Repairing Airbag Cables

Repairing Airbag Cables


CAUTION!
Only repair those cables which show visible signs of damage. If there is visible damage, make sure that only one cable repair is present after repairing. If no visible damage can be identified, the entire cable must be replaced. When carrying out repairs to airbag wiring harness: The spare parts offered in the Electronic Parts Catalog (EPC) must be used.


Safety regulations:
Safety regulations for handling components of airbag system.

General information on car battery.


Procedure for cable repair

In event of non-visible damage to wiring harness:
Disconnect plug connection on airbag module or on intermediate plug. Unpin contacts. Cut through one cable after the other at an appropriate position, do not under any circumstances cut through both cables at the same time. Insulate cables remaining in wiring harness with insulating tape. Now disconnect plug connection on airbag control unit. Unpin contacts. Cut through one cable after the other at an appropriate position and insulate with insulating tape, do not under any circumstances cut through both cables at the same time. Pin contacts of repair lead for airbag control unit into control unit plug. Assignment of repair leads is not relevant. Lay repair cable in car parallel to existing airbag lead. Now pin in contacts for airbag module or contacts of intermediate plug. Assignment of repair leads is not relevant. Cut off cess length of repair lead in proximity (visible area) of airbag module or of intermediate plug. Twist open cables. With the connectors and shrink-fit hoses in the Electronic Parts Catalog (EPC), reconnect the cables with the same cable colors. Twist cables again, open length (twisting) must not exceed 40 mm. Secure interface (shrink-fit hoses) with insulating tape to prevent cables from twisting open.

Instructions for cutting off, insulating, crimping cables, installing and removing contacts:
Cutting off and insulating cables.
Repairing a plug connection using connectors.
Installing and removing contacts.

In event of visible damage:
Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through both cables at the same time. Now, depending on scope of work, unpin contacts either on airbag control unit/module or intermediate plug. Cut off unpinned cables. Insulate cables remaining in wiring harness with insulating tape. Now pin in contacts of repair lead. Assignment of repair leads is not relevant. Lay repair lead in car parallel to existing airbag lead up to cutting point. Cut off excess length of repair lead. Twist open cables. Connect cables with connectors and shrink-fit hoses in Electronic Parts Catalog (EPC). Assignment of repair leads is not relevant. Twist cables again, open length (twisting) must not exceed 40 mm. Secure interface (shrink-fit hoses) with insulating tape to prevent cables from twisting open.

Instructions for cutting off, insulating, crimping cables, installing and removing contacts:
Cutting off and insulating cables.
Repairing a plug connection using connectors.
Installing and removing contacts.