;
- facia (in passenger air bag module area).
The component should be replaced if found to be distorted, broken or bent.

Accidents involving activation of the air bag system

Some componentsof the safety system must be replaced if the vehicle experiences a head-on collision
involving total or partial activation of the safety system.
In the case of partial activation (only pretensioners), these components are as follows:
- pretensioners;
- electronic control unit (must be replaced only after third activation of pretensioners).

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Fiat barchetta Electrical equipment
Air bags and pretensioners

In the case of total activation of the safety system, these components are as follows:
- air bag modules;
- pretensioners;
- electronic control unit.

Wiring and connectorsmustbe inspectedto identifysignsof burning,meltedouter insulationor dam-

age due to excessheat.
Damagedcomponentsmust be replacedif signs of damageare noted on the clock spring and electronic
control unit or air bag module anchorageareas.

Painting operations
No particular safety precautions need to observed in the case of painting and subsequent stove drying,
because the safety system (air bags and pretensioners) is designed to remain undamaged when the outer
vehicle surfaces are heated using normal paint drying systems.

It is forbidden to use naked flames near to modules.

All electronic control units (including the air bag systemcontrol unit) must neverthelessbe re-
moved if there is a likelihood of their being heated to 85°C or over).

DANGER TO HEALTH
Observe the following precautions when handling activated modules:
1. Use protective gloves and safety goggles.
2. Wash hands and exposed body parts after touching an activated air bag.

EFFECTS OF OVER-EXPOSURE
There is no potential risk of exposure to propellant because the system is fully sealed.
The propellant mixture is in the solid state and cannot be inhaled even if the gas generator cartridge
shouId break.
There is no danger to human health if any gas should emerge.
As a precaution, avoid contact wtih the skin and do not ingest the propellant.

In the case of
- Contact with the skin: wash immediately with soap and water.
- Contact with eyes: rinse the eyes immediately with running water for at least 15 minutes.

- Inhalation: take the patient out into the open air immediately.
- Swallowing: induce vomiting if the person is conscious.
Always call a doctor under these circumstances.
SAFETY REGULATIONS FOR HANDLING AIR BAG MODULES
Under normal conditions, driver and passenger side air bags are activated after receiving an electronic
trigger command during impact. The gas produced u~der these conditions is !1lainly no~-toxic nitroge~.
it is therefore important to ensure that personnel carrYing out work on the device when fitted to the vehi-
cle carefully observe the following safety reglations.
Personnel working on the devices must be specially trained.
When removing and replacing open (exploded) air bag modules, handle only one module at a time and
use g)oves and goggles for removal.
After the operations are completed, wash hands thoroughly using neutral soap and rinse eyes immedi-
ately in plenty of running water if they come into contact with powder residues.

Copyright Fiat Auto 89

Electrical equipment Fiat barchetta
Air bags and pretensioners
55.
The metallic parts of a recently detonated air
bag are very hot. Avoid touching these com-
ponents for several minutes (about 20 min-
utes) after the Air-Bag is activated.
A When removing and replacing UNEXPLODED
air bags, always rest the air bag module with
the opening flap and pre-marked tear lines
turned upward. Never place anything above
the flap.
B Do not supply the air bag module with
electric current in any way.

It is prohibited to test the continuity

of system components unless mod-
ules have been replaced by dummy
resistances.
P3WO90LO3

C Never repair Air Bag modules. Send all defective modules to the supplier.
D Do not heat the air bag module, e.g. by welding, percusion, drilling, machining etc.
- Never install air bag modules on a vehicle once they have been dropped or show any signs of damage.
- It is forbidden to keep air bag modules together with inflammable material or fuel.
- The gas generators must not come into contact with acid, grease or heavy metals. Contact with such
substances could lead to the production of poisonous or harmful gas and explosive compounds.
- Store parts in their original packing. During temporary storage, follow the same procedure for an air
bag module removed from the vehicle but not activated, i.e. always use a locked steel cabinet which is
suitably designed (steel impact-resistant cabinet with grilles to allow natural ventilation inside).The
cabinet must be equipped with special warning signs (DANGER EXPLOSIVES - DO NOT USE
NAKED FLAMES - NOT TO BE OPENED BY UNAUTHORIZED PERSONNEL).
- No-one working on a version fitted with an air bag is allowed to work from the front seats without
firstly rendering the system inoperative by turning the ignition key to STOP and then disconnecting
and insulating the battery, and then waiting for 10 minutes.
- If water and mud reach the level of device components as a result of exceptional atmospheric condi-
tions (floods, high tides etc.), the device must be replaced.
DISPOSING OF USED AIR BAG MODULES
Air bag modules fitted to a vehicle must not be demolished with the vehicle but must be removed be-
forehand.
Air bags cannot be scrapped without first being activated.
If the air bag module does not go off during an accident, the device must be considered still set to go off.
All unexploded material must be sent to GEMCA in Chivasso, indicating the following wording on the
delivery note:
""AIR BAG/PRETENSIONER DEVICE CONTAINING PYROTECHNIC CHARGE TO BE DE-ACTIVAT-
ED".
Devices must be sent to G EMCA in the original packs in which the parts were received. If these are not
available, the empty pack can be ordered from the Volvera parts store.
If air bag - pretensioner devices are replaced, the original pack is kept to use when forwarding unactivat-
ed devices to GEM CA.

Foreign markets
Check current local legislation for foreign markets and inform dealers.

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Fiat barchetta Electrical equipment
Air bags and pretensioners

Failure to respect the instructions listed here may causeair bags to be activated when not re-
quired and lead to personalinjury. Unactivatedair bagsmust NO Tbe disposedof via the normal
refuse disposal channels. Unactivated air bags contain harmful substancesthat could cause
personalinjury if the sealedcontaineris damagedduring disposal.Failureto disposeof air bags
in accordance with these instructions could constitute a breach of current legislation.

Ordering procedure
If necessary, devices may be ordered as required from the Parts After-sale department in Volvera using
only the VCR procedure because Dealers should not hold a stock of such parts. In any case, during in-
ternal handling they should be entered in a charge/discharge register which shows module identifica-
tion numbers and vehicle data (chassis no., registration data, model etc.)

NOTE For foreign markets,check current legislation and inform dealersaccordingly.

SAFETY REGULATIONS FOR HANDLING PRETENSIONERS
Pretensioners are explosive parts and must therefore be handled, moved and stored correctly in order to
prevent damage or injury
Under normal conditions, driver and passenger side air bags are activated after receiving a command
from the electronic ignition during impact. The gas produced under these conditions is mainly non-toxic
nitrogen.
The following rules must ABSOLUTELYbe observed to ensure operator safety and prevent
damageto the seatbelt pretensoinerunit. Before any operation, turn the ignition key to STOP,
removeand disconnectthe battery. Waitfor 10minutesbefore disconnectingpretensionercon-
nectors.
Any pretensionerthat does not go off in the caseof an accident should be consideredstill active. Pre-
tensionersthat do not explode and require replacementbecausethey are defective, out of warranty or
for any other reasonmust be returned (complete device) to the relevantcentre using the procedurede-
scribed for air bag modules.
The devicemust absolutely be replacedif due to exceptionalatmosphericconditions (floods,
high tides etc.), water and mud reach the height of device components.
Thepretensionerdoes not require any maintenanceand must not be lubricated under any cir-
cumstances.Theunit's efficiency cannot be guaranteedif its original condition is alteredin any
way.
A Never move pretensioners by holding
them by the pipe.
B Never move the pretensioner by holding
the belt.
C Never tamper with pretensioners or at-
tempt to repair them. Send all defective
pretensioners back to the supplier.
D Never subject pretensioners to percussion,
drilling, machining or heating due to weld-
Ing.

P3WO91LO2

Copyright Fiat Auto 91

Electrical equipment Fiat barchetta
Air bags and pretensioners

E Never allow the unit to drop or subject it to

impact. Pretensioners which have been
dropped from a height greater than 1 metre
must not be used but sent back to the sup-
plier.
When operations carried out on a vehicle
require temporary removal of the unit, use
a steel cabinet which meets legal require-
ments for the housing of explosive charges
(see instructions for air bag modules)
F Never bring naked flames, liquids, solvents
or lubricants close to the device and do not
expose to a temperature higher than 900 c.
With temperatures higher than 1650 C, the
gas generator may self-ignite.
When handling a device that has been acti-
vated, use gloves and protective goggles.
If the device has gone off, ALWAYS leave
P3WO92LO2 at least 20 minutes following activation be-
fore touching the device.
Wash hands with soap and water after
handling the device.

Ordering procedure
Follow the procedure already described for air bag modules.

Scrapping pretensioners
Follow the procedure already described for air bags.

ELECTRONIC DEACTIVATION OF PASSENGER SIDE AIR BAG

On this vehicre, operation of the passenger side air bag module can be inhibited if required by the cus-
tomer (e.g. if an approved baby seat is to be fitted on the front seat facing backwards). To carry out de-
activation, it is necessary to fit a special control unit with its own part number and a different coloured
container.
The control unit performs the following specific functions:
- it informs the user that the air bag module has been deactivated by altering the warning light blink
strategy when the vehicle ignition is turned on;
- it continues to carry out full diagnosis of the passenger air bag system.

When the ignition is turned on, the air bag fault warning light blinks for the first 4 seconds. After this it
continues to blink for a further 12 seconds if no errors are present in the system.
If errors are present following the ignition test (4 seconds), the bulb will stay on with a fixed light to in-
dicate that a fault has been detected.
If a fault is detected once the initial.test is complete (e.g. after 7 seconds of blinking), the bulb will stay
on with a fixed light from the time the fault is detected.

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Fiat bafchetta Electrical equipment
Air bags and pretensioners

REMOVING-REFITTING AIR BAG ELEC-

TRONIC CONTROL UNIT

1. Electronic control unit

2. Arrow showing direction of installation of
control unit
3. 30 pin connector
4. Diagnostic socket

Always fit and remove the control unit with

the ignition key turned to "STOP" and re-
moved and the battery negative lead discon-
nected and insulated. Wait 1 0 minutes before
carrying out the following operations.

98LO1

1. Working beneath the central console,

move the floor trim aside to gain access to
the control unit (1).
2. To remove the connector, turn the lever in
the arrowed dirction before removing the
connector and then unscrew the three re-
taining bolts to remove the control unit.

NOTE Reverseremoval operation sequence

to refit.

DO NOT CONNECT THE BATTERY

UNTIL INSTALLATION HAS BEEN
CARRIED OUT CORRECTLY
98LO2

NOTE After the operation, check the system

using a FIA T/ LANCIA TESTERor an-
other diagnostic instrument

Copyright Fiat Auto 93

Electrical equipment Fiat barchetta
Air bags and pretensioners
55.
REMOVING DRIVER'S SIDE AIR BAG

Safety measu res

Operations on air bag system components
must be carried out by specially trained per-
sonnel and the following safety measures
must be STRICTLY adhered to.
During removal and replacement operations,
it is necessary to use polythene gloves and
protective goggles.
Disconnect the battery terminals and wait 10
minutes before removing the air bag device.
Do not use naked flames near the air bag and
air bag system components.
Individual damaged or defective parts must
not be repaired or tampered with in any way
but replaced as a whole unit.
P3WO99LO1 See page 89 for further information on safety
procedures.

Operation sequence
1. Remove the lower trim from the upper
steering shaft by unscrewing the three 3
mm hexagonal-headed socket screws in-
dicated by arrows;

2. Unscrewthe three 5 mm hexagonal-head-

ed socket screws locatedto the rearof the
steering wheel. Turn the steering wheel
and position asshown in the figure to gain
accessto each screw.

P3WO99l02

Following removal, unactivated air

bag modulesshould immediatelybe
placed in a speciallymarkedcabinet
and locked away.
The module should be placed with
the metal part resting on the surface
as shown in the figure.
P3WO99l03

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Fiat barchetta Electrical equipment
Air bags and pretensioners

1 Remove device (1) by turning it to the left

and holding it upright, then disconnect
the 2-way connector and remove the air
bag.

REMOVING-REFITTING CLOCK SPRING

Removing steering wheel

2. If present, remove the rubber cover (1 ) fit-
ted to the retaining nut;

During assembly, fit a new cover if

the vehicle is not fitted with one.

3. Remove the staking and loosen the nutre-

taining the spring to the steering column.
Then turn the steering wheel fully to the
right;

Copyright Fiat Auto 11-98 - Supersedes previous version 95

Electrical equipment
AIR BAG AND PRETENSIONERS

1. With the steering wheel turned fully to the

right, lock the wheels in position using an
appropriate tool (a possible solution using
grip pliers is shown in the figure).

2. Disconnect the 2-way connector supply-

ing the horns (1) by undoing the tab and
unscrewing the steering wheel retaining
nut.

3. Mark the position of the steering wheel

hub in relation to the steering column.
P3W101 LO2

96 Publication no. 506.586/08

 Fiat barchetta Electrical equipment
Air bags and pretensioners

1 Release and remove the steering wheel by

undoing the ring nut without withdrawing
leads of horn (1) and clock spring (2).

-
C__J
~ ~

Removing clock spring

./
-~ 2. Ensurethat removalof the steering wheel
\\ has causedthe upper clock spring ring to
lift and lock it in position;
\
P3W102LO2

3. If the upper clock spring ring turns round,

grasp it diametrically and pull up. A click
will be heard when it locks into position;

Copyright Fiat Auto 97

~
 Electrical equipment Fiat barchetta
AIR BAG AND PRETENSIONERS

1
" /
/
/
('

\
'"'
0
~

:~"(
~\
1. Carefully remove the horn supply lead
with the black 2-way connector from the
slot on the steering wheel hub.
\
P3W103LO1

2 I'
/ ('

\\
\\\ 0 '\
::=J
/'
r"'I ~ '-.
0 ~
",.
/:...~~...,
--< 2. Carefully remove the air bag supply lead
""'" with the white 2-way connector from the
slot on the steering wheel hub.
P3W103LO2

~v< r_"Q~
"'"
g
~~, ~ '~~
d/l ~

3. Unscrew both bolts shown in the figure

and remove the upper steering column
trim.
P3W103LO3

98 Publication no. 506.586/08