Replacing ITS Head Airbag

Removing And Installing/Replacing Left Or Right ITS Head Airbag (model Not Fitted With Sliding/tilting Sunroof)

CAUTION!
Observe safety regulations for handling airbag modules and pyrotechnical seat belt tensioners.
Incorrect handling can activate airbag and cause injury.

Remove headliner, Version without slide/tilt sunroof.
Remove trim for instrument panel.

Installation summary, retaining elements, ITS head airbag E39

NOTE: The rear grab handle retainer is different for the sedan and the touring.

NOTE: Version of gas generator up to 09 / 2000:

Disconnect plug connection for gas generator ITS head airbag.

Release screw (1).
Remove gas generator, ITS head airbag (2).

Installation:
Tightening torque.Specifications

Installation:

Lug (1) of ITS head airbag gas generator must be secured in bore hole (2) of support tube retainer!

NOTE: Version of gas generator from 09/ 2000;

Disconnect plug connection for gas generator, ITS head airbag, refer also to 72 12... Unlocking/locking airbag plug connections.

Installation:
Ensure plug connection is correctly engaged.

Unscrew screw.
Remove ITS head airbag gas generator.

Installation:
Tightening torque: Specifications

Installation:
Mount gas generator, ITS head airbag, in bore hole of A-pillar. Install and clip in additional retaining clip.

Installation:

Lug (1) of ITS head airbag gas generator must be secured in bore hole (2) of support tube retainer!

Tighten down retaining screw.
Tightening torque: Specifications

The gas generator, ITS head airbag, will be altered from 09/2000.
The housing of the ITS head airbag gas generator has been extended and an additional retaining clip has been inserted for the gas generator.

Illustration of gas generators, ITS head airbag:
- 1 = Gas generator, ITS head airbag, up to 09 / 2000
- 2 = Gas generator, ITS head airbag, from 09 / 2000
- 3 = Additional retaining clip to gas generator, ITS head airbag, from 09/ 2000

NOTE: If a gas generator of version up to 09 / 2000 is replaced by a gas generator from 09/ 2000, it will be necessary to provide a bore hole for the additional retaining clip.

The necessary conversion work is described below:
Install new gas generator from 09 / 2000.

Close additional retaining clip and push onto installed gas generator.
Distance (A) from edge approx. 20 mm.

Mark position of catch of holding clip of additional retaining clip on A-pillar (e.g. coat tip of holding clip with paint, this produces the center point of the bore hole).

NOTE: View from footwell upwards in direction of A-pillar.

Remove gas generator, ITS head airbag.
Remove or cover car components affected in area of bore hole to be provided and in area of swarf.

Drill a bore hole of 11 mm dia.
Remove swarf.
Deburr bore hole and protect against rust.

NOTE:
Further alterations will be necessary if an ITS head airbag gas generator of version up to 09 / 2000 is replaced by an ITS head airbag gas generator from 09/ 2000.
The plug for the gas generator, ITS head airbag, is modified and the cable length must be extended, necessitated by the modified gas generator.
Procedure for extending airbag cables is the same as the procedure for cable repairs:
If wiring harness is visibly damaged.
Service and Repair

Also check whether the B-pillar trim of version from 09 / 2000 is fitted.
1 = B-pillar trim up to 09 / 2000
2 = B-pillar trim from 09 / 2000, trim is lined all round up to rear side.

On the B-pillar trim from 09 / 2000, the trim is lined all round up to the rear side.
This prevents the ITS head airbag with gas generator from 09/ 2000 being damaged on activation by the B-pillar trim.
It is absolutely essential to fit an B-pillar trim of version from 09 / 2000 if an ITS head airbag gas generator of version from 09 /2000 is fitted.

NOTE: The conversion work ends here.

Release retaining screw, A-pillar.

NOTE: Screw is held in end fitting by locking washer.

Installation:
Tightening torque:

View of mounting bolt on A-pillar with end fitting of ITS head airbag
1. End fitting of ITS head airbag
2. Lockwasher
3. Mounting bolt on A-pillar

NOTE:
A-pillar bracket at bottom was fitted up to 09/98 only.
Release screw (1).
Push bracket at bottom of A-pillar upwards (2).
Remove bracket at bottom of A-pillar towards front (3).

Installation:
During installation, ensure that retaining lug is correctly seated in body.

View, bracket at bottom of A-pillar
1. Bore for retaining screw in body
2. Retaining bore for retaining lug of bracket at bottom of A- pillar in body

CAUTION!
In the area of the bracket at bottom of A-pillar (1), the retaining clip (2) of the panel for roof pillar is located at front.

Installation:

During installation, it is absolutely essential to ensure that the lug (1) of the grommet (2) of the retaining clip for the front roof pillar trim (3) is located above the ITS head airbag (4).
If this is not the case, the ITS head airbag may be damaged by sharp edges of the retaining clips for the front roof pillar trim.
This limits the functionality of the ITS head airbag or, in extreme cases, results in its failure!

Release screw (1).
Push bracket at top of A-pillar downwards (2).
Remove bracket at top of A-pillar towards fronts (3).

Installation:
During installation, ensure that retaining lug is correctly sealed in body.

View, bracket at top of A-pillar
1. Retaining bore for retaining lug of bracket at top of A-pillar in body
2. Retaining lug on bracket on A-pillar must snap into place in retaining bore
3. ITS head airbag

Remove ITS head airbag from front grab handle bracket from below.

CAUTION!
Do not damage the ITS head airbag in the process!

Installation:

Ensure that ITS head airbag is correctly positioned in grab handle bracket.
The retaining clip (2) of the front grab handle bracket (1) must be above the ITS head airbag (3).

CAUTION!
The retaining clip (2) must not have any sharp edges in the area of the ITS head airbag!
Danger of damage to the ITS head airbag!
Replace bracket for front grab handle if necessary.

Release screw (1).
Push bracket on B-pillar upwards (2).
Remove bracket on B-pillar towards front (3).

Installation:
During installation, ensure that retaining lug is correctly seated in body.

View of bracket on B-pillar
1. Retaining bore for retaining lug of B-pillar bracket in body
2. Retaining lug on bracket on B-pillar must snap into place in retaining bore
3. Bracket on B-pillar
4. ITS head airbag
5. Cover, welded seam

Release screw (1).
Replace bracket for rear grab handle (2).

Installation:

Summary of rear grab handle bracket.
1. Sedan
2. Touring

Installation:

Ensure that ITS head airbag is correctly positioned in rear grab handle bracket.
The retaining clip (2) of the rear grab handle bracket (1) must be above the ITS head airbag (3).

CAUTION!
The retaining clip (2) must not have any sharp edges in the area of the ITS head airbag!
Danger of damage to the ITS head airbag!
Replace bracket for rear grab handle if necessary.

Release rear retaining screw (1).

NOTE: Retaining screw (1) is held in place by a locking washer in end fitting (2).

Installation:
Remove ITS head airbag.

View of rear retaining screw with end fitting of ITS head airbag
1. End fitting of ITS head airbag
2. Lock washer
3. Retaining screw, rear

Installation:
It is absolutely essential to ensure that the covers of the welded seams (1 and 2) are fitted. The covers must not reveal any damage, e.g. sharp edges of welded seams are openly visible or perceptible.
It necessary, replace damaged covers and eliminate the cause of the damage!
The ITS head airbag can be damaged by sharp edges when it is triggered.
This limits the functionality of the ITS head airbag or, in extreme cases, results in its failure!

View, cover, welded seam, A-pillar
1. Bracket, water drain, sliding/tilting sunroof, and wire harness, A-pillar
2. Cover, welded seam, A-pillar
3. ITS head airbag

View, cover, welded seam, inside roof frame for B-pillar
1. Cover, welded seam inside roof frame for B-pillar
2. B-pillar
3. Bracket for front grab handle