Attachment Bulletin # 690506

Group: 69

Number: 05-06

Date: NOV. 17, 2005

Subject:
Airbag Lamp ON, Upper Limit of Side Airbag Exceeded

Model(s):

A4 2002 --> 2006 to VIN 6A072674

Cabriolet 2003 --> 2006

Supersedes T.B. Group 69 number 05-05 Dated Jun. 2, 2005 due to VIN information added to header for A4 Model.

Condition

Airbag warning lamp in Instrument Cluster is ON and the following sporadic DTC(s) are stored in DTC memory.

^ 01217 001 "Igniter for side airbag driver's side -N199- Upper limit exceeded"

^ 01218001 "Igniter for side airbag passenger side -N200- Upper limit exceeded"

May be caused by sporadic too high resistance in the connector between the airbag and seat harness.

Service

Prior to performing the following procedure:

WARNING
When working on ANY airbag system
ALWAYS read and follow Repair Manual
WARNINGS, Precautions, Notes and Tips!

See Repair Manual, Repair Groups 69 and 72, for detailed information.

Tip:

Part numbers listed in this Technical Bulletin are for reference only. Always check with your Parts Department for the latest parts information.





Parts required:

Procedure:

Tip:

Note, and if necessary, determine radio code for vehicles equipped with coded anti-theft radio.

- Disconnect battery Ground (GND) strap.

- Remove seat (see Repair Manual Body Interior Group 72 Seat Frames).





- Attach Airbag adapter (arrow) to seat harness:

^ VAS 6036 (see Repair Manual, Body Interior 72 - Seat frames "Airbag adapter VAS 6036 connecting").

Tip

^ The adapter must remain connected as long as the seat is removed from the vehicle.

^ Seat must be mounted on the seat mounting rack VAS 6095.

Tip:

Before repairing the seat harness, Technicians must ground themselves and the tools to be used by touching the mounting rack. If the repair is interrupted technicians must again ground themselves when returning to finish the repair.

WARNING
The airbag unit must not be left unattended.





- Cut igniter wire 1 (arrow) next to airbag connector (on airbag side).





- Cut igniter wire 1 (arrow) next to airbag connector on (seat harness side).

^ Using VAS 1978A wiring repair kit including crimping tool VAS 1978/1 with VAS 1978/24 insert:

- Strip wires and splice using a 4 inch section of repair wire (Part No: 000 979 010) and 2 butt connectors (Part No: 111 971 941A).

^ This allows the harness additional slack.

- Repeat above steps for igniter wire 2.

Tip:

On some vehicles the ground wire for the airbag is run outside, and along the connector. If this is observed, Do Not cut the ground wire.





- Repeat above steps for ground wire 3, crimping one pair of wires at a time until the connector is removed.

- Discard connector.





- Twist repaired wires (arrow).





- Wrap repair using yellow electrical tape (arrow) to indicate that the wiring harness has been modified.

- Secure repaired harness with tie wraps.

- Install seat (see Repair Manual Body Interior Group 72 Seat Frames).

- Switch ignition ON.

WARNING
Ensure that there is no person inside the vehicle when connecting the Battery Ground (GND) strap.

- Reconnect battery Ground (GND) strap.

- Connect the VAS 5051 or 5052 diagnostic tool and clear any stored DTCs and verify repair.

- Program radio station presets if necessary.

- Check vehicle equipment (radio code, clock, electrical windows) as per Repair Manual and/or Owner's Manual.





When procedure applies to vehicles with- in the New Vehicle Limited Warranty, use the table.