Restraints - Warning Light ON, DTCs 46 & 49
911 Turbo (996)1/04
Binder - 6, Body Equipment
Airbag Warning Light Comes On: Fault Codes 46 and 49
Vehicle Type:
911 Turbo (996)/911 GT2 (996)
Model Year:
As of '01 (1)
Concerns:
Airbag warning light comes on. Fault codes 46 and 49.
Information:
If one or more of the above-mentioned fault codes are read out during diagnosis after the airbag warning light has come on, this means that the following measure must be carried out on the driver's seat and/or the passenger's seat.
Procedure:
Measure for fault code 46 or 49:
Depending on the fault code, changing the driver's side seat plug connection plug and installing a new belt buckle on the driver's seat (fault code 46) or passenger's seat (fault code 49).
Parts Information
Tools
1. Disconnect battery.
Caution!
Danger of injury by airbag/side airbag when the power supply is interrupted. Assembly work can trigger the airbag unintentionally!
> Begin further work on the vehicle only after a waiting time of 1 minute.
2. Remove seat; see 911 Turbo (996) Technical Manual, Group 7, Repairs, 72 01 19 - Removing and installing front seat.
3. Work on the "seat" plug connection (disconnection points X16 and X17 on the circuit diagram). The existing contact springs must be replaced by gold-plated and greased springs on the vehicle-side plug of the "seat" plug connection.
Connector X16 = driver's side,
Connector X17 = passenger's side.
3.1 Unwrap the banding of the driver's side wiring harness according to the new leads which are to be installed.
3.2 Open the vehicle-side plug. To do this, lever out the plug cap (Figure 1, arrow A) at the pivot point using a small flat screwdriver. Then lift the blue bar (arrow B) with the screwdriver and pull it out of the plug.
3.3 Carefully remove the movable side of the plug (arrow C), and pull the plug housing out (arrow D).
3.4 Work on the leads/contact springs in the plug (arrow D).
Caution!
Possibility of mixing up the leads!
> Complete only one lead at a time.
> Work on the leads/contact springs in sockets B5, B6, B7 and B8 on the driver's side. On the passenger's side, work on only those leads/contact springs that are in sockets B7 and B8.
> Trim the wires in such a way that the connection points are offset with respect to each other.
3.4.1 Unlock and push out a contact spring using pressout tool 89058 (Figure 2).
3.4.2 Trim the lead in accordance with the new lead.
Note:
The new lead should be approx. 50 mm longer (allowance for wire-end ferrule and shrink tubing).
3.4.3 Strip approx. 10 mm of insulation from the ends of both leads, twist the ends together and insert them in a 2.5 x 7 wire-end ferrule (Figure 3).
3.4.4 Join the leads in the wire-end ferrule using a pair of crimping pliers (Figure 4, Item A).
3.4.5 Solder the tips of the projecting ends of the leads (Item B).
3.4.6 Insulate the soldered joint with 4 x 35 shrink tubing.
Caution!
Damage to the interior and the leads from the heating effect of the heat gun!
> Observe the blower outlet direction of the heat gun during the shrinking procedure.
> Close the open end of the shrink tubing using a pair of flat-nosed pliers (Item C).
3.4.7 Snap the contact spring into the housing socket again.
3.4.8 Use electrical tape to secure the lead to the wiring harness in the area of the shrink tubing.
3.5 Follow the same procedure for work on the other leads/contact springs. Trim the wires in such a way that the connection points are offset with respect to each other.
3.6 Reassemble the plug in reverse order. When doing so, replace the previous plug cap (See Figure 1, Item A) with the plug cap contained in the service set.
Caution!
Airbag warning light lights up if tie-wrap is insufficiently fastened.
> Bundle all leads on the vehicle-side plug on the plug cap using a tie-wrap (Figure 4).
3.7 Bundle the seat ground lead again. Add more banding if necessary.
4. Replace belt buckle.
A new belt buckle with gold-plated contact pins must be installed. A strain relief element for the belt buckle wiring harness is intended on the seat-side plug.
4.1 Remove the previous belt buckle; see Boxster Technical Manual, Group 6, Repairs, 69 24 19 - Removing and installing the front belt buckle.
4.2 Install the new belt buckle.
Distinguishing the belt buckles:
The belt buckles can be recognized by way of the stamped part number and by the plug color.
Driver's seat - 996.803.183.09, blue plug
Passenger's seat - 996.803.183.10, green plug.
Caution!
Airbag warning light lights up if tie-wrap is insufficiently fastened.
> The tie-wraps for the strain-relief element of the belt buckle wiring harness for the seat-side plug must be installed according to the following Steps 4.3.
4.3 Strain relief element for driver's and passenger's seats:
Bundle the leads in the plug housing with a tie-wrap (Figures 6 and 7).
5. Reinstall seat.
6. Connect the battery. Enter radio code, if necessary.
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