Audi A4 1997 2001 User Manual

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69-40
Airbags, servicing
Airbag system, safety precautions
WARNING!
Checking, removing, installing and servicing may ONLY be performed by qualified personnel.
Never perform tests using a test light or multimeter.
Airbag system may only be tested when installed in vehicle using VAG1551/VAG1552 scan tool.
Battery must be disconnected before performing any work on airbag system.
Work can begin immediately after disconnecting the battery.
When connecting the airbag system to a voltage source, no one should be in the vehicle interior.
Always install airbag units in the vehicle as soon as they are removed from the
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A
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packaging.
If installation work is interrupted, immediately return the airbag unit to its original packaging.
NEVER leave an airbag unit unattended.
fter removing from the vehicle, ALWAYS la y the airbag down with impact absorbing pad (padded side) facing up.
Never attempt to open or service airbag components. Always use new parts.
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WARNING!
DO NOT install an airbag unit that has fallen on a hard surface or experienced mechanical damage.
Airbag units have an expiration date (see sticker on B-pillar). If airbag units are replaced, pull sticker with expiration date off new airbag unit and place it over old sticker on B-pillar. Airbag unit and sticker must be replaced after 14 years.
If there is no sticker on the B-pillar, airbag change must be indicated in service plan.
Airbag unit must not be treated with grease, cleaners or similar materials and must not be
exposed to tem peratures above 100 C (212
F), even for short periods.
Always use the following work sequence when
replacing airbag units:
1 - Remove old airbag unit and lay down with padded side facing up, for side curtain airbag, observe additional safety precautions page
69-49 .
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2 - Remove new airbag unit from transport
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container and lay down with padded side facing up, for side curtain airbag observe additional safety precautions page 69-49 .
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3 - Immediately place old airbag in transport container.
4 - Install new airbag in vehicle.
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69-42
Airbag units, replacing after an accident
Accident with activation of airbag and belt tensioners (up to and including airbag 7)
Airbag control module must be replac ed afte r
every activation of airbag and belt tensioners
Accident with activation of airbag and belt tensioners (for airbag 8) (integrated as of
For vehicles with airbag 8, display will indicate
10/98)
Notes:
airbag front and side or airbag front and side curtain.
Airbag control mo dul e can be used for up to three side-/side curtain air bag and/or belt tensioner activations.
After the third activation, the DTC "Control Module Malfunctioning" will appear.
Airbag control module must be repla c ed:
After driver-side and/or passenger-side airbag deployment.
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If housing is damaged.
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If there is a deformation of body channel, within a circumference of 200 mm around control module.
After three side-/side curtain airbag deployments.
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69-43
All models Always replace any deployed airbag unit and
the following
Also replace t he following if pa ssenger-side
airbag deployed:
Flap and mounting frame for airbag (do not reshape deformed mounting frames) and instrument panel (if damaged).
Lateral acceleration sensor (if floor pan in area near sensor is deformed).
Also replace the following if driver-side airbag
deployed:
Spiral spring with slip ring.
Lateral acceleration sensor (if floor pan in area near sensor is deformed).
Also replace t he following if si de airbag
deployed:
Lateral acceleration sensor for the deployed side airbag.
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Seatback cushion.
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Backrest cover.
Lateral acceleration sensor that hasn't been activated (if area near it in floor pan has been deformed).
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Also replace t he following if si de curtain airbag
deployed:
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69-44
Acceleration sensor for deployed side airbag.
Molded headliner .
Trim panels at A - pillar, B-pill ar, C-pillar an d D­pillar.
Acceleration sensor that hasn't been activated (if floor pan in area near sensor is deformed).
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69-45
Also
All seatbelts with activated belt t ensio ner s. On Board Diagnostic will reco gnize if belt
tensioners have been activated for airbag V, 7 and 8.
A - if airbag control module has been triggered:
Front seat belt tensioners:
Read Measuring Value Block 1
1 2 3 4
- Read Measuring Value Block display group 1:
Repair Manual, Body On Board Diagnostic (OBD), Repair Group 01
Activated belt tensioners can be identified by "0111" or "too large"
indicated on display.
Rear seat belt tensioners:
Read Measuring Value Block 2
1 2 3 4
- Read Measuring Value Block display group 2:
Repair Manual, Body On Board Diagnostic (OBD), Repair Group 01
Activated belt tensioners can be identified by "0111" or "too large"
indicated on display.
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69-46
B - If airbag control module is replaced:
- Check DTC memory:
Repair Manual, Body On Board Diagnostic
(OBD), Repair Group 01
Activated belt tensioners can be identified by the
DTC: "Ignitor for belt tensioner - resistance is too high"
- If necessary (visual check) also replace: all damaged components.
Accident without airbag deployment
If airbag Malfunction Indicator Lamp (MIL ) -K 75-
does not indicate a DTC, then airbag components do not need to be replaced. Check seat belts separately.
After replacing airbag units or the control module,
attach label (only tear-off strip) to registration card and send in registration card.
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Airbag system side airbags, safety precautions
WARNING!
Checking, removing, installing and servicing may ONLY be performed by qualified personnel.
Following the same safety precautions as for driver and passenger-side airbags.
Only use original equipment seat covers and backrest covers that are approved for use with side airbags (identified by a label on the fabric).
Do not use extra seat covers over the seat as they interfere with proper side airbag operation.
The driver's seat does not have a seat occupant
Do not use seat cushion supports, mats or similar sin ce they imp are seat occupant sensor and airbags
Note:
sensor.
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WARNING!
For vehicles without heated seats, a dummy seat heating element is installed (heating element without heating wire).
The seat backrest foam must not be cut out in the area of th e side airbag.
When installing, seam near side airbag must be straight.
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69-48
WARNING!
All upholstery clips must be replaced (metal and plastic clips).
Only use genuine Audi replacement upholstery clips.
When installing, all upholstery clips must be installed at the same location from which they were removed.
If the seat cover is damaged (rips, burn holes etc) near the side airbag, always replace the seat cover to ensure proper side airbag inflation.
Seat cover may not be repaired in the area near the side airbag (special thread and an exact seam are used).
Always replace seat cover if side airbag has deployed.
All damaged components must be replaced after an accident. If no damage to the airbag unit is found, the airbag unit can be reused.
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Side airbag units have an expiration date
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(see sticker on B-pillar). If side airbag units are replaced, pull sticker with expiration date off new side airbag unit and place it over old sticker on B-pillar. Replace side airbag unit and sticker after 14 years.
Page 15 of 75Airbags, servicin
If there is no sticker on the B-pillar, airbag change must be indicated in service plan.
If side airbag unit is replaced, pull airbag number sticker off side airbag unit and stick it to the seat pan.
Do not use a needle or other sharp objects to poke around area near airbag and sensor mat.
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69-49
Additional safety precautions for side curtain protection airbag
WARNING! All safety precautions for the driver and
passenger-side airbags apply, as w ell as the following:
Visually check the vehicle's trim panels for damage before every installation.
Do not attempt any repair work on the vehicle trim panels (top trim panels for A­pillar, B-pillar, C-pillar and D-pillar).
Make sure the trim panel is securely fitted during installation.
Side curtain airbags must only be folded at its intended location (transition of roof to A­pillar).
To carry out repairs behind the side curtain airbag, always remove the entire unit first.
After removal, always carry the side curtain airbag in the folded position.
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69-50
WARNING!
After removal, place the side curtain airbag into the transport container in the folded position or lay on a clean, even surface (on a blanket or in the luggage compartment).
After servicing the body of vehicle in vicinity of airbag, check the body for welding beads, deformations and chafe marks (compare to opposite side of the vehicle).
Always hold the side curtain airbag securely.
After removal, always fold the side curtain airbag and grasp by the igniter (thumbs toward E-connection).
Always keep one hand on the igniter.
Never twist, wind, bend, throw, spin, pull, hang, squeeze, press, pinch or clamp the side curtain airbag.
If any contamination penetrates into the fabric (i.e. oil, grease, lacquer, paint or solvent), the unit must always be replaced.
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69-51
Airbag component locations, overview
1 - Driver-side airbag unit
Removing m.y. 1998 page 69-53 Removing m.y. 1998 page 69 -54
2 - Driver-side airbag unit (sport steering
wheel)
Removing m.y. 1998 page 69-58 Removing m.y. 1998 page 69 -61
3 - Airbag control module -J234-
Removing and installing page 69-74
4 - Passenger-side airbag unit
Removing page 69-70 Locking and activating (adaptation)
Repair Manual, Body On Board Diagnostic
(OBD), Repair Group 01
5 - Seat occupant sensor
Removing and installing page 69-83
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69-52
6 - Side airba g
Removing and installing page 69-75
7 - Crash sensor for side airbag
Removing and installing page 69-85
8 - Spiral spring
Removing and installing m.y. 1998
page 69-64
Removing and installing from sport steering wheel m.y. 1998 page 69-67
Removing and installing m.y. 1998
page 69-68
9 - Data Link Connector (DLC)
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69-53
Always follow airbag safety precautions when
Driver-side airbag unit ( m.y. 1998), removing and installing
- Disconnect battery Ground (GND) strap.
Note:
working on airbag system components ( page
69-40 ).
-
Using T30 Torx bit, unbolt airbag unit on both left and right side of steering wheel.
Tightening torque: 6 Nm (53 in. lb)
- Carefully pull back airbag unit.
- Disconnect harness connector from airbag unit.
- Place airbag unit on suitable surface with impact padding facing up.
- When installing, make sure harness connector audibly engages (clicks).
WARNING! No one may be in vehicle when connecting battery Ground (GND)
strap.
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- Switch ignition on and connect battery Ground (GND) strap.
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69-54
Driver-side airbag unit (m.y. 1998 ), removing and installing
WARNING! Follow all safety precautions when working on
the airbag page 69-40 .
1 - Steering wheel
2 - Harness connector for spiral spring 3 - Harness connector for airbag unit 4 - Multipoint socket
5 - Airbag unit 6 - Threaded bushing
Removing page 69-57
- Secure loose cable at location indicated by arrow -A-.
Always replace 60 Nm (44 ft lb)
7 -
Torx bolt (T30)
8 -
Torx wrench (T30)
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69-55
9 - Spiral spring
10 - Harness connector for heated steering
wheel
Removing
WARNING! Follow all safety precautions when working on
airbag page 69-40 .
- Release steering wheel adjuster.
- Pull steering wheel as far out and up as possible.
- Place steering wheel vertical.
-
Remove Torx bolt (T3 0) .
-
Turn steering wheel 1/2 turn (180 ) back and remove second Torx bolt (T30).
- Pull connector - 3 - from airbag unit.
- Place airbag unit on appropriate surface with impact padding facing up.
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69-56
Installing
- When installing, make sure connector audibly engages (clicks).
WARNING! Make sure no one is in vehicle.
- Switch ignition on and connect battery Ground (GND) strap.
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69-57
Steering wheel, removing and installing
Removing
- Remove airbag unit page 69-54 .
- Center steering wheel (whee l s are straight).
- Remove bolt - 4 -.
- Disconnect harness connectors - 2 - and - 10 -.
Installing
- Center steering wheel (wheels straight).
- When installing, make sure harness connectors audibly engage (click).
- Replace bolt - 4 - and tighten to 60 Nm (44 ft lb).
- Install airbag unit page Page 69-54 .
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69-58
Driver-side airbag for sport steering wheel ( m.y. 1998), removing and installi ng
WARNING! Follow all safety precautions when working on
airbags page 69-40 .
1 - Bolts to secure upper part of carrier unit
2 - Harness connector for airbag unit 3 - Airbag unit 4 - Nut for steering wheel
5 - Bolts to secure lower part of carrier unit.
6 -
Torx bolt (T30)
5 Nm (44 in. lb)
42 Nm (31 ft lb)
5 Nm (44 in. lb).
6 Nm (53 in. lb)
7 - Securing cable for spiral spring
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69-59
8 - Spiral spring 9 - Journal
10 - Transportation protection
Removing
Installing
Notes:
- Unbolt airbag unit fr om behi nd usi ng Torx wrench (T30).
- Remove airbag unit -3- and d isconnect harness connector -2-.
- Place airbag unit on appropriate surface with impact padding facing up.
Make sure harness connector -2- audibly engages (clicks).
When installing airbag unit, first tighten right Torx bolt.
WARNING! Make sure no one is in vehicle.
- Switch ignition on and connect battery Ground (GND) strap.
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69-60
Airbag sport steering wheel, retrofitting
For vehicles m.y. 1995 that were equipped with an airbag as standard equipment, an Audi dealer can retrofit the vehicl e with an ai rb ag sport steering wheel.
The following components are required: airbag
sport steering wheel, airbag unit and applicable label for the vehicle (e.g. S4).
Remove the sticker with the expiration date from
the new airbag unit and apply it to the airbag identification plate on the lower driver-side B­pillar.
If the vehicle does not have a label, note airbag
replacement in the maintenance plan.
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69-61
Driver-side airbag for sport steering wheel (m.y. 1998 ), removing and installing
WARNING! Follow all safety precautions when working on
airbags page 69-40 .
1 - Sport steering wheel
2 - Harness connector for spiral spring 3 - Airbag unit 4 - Multipoint socket
5 -
Torx bolt (T30)
6 -
Torx wrench (T30)
Removing page 69-63
Always replace 60 Nm (44 ft lb)
7 Nm (62 in. lb)
7 - Spiral spring
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69-62
Removing
WARNING! Follow all safety precautions when working on
airbags page 69-40 .
-
Unbolt airbag unit usi ng Torx wrench (T 30 ) .
- Disconnect harness connector - 2 -.
- Place airbag unit on appropriate surface with impact padding facing up.
Installing
- Make sure harness co nnector - 2 - audibly engages (clicks).
- Install airbag unit and tighten to 7 Nm (62 in. lb).
WARNING! Make sure no one is in vehicle.
- Switch ignition on and connect battery Ground (GND) strap.
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69-63
Sport steering wheel, removing and installing
Removing
- Remove airbag unit page Page 69-61 .
- Center steering wheel (wheels straight).
- Remove bolt - 4 - .
Installing
- Center steering wheel (wheels straight).
- Replace bolt - 4 - and tighten to 60 Nm (44 ft lb).
- Install airbag unit page Page 69-61 .
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69-64
Spiral spring ( m.y. 1998), removing and installing
WARNING! Follow all safety precautions when working on
airbags page 69-40 .
- Disconnect battery Ground (GND) strap.
- Wheels must be facing straight ahead.
- Remove airbag unit page 69-53 .
- Remove steering wheel.
Repair Manual, Suspension, Wheels, Steering,
Repair Group 48
- Remove bolts -5- (4x) fro m carrier unit -6-.
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69-65
- Remove bolts -7- (4x) from sp iral spring -8-.
WARNING! Steering wheel and spiral spring can only be
removed with the wheel straight-ahead. Do not rotate spiral spring after it is removed.
Notes:
Even if spiral spring has been turned, determine center position.
From the center position, the spiral spring should rotate approx. 3 1/2 revolutions in both directions.
1 - Airbag unit 2 - Harness connector for airbag and horn 3 - Mounting bolt for steering wheel 4 - Harness connector for horn 5 - Bolt (4x)
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69-66
6 - Carrier unit 7 - Bolt (4x) 8 - Spiral spring
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69-67
Sport steering wheel spiral spring ( m.y.
1998), removing and installing
Notes:
- Remove bolts -1- (3x).
- Tightening torque: 5 Nm (44 in. lb)
- Remove carrier unit. Disconnect harness
- Remove bolts -5- (3x).
- Tightening torque: 5 Nm (44 in. lb)
- Remove lower part of carrier unit. Disconnect
- Remove bolts securing spiral spring.
- Pull spiral spring downward and remove. Do not
Wheels must be facing straight ahead. Before removing spiral spring, remove airbag
unit and steeri ng wheel.
connectors.
harness connectors.
rotate spiral spring while it is removed.
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69-68
Spiral spring, removing and installing
Driver-side airbag un it and steering wheel removed
- Pull steering column all the way out and down.
- Remove bolt -1- (2x). Tightening torque: 2.8 Nm (25 in. lb)
- Remove handle -2-.
- Remove two Phillips-head screws (arrows). Tightening torque: 0.6 Nm (5 in. lb)
- Remove upper section of steering column switch -1-.
To install, insert upper shell into retaining tab in lower shell, swing down and install screws.
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69-69
- Remove bolts -2- (2x). Tightening torque: 0.6 Nm (5 in. lb)
- Remove hex bolt -1 -. Tightening torque: 0.6 Nm (5 in. lb)
- Remove lower trim for steering wheel switch -3-.
- Disconnect harness connector -1-.
- Release retaining tab (arrows) and pull spiral spring from steering wheel switch.
Notes:
Wheels must be in straight-ahead position when removing or installing spiral spring.
A new spiral spring is secured in the centered position using a tie wrap.
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69-70
Passenger-side airbag unit, removing and installing
1 - Passenger-side airbag unit
WARNING! Follow all safety precautions when working on
airbags page 69-40 .
Removing:
- Disconnect battery Ground (GND) strap.
WARNING! Do NOT disconnect red 2-pin harness
connector on side airbag unit under any circumstances.
Remove passenger-side knee bolster
page 68-1 .
- Disconnect harness connector (tunnel connection to rear and left of airbag unit)
Fig. 1 .
- First, disconnect both angle brackets -4-.
- Remove both angle brackets -3-.
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69-71
- Remove bolts -2- at passenger-side airbag.
- Remove airbag unit.
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69-72
Note:
- Place airbag unit on suitable surface with impact padding facing up.
Always replace instrument panel after passenger­side airbag has deployed.
Installing:
- Install airbag unit.
- Make sure harnes s connector -6 - audibly engages (clicks).
- Switch ignition on.
WARNING! Make sure no one is in vehicle.
- Connect battery Ground (GND) strap.
2 - Bolts (2x)
Always replace after airbag has deployed 12 Nm (9 ft lb)
3 - Support
Always replace after airbag has deployed
4 - Angle bracket
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5 - Bracket
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69-73
Fig. 1 Disconnecting airbag harness connector
- Using screwdriver, push harness connector -1- for passenger-side airbag over retaining tab -2- and disconnect harness connector in direction of arrow -3-.
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69-74
Airbag control module -J234-, removing and installing
- Disconnect battery Ground (GND) strap.
- Remove front center cons ole page 68-30 .
- Disconnect securing bracket at harness connector -3-.
- Disconnect harness connector -3- from control module -1-.
- Remove nuts -2- (3x).
Tightening torque: 6 Nm (53 in. lb)
- Remove airbag control module -J234-.
Note:
If the airbag control module is replaced, the new control module must be coded.
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Side airbag, removing and installing
WARNING!
Follow all safety precautions when working on airbags page 69-40 .
Before starting work on seats, connect VAS5094 airbag adapter page 72-9 .
Removing
- Disconnect battery Ground (GND) strap.
- Remove seat page 72-2 .
- Remove outer trim pieces and trim on side of seat page 74-16 .
- Remove harness connector -2-.
- Disconnect Ground (GND) strap from harness connector -2-, cham ber 4.
- Disconnect harness connector for side airbag -1­from connector strip -5- by pressing on retaining tab.
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- Disconnect intermediate connector for seatback heater -6-.
- Disconnect harness connector for side airbag -1­from outer edge of seat Fig. 1
- Remove side airbag unit page 69-79 .
1 - Harness connector for side airbag 2 - Harness connector for sensor mat 3 - Retaining tab 4 - Harness connector for seat heater 5 - Connector strip 6 - Intermediate connector for seatback
heater
7 - Airbag number sticker
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8 - Bar in connector
Installing:
WARNING!
To ensure that the side airbag functions properly, when working on backrest cover, always install new upholstery clips in the same locations they were removed from.
Only use seat covers approved for use with side airbags.
- Install harness connector -2- at same location as when removed and ensure that bar -8- points toward tunnel.
- Switch ignition on.
- Close doors.
WARNING! Make sure no one is in vehicle.
- Connect battery Ground (GND) strap.
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Fig. 1 Wiring location on outer edge of seat
- Remove backrest cover page 74-12 .
- Unclip clip -2- (1x).
WARNING! When installing side airbag cable -1-, make sure that it doesn't rub
against any moving parts.
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Side airbag unit, removing and installing
WARNING! Before starting work on seats, connect
VAS5094 airbag adapter page 72-9 .
Removing
- Remove bolts -2- (2x).
WARNING!
Do NOT reuse bolts -2-. Replace the metal bolts with M5 bolts and nuts supplied.
Drill mounting holes to 5.5 mm. Tightening torque: 5.5 Nm (49 in. lb)
Note:
Illustration is shown without anti-crush fleece.
- Carefully disconnect side airbag -1 - at retaining clip -5-.
- Remove side airbag -1-.
- Place airbag unit on appropriate surface with impact padding facing up.
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Installing
Note:
Do not cut anti-crush fleece -4- in area near retaining clip -5-.
- Remove anti-crush fleece - 4- before drilling.
- Drill out mounting holes to 5.5 mm.
- Pull anti-crush fleece -4- over seat backrest frame.
- Clip side airbag -1- with anti-crush fleece into place.
- Install bolts -2-, pull up anti-crush fleece -4-, install nuts and tighten to
5.5 Nm (49 ft lb).
- Remove expiration date sticker from airbag unit and place over old sticker on driver's door.
- If vehicle does not have label, note airbag replacement in maintenance plan.
- Remove airbag number stick er from airbag unit and place over old sticker on seat pan page 69-75 , item -7-.
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Side airbag for Recaro seat, removing and installing
WARNING!
Follow all safety precautions when working on side airbag.
Before starting work on seats, connect VAS5094 airbag adapter page 72-9 .
1 - Backrest 2 - Side airbag unit
Removing:
- Remove Recaro seat page 72-25 .
- Remove mounting trim page 72-41 .
- Disconnect yellow airbag harness connector un der seat.
- Disconnect black Ground (GND) harness connector for airbag, located under seat.
- Unbolt bolt -4- on retai ner -6- on underside of side airbag unit -2-.
- Push side airbag unit -2- downward.
- Carefully pull out sid e ai rb ag uni t -2-.
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Installing:
WARNING! Make sure vehicle is not occupied.
Note:
Always replace bolt -4-.
- Install side airbag unit -2- so that engaging pins -3- engage in locating holes -7-.
- Push side airbag unit up to stop.
- Tighten new bolt -4- on side airbag unit to 10 Nm (7 ft lb).
- Install airbag cable -5-.
- Connect yellow harness connector of airbag cable and black harness connector for airbag Ground (GND) strap underneath seat.
- Reinstall mounting trim.
3 - Engaging pins 4 - Bolt
10 Nm (7 ft lb)
5 - Airbag cable
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6 - Retainer 7 - Locating holes
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The seat occupant sensor will be us ed at a later
Seat occupant sensor, removing and installing
WARNING! Before starting work on seats, connect VAS
5094 airbag ad apter page 72-9 .
Note:
time.
- Removing seat page 72-2 .
- Remove seat cover pa ge 74-15 .
Note:
Sensor mat is only available as a replacement part which includes seat heater and seat cushion.
- Press retaining tabs -3- and disconnect connector -1- for seat occupant sensor from connector strip -4-.
- Disconnect Ground (GND) strap from harness connector -1- (location ­4-).
- Unclip harness connector -5- and disconnect intermediate connector to backrest.
- Remove seat cushion along with sensor mat and seat heater from seat pan.
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- When installing, make sure bar -2- points toward tunnel.
- After installing sensor mat, test sensor mat function using VAG1551 Scan Tool (ST) page
69-84 .
Testing sensor mat function
Note:
Illustration is shown without cover.
- Remove any seat mats before testing sensor mats.
- Connect
VAG1551 scan tool
Repair Manual, Body
On Board Diagnostic (OBD), Repair Grou p 01 .
-
Select Read Measuring Value Block (function
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08) and
g
input display group number 003
Repair Manual, Body
On Board Diagnostic (OBD), Repair Grou p 01 .
Read Measuring Value Block number 2 for seat
occupant sensor passenger side indicates: not occupied.
- Test each sensor group by pressing on them with your hand until display changes from "not occupied" to "occupied" (max. load 12 kg).
Page 55 of 75Airbags, servicin
Note:
If "occupied" is indicated, even though you are not pressing sensor group, either the sensor mat is malfunctioning or the seat cover is too tight.
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Crash sensor for side airbag, removing and installing
WARNING! Before starting work on seats, connect VAS
5094 airbag ad apter page 72-9 .
Notes:
A crash sensor for the side airbag is located under both the driver's and passenger's seats.
Both crash sensors for the side airbags are identical.
When installed, the arrow points down.
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Removing
- Disconnect battery Ground (GND) strap.
- Remove front seat page 72-2 .
- Remove lower A-pillar trim page 70-72 .
- Unclip sill molding and fold upward.
- Pull up floor mat -4- near sensor.
- Disconnect harness connector -2- from crash sensor for side airbag -1-.
- Remove bolts -3- (2x).
Tightening torque: 6 Nm (53 in. lb)
- Remove crash sensor for side airbag -1-.
Installing
- Switch ignition on.
- Close doors.
WARNING!
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Make sure no one is in vehicle.
- Connect battery Ground (GND) strap.
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Side curtain protection airbag, servicing
Special tools and equipment
VAS 5122
VAG 1783
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Side curtain protection airbag (sedan), removing and installing
WARNING! Follow all safety precautions when working on
airbags page 69-40 and side curtain airbag
page 69-49 .
1 - Side curtain airbag
Removing:
- Remove bolts - 4 - (2x).
- Unclip side curtain airbag at clip - 3 -.
- Remove upper A-pillar tr im panel
page 70-88 .
- Remove upper B-pillar trim without loosening seat belt page 70-91 .
- Remove upper D-pillar trim page 70-
96 .
- Fold front portion of side curtain airbag toward rear and secure at Velcro strip
(inset).
- Remove bolts - 8 - (2x).
- Remove igniter - 5 - at clip - 7 -.
- Disconnect harness connector for side curtain airbag Fig. 2 .
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WARNING!
- Remove side curtain airbag - 1 - by grab handle adapters - 2 -.
Always follow installation sequence for side curtain airbag.
Installing:
- Secure side curtain airbag at grab handle adapters - 2 - (2x) using pre-assembly clips Fig. 5
- Clip igniter - 5 - in at clip - 7 -.
- Install bolts - 8 - (2x) Fig. 1 .
- Release front portion of airbag - 1 - and fold it back to A-pillar, during this, twist­securing seam -A- must face center of vehicle.
- Clip in side curtain airbag using clip - 3 -.
- Install bolt - 4 - Fig. 3 .
- Remainder of in stallation is in reverse order of removal
- Switch ignition on.
WARNING! Make sure the passenger compartment is not
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occupied before connecting the battery Ground (GND) strap.
- Connect battery.
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2 - Grip handle adapter 3 - Clip 4 - Bolts (2x)
4 Nm (35 in. lb) Self-locking Always replace Always clean threaded holes for drive
flange bolts (e.g. using tap )
5 - Igniter 6 - Side curtain airbag harness connector 7 - Clip 8 - Bolts (2x)
4 Nm (35 in. lb) Self-locking Always replace Always clean threaded holes for drive
flange bolts (e.g. using tap ) Use VAS5 122 and VAG 1783
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Fig. 1 Igniter at D-pillar
- Engage clip -7- in mount -A-.
- Install bolts -8-. Tightening torque: 4 Nm (35 in. lb) Use VAS 5122 and VAG 1783
1 - Side curtain airbag 5 - Igniter 6 - Airbag connector 7 - Clip
Fig. 2 Disconnecting harness connector for side curtain airbag
- Press catches -A- and disconnect harness connector in direction of
arrow.
6 - Side curtain airbag harness conne ctor
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Fig. 3 Side curtain airbag at lower A-pillar
- Install lower bolt -A- first.
1 - Side curtain airbag 4 - Bolts (2x)
Tightening torque: 4 Nm (35 in. lb)
Fig. 4 Side curtain airbag at upper A-pillar
- Engage clip -3-.
- Bolt -A- must be attached along with A-pillar trim panel.
1 - Side curtain airbag 3 - Clip
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Fig. 5 Mounting side curtain airbag at roof grab handle
The procedure is the same at the front and the rear.
- Insert pre-assem bl y cli p -A - in to mo unting point -C-.
- Insert pins -B- in mounting points -D-.
- Twist-securing seam -E- must face center of vehicle.
1 - Side curtain airbag 2 - Grip handle adapter, delivery casing airbag
Notes:
After reconnecting the battery, check and activate the vehicle's electrical equipment (radio, clock, window regulators) according to the repair manual and/or Owner's Manual.
If the airbag Malfunction Indicator Lamp (MIL) -K75- indicates a malfunction, the DTC memory must be erased and then checked again using the VAG1551 scan tool.
Repair Manual, Body On Board Diagnostic (OBD), Repair Group 01
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Side curtain protection airbag (Avant), removing and installing
WARNING! Follow safety precautions for working on
airbags page 69-40 and side curtain airbag
page 69-49 .
1 - Side curtain airbag
Removing:
- Remove bolts - 4 - (2x).
- Unclip side curtain airbag at clip - 3 -.
- Remove upper A-pillar tr im panel
page 70-88 .
- Remove upper B-pillar trim without loosening seat belt page 70-91 .
- Remove upper C-pillar trim page 70-
106 .
- Remove upper D-pillar trim page 70-
107 .
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- Fold front portion of side curtain airbag toward rear and secure at Velcro strip
(inset).
WARNING! NEVER disconnect the yellow 2-pin harness
connector on the side curtain airbag!
- Disconnect harness connector for side curtain airbag behind side trim panel
Fig. 2 .
- Remove cable from D-pillar.
- Remove bolts - 8 - (2x).
- Remove igniter - 5 - at clip - 9 -.
- Disengage retaining tab - 7 -.
- Remove side curtain airbag - 1 - by grab handles - 2 -.
WARNING! Always follow installation sequence for side
curtain airbag.
Installing:
- Secure side curtain airbag at grab handle adapters - 2 - (2x) using pre-assembly clips Fig. 5 .
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- Install bolts - 8 - (2x) Fig. 1 .
g
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- Release front portion of airbag - 1 - and fold it back to A-pillar, during this, twist­securing seam -A- must face center of vehicle.
- Clip in side curtain airbag using clip - 3 -
Fig. 4 .
- Install bolt -4- Fig. 3 .
- Remainder of in stallation is in reverse order of removal
- Switch ignition on.
WARNING! Make sure the passenger compartment is not
occupied before connecting the battery Ground (GND) strap.
- Connect battery.
2 - Grip handle adapter 3 - Clip 4 - Bolts (2x)
4 Nm (35 in. lb) Self-locking Always replace
Always clean threaded holes for drive
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flange bolts (e.g. using tap )
g
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5 - Igniter 6 - Side curtain airbag harness connector 7 - Retaining tab 8 - Bolts (2x)
4 Nm (35 in. lb) Self-locking Always replace Always clean threaded holes for drive
flange bolts (e.g. using tap ) Use VAS 5122 and VAG 1783
9 - Clip
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Fig. 1 Igniter at D-pillar
- Remove bolts -8-.
- Remove airbag in dire ction of arrow.
- Cable rolled up in delivery condition. 5 - Igniter 6 - Harness connector 7 - Retaining tab 8 - Bolts (2x)
Use VAS 5122 and VAG 1783
Tightening torque: 4 Nm (35 in. lb) 9 - Clip A - Felt
Fig. 2 Disconnecting harness connector for side curtain airbag
- Press catches -A- and disconnect harness connector in direction of
arrow.
6 - Side curtain airbag harness conne ctor
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Fig. 3 Side curtain airbag at lower A-pillar
- Install lower bolt -A- first. 1 - Side curtain airbag 4 - Bolts (2x)
Tightening torque: 4 Nm (35 in. lb)
Fig. 4 Side curtain airbag at upper A-pillar
- Engage clip -3-
- Bolt -A- must be attached along with A-pillar trim panel. 1 - Side curtain airbag 3 - Clip
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Fig. 5 Mounting side curtain airbag at roof grab handle
Front and rear roof grab handles are mounted the same way.
- Insert pre-assem bl y cli p -A - in to mo unting point -C-.
- Insert pins -B- in mounting points -D-.
- Twist-securing seam -E- must face center of vehicle. 1 - Side curtain airbag 2 - Grip handle adapter, delivery casing airbag
Notes:
After reconnecting the battery, check and activate the vehicle's electrical equipment (radio, clock, window regulators) according to the repair manual and/or Owner's Manual.
If the airbag Malfunction Indicator Lamp (MIL) -K75- indicates a malfunction, the DTC memory must be erased and then checked again using t he VAG 1551 scan tool.
Repair Manual, Body On Board Diagnostic (OBD), Repair Group 01
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Page 1 of 55Central locking On Board Diagnostic (OBD
)
01-69
Central locking On Board Diagnostic (OBD)
The new generation of central locking is capable
Central locking has two pneumatic circuits. For
General Information
of On Board Diagnostic. Use of DTC memory, Output Diagnostic Test Mode and Read Measuring Value Block facilita tes the search for malfunctions. The central locking system variation can also be coded using the VAG1551 Scan Tool (ST).
central locking without keyless entry, the first circuit controls only the fuel filler flap; for central locking with the keyless entry system, the first circuit controls both the fuel filler flap and the driver-side door. The second circuit controls all remaining locking point s.
On the safety-version of central locking, if the
driver-side (or passenger-side door) is unlocked with a single command, then only that door and the first pneumatic circuit are opened. If there is another unlocking command within 5 seconds, the second pneumatic circuit is also triggered and the whole v ehicle is unlocked.
If the rear lock cylinder is triggered only once, all
doors will remain locked. The rear lid (or tailgate) will automatically re-lock itself after about 5 seconds.
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Interior lighting will gradually increase in intensity
)
until fully illuminated (within about 1.5 seconds) when unlocking (fades off when locking).
Page 2 of 55Central locking On Board Diagnostic (OBD
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)
The control of the luggage compartment lighting
proceeds from the central locking pump to the rear lid (or tailgate) contact switch. The lighting will be switched off while the rear lid is open when a certain speed threshold is surpassed (about 5 km/h) or after 10 minutes.
The new remote transmitter now uses radio
frequency. For vehicles using the radio frequency remote locking system, the receiver is integrated into the central locking pump. The remote locking antenna is integrated into the wiring harness.
If no doors (or the rear lid) have been opened
within 60 seconds after the central locking system is triggered via radio frequency, central locking automatically relocks everything.
Page 3 of 55Central locking On Board Diagnostic (OBD
01-70
If the anti-theft alarm system is armed, central
locking cannot be opened via internal buttons.
All vehicles with an anti-theft system are
equipped with an ultrasonic interior monitoring system. This could be an interior monitor of the 1st generation (without OBD) or of the 2nd generation (with OBD). All that is necessary is the proper coding of the central locking system
page 01-91 .
Confirmation can be received fr om centr al
locking as to whether the alarm system has been armed while locking the doors. The confirmation can be signalled by means of a short anti-theft
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horn signal or by a brief flashing of the
)
emergency flashers. Central locking can also be coded to give no confirmation at all.
Activation of keyless entry can be signalled by a
flashing of the emergency flashers.
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Page 5 of 55Central locking On Board Diagnostic (OBD
)
01-71
Electrical Wiring Diagrams, Troubleshooting &
Central Locking On Board Diagnostic (OBD), initiating
Requirements
Power supply and fuses for relevant system OK
Component Locations bi nde r
VAG1551 Scan Tool (ST) connected page
01-1
Notes:
If the display remains blank, check VAG1551 voltage supply according to wiring diagram,
The Scan Tool (ST) HELP button can provide additional operating instruction.
The button is used to advance through the program sequence.
If an incorrect entry is made, press the -C­button to escape.
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Page 6 of 55Central locking On Board Diagnostic (OBD
)
Rapid data transfer HELP Insert address word XX
- Switch printer on by pressing PRINT button (indicator lamp in button lights up).
- Press button -1- to select "Rapid data transfer" operating mode 1.
Indicated on display
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g
Page 7 of 55Central locking On Board Diagnostic (OBD
)
01-72
Rapid data transfer Q 35 - Central Lockin
Rapid data transfer Scan Tool sends address word 35
8L0862257B CL-Pump, DWA, Func D04 Coding 12172 WSC 06812
8L0862257B CL-Pump, DWA, Func D04 Coding 16140 WSC 06812
Address word for central locking: 35
- Press buttons -3- and -5- to insert "Central Locking" address word 35.
Indicated on display
- Press -Q- button to confirm input.
Indicated on display
Vehicles 1997:
After about 5 seconds, display indicates (for example):
Vehicles 1998 :
After about 5 seconds, display indicates (for example):
All vehicles:
Rapid data transfer HELP Select function XX
-
Press button.
Indicated on display
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Page 8 of 55Central locking On Board Diagnostic (OBD
)
01-73
Note:
A list of available functions is printed out when
the HELP button is pressed.
On Board Diagnostic (OBD) functions
The following func tions are possible: 01 - Check Control Module Versions page 01-
85 .
02 - Check DTC Memory page 01-74 . 03 - Output Diagnostic Test Mode page 01-
88 .
05 - Erase DTC Memory page 01-137 . 06 - End Output page 01-139 . 07 - Code Control Modul e page 01-91 . 08 - Read Measurin g Value Block page 01-
99 .
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01-74
Check DTC Memory (scan tool function
02)
Note:
The DTC display information is updated only
when initiating the On Board Diagnostic (OBD) program or when using the "Erase DTC Memory" function 05.
- Switch printer on by pressing PRINT button (indicator lamp in button lights up).
Rapid data transfer HELP Select function XX
Carrying out "Check DTC Memory" function 02
Indicated on display
- Press buttons -0- and -2- to select "Check DTC Memory" function 02.
Rapid data transfer Q 02 - Check DTC Memory
Indicated on display
- Press -Q- button to confirm input.
X DTC recognized
The number of stored DTCs is indicate d on display.
The stored malfunctions are displayed and printed out in sequence.
- Look up printed malfunctions in the DTC table and repair all malfunctions page 01-76 .
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)
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No DTC recognized
Rapid data transfer HELP Select function XX
If the message "No DTC recognized" is displayed, the program can be returned to the starting point by pressing the button.
Indicated on display If something else is displayed:
Scan tool operating instructi on s
- Erase DTC Memory (functio n 05) page 01-137 .
- End Output (function 06) page 01-139 .
- Disconnect VAG1551 Scan Tool (ST) from Data Link Connector (DLC).
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)
01-76
Diagnostic Trouble Code (DTC) table, central locking
Notes:
The following table lists all the DTCs that can be recognized by the control module for central locking and printed out by the VAG1551 Scan Tool (ST). The DTCs are listed in order according to their 5-digit numbers.
DTC 5-digit numbers appear only on the print-out from the scan tool.
Before replacing a component shown as malfunctioning, check wiring and connections to the component as well as the Ground (GND) connections according to the relevant wiring diagram.
When a repair has been completed, check and then erase DTC memory using the VAG1551 Scan Tool (ST). After that, the vehicle should be locked again (with key or remote control) and DTC memory checked again.
DTC memory records all static and sporadic malfunctions. When a malfunction occurs, it is first identified as a static malfunction. If it does not occur again it is registered as a sporadic malfunction, and the letters "/SP" appear at the right of the display.
When the ignition is switched on, all existing malfunctions are automatically re-classified as sporadic malfunctions and will only be registered as static malfunctions if they still occur after testing.
Sporadic malfunctions which no longer occur after 50 driving cycles are erased automatically.
The three digit malfunction type number appearing next to the DTC is a data code which may be disregarded.
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DTC VAG 1551 scan tool
display 00955
Key 1 Adaptation limit
exceeded
00956
Key 2 Adaptation limit
exceeded
00957
Key 3 Adaptation limit
exceeded
Possible cause
Key not matched Key operated more than 200 times
while out of range
Key not matched Key operated more than 200 times
while out of range
Key not matched Key operated more than 200 times
while out of range
Corrective action
- Perform remote transmitter coding procedure page
01-105
- Perform remote transmitter coding procedure page
01-105
- Perform remote transmitter coding procedure page
01-105
00958
Key 4 Adaptation limit
exceeded
00991
Interior lighting
Key not matched Key operated more than 200 times
while out of range
- Perform remote transmitter coding procedure page
01-105
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Page 13 of 55Central locking On Board Diagnostic (OBD
)
Short circuit to positive
Short circuit to in wiring
- Repair wiring according to wiring diagram.
Electrical Wiring Diagrams, Troubleshooting &
Component Locations bi nde r
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01-78
DTC VAG 1551 scan tool
display 01360
Open ATW Switch Short circuit to
Ground
01361
Close ATW Switch Short circuit to
Ground
Possible cause
Short circuit to Ground in wiring 1) Door contact switch, driver's-side -
F2- faulty
Short circuit to Ground in wiring 1) Door contact switch, driver's-side -
F2- faulty
Corrective action
- Repair wiring according to wiring diagram.
Electrical Wiring Diagrams, Troubleshooting &
Component Locations bi nde r
- Check -F2- and replace if necessary.
- Repair wiring according to wiring diagram.
Electrical Wiring Diagrams, Troubleshooting &
Component Locations bi nde r
- Check -F2- and replace if necessary.
01362
Close Switch for Tailgate-F124
Short circuit to Ground
Short circuit to Ground in wiring 1) Trunk lock alarm/central locking
switch -F124- faulty
- Repair wiring according to wiring diagram.
Electrical Wiring Diagrams, Troubleshooting &
Component Locations
- Check -F124- and replace if necessary.
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1)
)
A malfunction is stored if the Ground is connected for more than 1 min. (e.g. due to an incorrect operation of central
locking). Only initiate a repair if there is a proper complaint, otherwise erase DTC memo ry page 01
-137 .
Page 15 of 55Central locking On Board Diagnostic (OBD
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)
01-79
DTC VAG 1551 scan tool
display 01363
Switch for CL; Drivers Door-F59
Incorrect Signal
01364
Switch for CL; Passenger Door­F114
Incorrect Signal
01365
Lock/Unlock Switch/Button Int.
Short circuit to Ground
Possible cause
This indication can be caused by the system itself. There is no malfunction of driver's door central locking system switch -F59-.
This indication can be caused by the system itself. There is no malfunction of passenger door central locking system switch -F114-.
Short circuit to Ground in wiring 1) Switch for interior lock, drive r's sid e -E15 0- fau lt y
Corrective action
- Ignore DTC and erase DTC memo ry page 01-137 .
- Ignore DTC and erase DTC memo ry page 01-137 .
- Repair wiring according to wiring
diagram.
Electrical Wiring Diagrams,
Troubleshooting & Component Locations binder
- Check -E150- and replace if
necessary.
1)
A malfunction is stored if the Ground is connected for more than 1 min. (e.g. due to an incorrect operation of central
locking). Only initiate a repair if there is a proper complaint, otherwise erase DTC memo ry page 01-137 .
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)
01-80
DTC VAG 1551 scan tool
display 01365
Lock/Unlock Switch/Button Int.
Short circuit to B+
01366
Open Via Crash Signal
Short circuit to Ground
Open/short circuit to B+
Possible cause
Short circuit Short circuit to Ground in wiring Switch for interior lock, driver's side -E150-
faulty
Output Diagnostic Test Mode performed at airbag control module -J234-
Airbag control mo dul e -J234- was triggered Short circuit in wiring between airbag control
module and central locking control module
Corrective action
- Repair wiring according to wiring diagram.
Electrical Wiring Diagrams, Troubleshooting
& Component Locations binder
- Check -E150- and replace if necessary.
- Erase DTC memory page 01-137 .
- Repair wiring according to wiring diagram.
Electrical Wiring Diagrams, Troubleshooting
& Component Locations binder
01367
Switch on Via CL Pump
Too little pressure in pneumatic lines Central locking pump faulty
- Check pneumatic lines for leaks.
- Exchange central locking pump.
- Check all actuators of central locking system and replace if necessary.
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01-81
DTC VAG 1551 scan tool
display 01368
Alarm Via Luggage Compartment Switch
01369
Alarm Via Front Hood Switch
01370
Alarm Via Interior Scanning
Short circuit to Ground
Possible cause
Anti-theft system triggered by unauthorized opening of rear lid
Trunk lid alarm switch -F123- faulty
Anti-theft system triggered by unauthorized opening of hood
Hood alarm switch -F120- fault y
Anti-theft system triggered by control module for ultra-sound sensors -J347-
Control module for ultra-sound sensors -J347­faulty
Short circuit in wiring between control module for ultra-sound sensors and central locking control module
Corrective action
- Erase DTC memory.
- Replace -F123-.
- Erase DTC memory.
- Replace -F120-.
- Erase DTC memory.
- On Board Diagnostic (OBD) ultra-sound interior monitoring page 01-108 .
- Repair wiring according to wiring diagram.
Electrical Wiring Diagrams,
Troubleshooting & Component Locations binder
01371
Alarm Via Door Conta ct
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Switch Driv. Side
Anti-theft system triggered by unauthorized opening of dri ver-side door
Door contact switch, driver's side -F2- faulty
- Erase DTC memory.
- Replace door contact switch -F2-.
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DTC VAG 1551 scan tool
display 01372
Alarm Via Door Ctact. Switch Rear PS
01373
Alarm Via Radio Ground Teminal
01374
Alarm Via Terminal 15
Possible cause
Anti-theft system triggered by unauthorized opening of passenger-side and/or rear door(s)
Door contact switches -F3-, -F10-, -F11- faulty
Anti-theft system triggered by unauthorized removal of radio
Ground connection for anti-theft system has an open circuit
Anti-theft system triggered by unauthorized starting (short circuiting )
Short circuit between ter m in al 30 and 15
Corrective action
- Erase DTC memory.
- Replace contact switch -F3-, -F10-, -F11-.
- Erase DTC memory.
- Provide Ground connection.
- Erase DTC memory.
- Repair wiring according to wiring diagram.
Electrical Wiring Diagrams,
Troubleshooting & Component Locations binder
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01-83
DTC VAG 1551 scan tool
display 01384
Alarm via Broken Glass Sensor
(rear window)
01389
Tailgate Open Switch­F124
Short circuit to Ground
Possible cause
Anti-theft alarm triggered by attempted break-in at rear window
Open in rear window defroster circuit False alarm
Short circuit to Ground in wiring Trunk lock alarm/central locking switch -
F124- faulty
Corrective action
- Erase DTC memory
- Check and repair wiring and connectors per wiring diagram.
Electrical Wiring Diagrams, Troubleshooting &
Component Locations bi nde r
- Replace rear window
Repair Manual, Body Exterior, Repair Group 64
- Repair wiring according to wiring diagram.
Electrical Wiring Diagrams, Troubleshooting &
Component Locations bi nde r
- Replace -F124- in trunk lock.
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01-84
DTC VAG 1551 scan tool display 01403
Broken Glass Sensors
Broken glass sensor for rear left side window -G183
or Broken glass sensor for rear
right side window -G184
65535
Control Module Malf unctioning
Possible cause
Anti-theft alarm triggered by attempted break-in at one of the side windows
Open in circuit of one of the side windows
False alarm
Corrective action
- Erase DTC memory
- Check and repair wiring and connectors per wiring diagram.
Electrical Wiring Diagrams,
Troubleshooting & Component Locations binder
- Replace side window as necessary
Repair Manual, Body Exterior, Repair
Group 64
- Replace control module.
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)
01-85
Rapid data transfer HELP Select function XX
Rapid data transfer Q 01 - Check Control Module Versions
8L0862257B CL-Pump, DWA, Func D04 Coding 12172 WSC 06812
Check Control Module Versions (scan tool function 01)
Indicated on display
- Press buttons -0- and -1- to select "Check Control Module Versions" function 01.
Indicated on display
- Press -Q- button to confirm input.
Vehicles 1997
Indicated on display
Explanation of display
8L0862257B: Part No. of central locking control modules Central locking pump, Anti-theft system: component identification D04: software version Coding 12172: coding page 01-91 WSC 06812: dealership number
-
Press button
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Page 24 of 55Central locking On Board Diagnostic (OBD
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01-86
8L0862257BCL-Pump, DWA, Func D04 Coding 16140 WSC 06812
Vehicles 1998
Indicated on display
Explanation of display
8L0862257B: Part No. of central locking control modules Central locking pump, Anti-theft system: component identification D04: software version Coding 16140: coding page 01-91 WSC 06812: dealership number
-
Press button
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)
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All vehicles:
If one of these messages is indicated on the
display, perform On Board Diagnostic (OBD) according to OBD instructions:
Rapid data transfer HELP Control module does not an swer
Indicated on display or
Rapid data transfer HELP Error in communication link
Indicated on display or
Rapid data transfer HELP K wire not switching to Ground
Indicated on display or
Rapid data transfer HELP K wire not switching to B+
Indicated on display
- Check wiring connections for Data Link Connector (DLC).
Rapid data transfer HELP
Electrical Wiring Diagrams, Troubleshooting & Component Locations
binder
Note:
If nothing appears on display:
Scan tool operating instructi on s
Indicated on display
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