Seat Belt Systems: Service and Repair

Pyrotechnic Belt Tensioners, Disposal

- The scrapping of gas generators which have not been triggered represents a hazard.
- In line with the relevant accident prevention regulations, the gas generator of the belt tensioner unit must be rendered inoperable before scrapping.
- This is necessary because pyrotechnic devices can cause injury if disposed of incorrectly (e.g. using a blow torch).
- Seat belts which need to be removed (e.g. after an accident in which the belt tensioner was not activated) must be triggered before removal.
- This does not apply to malfunctioning seat belts (sticking, failure to retract) which are required for factory analysis.
- Observe regulations governing transportation of explosive substances.
- Procedure for triggering front pyrotechnic belt tensioners:

NOTE:
- Whenever possible, pyrotechnic belt tensioners must be deployed outside the vehicle. Use Airbag and Pyrotechnic Deployment Device J-44210 and follow instructions in booklet.
- The procedure that follows is for deployment of tensioners mounted inside a vehicle.

Sedan and Avant front
- Remove upper B-pillar trim, without side curtain airbag with side curtain airbag.
- Remove lower B-pillar trim.
- Remove outer seat belt attachment point.
- Cut webbing with scissors above latch plate (approx. 20 cm above belt reel).

Sedan rear center
- With solid backrest

- Remove rear seat bench.
- Remove rear backrest.
- Remove parcel shelf in case of solid backrest.
- Completely pull out belt and tie a knot as close as possible to the belt retractor to keep from rolling up (for belt usage sensor).

- For foldable rear seatback

- Remove 2/3 rear backrest.
- Remove 2/3 rear backrest upholstery until the upholstery can be removed with the cushion.
- Completely pull out belt and tie a knot as close as possible to the belt retractor to keep from rolling up (for belt usage sensor).

Sedan rear outer
- For solid seatback

- Remove rear seat bench
- Remove rear backrest
- Remove parcel shelf
- Completely pull out belt and tie a knot as close as possible to the belt retractor to keep from rolling up (for belt usage sensor).

- For foldable rear backrest

- Remove rear seat bench.
- Remove 2/3 rear backrest.
- Remove 1/3 rear backrest.
- Remove parcel shelf.
- Completely pull out belt and tie a knot as close as possible to the belt retractor to keep from rolling up (for belt usage sensor).

Avant rear center
- Remove 2/3 rear backrest.
- Remove 2/3 rear backrest upholstery until the upholstery can be removed with the cushion.
- Completely pull out belt and tie a knot as close as possible to the belt retractor to keep from rolling up (for belt usage sensor).

Avant rear outer
- Remove rear seat bench.
- Remove side luggage compartment trim.
- Completely pull out belt and tie a knot as close as possible to the belt retractor to keep from rolling up (for belt usage sensor).

All
- Disconnect connector from belt reel and connect wiring harness (Part No. 8D1 971 259) to belt tensioner.
- Cut off connector on other end, strip the ends of the two wires and slit the cable sheath until the ends of the wires are at least 30 cm apart.
- Make sure there is nobody in the vehicle.
- Trigger gas generator with doors closed and windows open using wiring harness and external battery (outside vehicle).
- Make sure adequate vehicle ventilation after triggering.
- Belts can be disposed of with commercial refuse after removal.
- Always wash hands after handling belt tensioners which have been activated.
- Observe safety precautions for handling pyrotechnic belt tensioners.
- The procedure for triggering the rear pyrotechnic belt tensioners is the same as for the front belt tensioners (remove rear shelf or remove upholstery from 2/3 backrest, cut webbing and trigger belt tensioner).