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Volkswagen Polo Service & Repair Manual: Airbag and Belt Tensioner Wire Repair Information

  Note
Observe general notes for repairs on the vehicle electrical system. Refer to → Chapter „Vehicle Electrical System, General Repair Information“.
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 Parts Catalog.
  Note
Air bag wires and the safety belt tensioner wiring harness may repaired only with the Wiring Harness Repair Set -VAS1978B- and previous versions.
Observe general notes for repairs on the vehicle electrical system. Refer to → Chapter „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 → Body Interior; Rep. Gr.69.
   
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).
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.
 

Airbag and Belt Tensioner Wire Repair Information

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.
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.
 

Airbag and Belt Tensioner Wire Repair Information

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.
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.
 

Airbag and Belt Tensioner Wire Repair Information

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