Restraints and Safety Systems: Service Precautions
Safety Regulations For Airbag And Seat-belt Pretensioner Units
Tools and materials
Materials
- Use Porsche work clothing.
General warning notes
General warnings for handling airbag and belt tensioner units
CAUTION: Danger of injury and material damage if airbag unit is not handled correctly
- Triggering of airbag unit.
- The airbag units are pyrotechnical items in hazard class T 1.
- Handling, transport and storage of these units must conform to hazardous goods regulation and explosives legislation.
- The listed statutory requirements refer to the Federal Republic of Germany. The relevant valid regulations must be observed in all other countries. Enquire of the importer for the country concerned.
- The commencement of work with pyrotechnical items must be reported 14 days in advance to the Trade Supervisory Office (responsible authority).
- Airbag units must only be dispatched in transport packaging officially approved for that purpose.
- Internally and otherwise, they must always be transported in the luggage compartment or cargo hold of a vehicle using the above-mentioned transport packaging.
- They must not be transported in the passenger compartment.
- Airbag units must be stored in accordance with the second ordinance of the explosives legislation.
- This ordinance stipulates that small quantities of materials and items may be stored at certain locations without special storage approval.
- Airbag units must be kept in a locked place.
- When storing airbag units, ensure that the airbag opening faces upwards (risk of injury caused by inflation of the airbag units in the event of accidental ignition).
- Airbag units must be stored in a dry place and must not be stored together with other hazardous goods (varnishes, etc.).
- Loose airbag units or airbag units located in a removed steering wheel must never become the actual (physical) property of the customer.
- The possession of loose airbag units not installed in the vehicle is not permissible in the private sector.
- Airbag units may become the property of the customer only when installed in the vehicle.
Warnings about assembly and straightening work
CAUTION: Danger of personal injury and material damage as a result of malfunction of the airbag system.
- Malfunction of the airbag system
- Never drive with an airbag triggering unit that has not been taught.
- The airbag triggering unit must be taught using the PIWIS Tester 97180! Until the airbag triggering unit has been taught, the warning light lights up continuously.
- Inspection and assembly work must only be carried out by specialist staff.
- Before working on the airbag system and also when working on neighbouring parts where there is a risk because live parts are close to the airbag system, always implement the following safety measures:
- Remove ignition key.
- Disconnect and cover the negative terminal of the battery.
- After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar tools must not be started until after a waiting period of 1 minute.
- This is necessary in order to interrupt the power supply to the airbag system and to ensure it is not triggered accidentally.
- Airbag units must be fitted immediately after being removed from their storage location.
- Airbag units must never be left lying around unattended.
- If work is interrupted, airbag units must immediately be locked away again!
- Airbag units must not come into contact with grease, oil, detergents, liquids, or similar substances.
- Airbag units must not be exposed to temperatures above 90 °C.
- Airbag units and control units which have fallen from a low height must no longer be installed.
- Additional linings, stickers or similar must not be attached in the vicinity of the airbag units.
- Changes must not be made to the wiring or the components of the airbag system.
- The battery must always be disconnected before starting straightening and welding work with an electrical welding unit.
- Electrostatic charge: In general, suitable work clothing and footwear are to be worn. Refer to Safety regulations for handling tools and materials for airbag and belt tensioner units
- Do not remove the short-circuit spring of the plug contacts.
- Never connect airbag units to electrical power sources not in accordance with regulations (danger of immediate ignition). Only use testers prescribed by the manufacturer. Airbag diagnosis 6901.
- If you have to perform welding in the immediate vicinity of the airbag triggering unit, ensure it is removed before starting work.
- Airbag components must not be repaired.
- Airbag components must always be replaced.
- Cleanse your hands after touching ignited airbag units.
Information for airbag and seat-belt pretensioner units
Dangers for persons and the environment
NOTE:
- Dangers for persons and the environment
- Injury caused by incorrect triggering of the installed unit.
- Injury caused by spinning away, e.g. of the entire unit.
- Burns caused by touching the hot surfaces of a triggered unit.
- Damage to hearing due to the explosion when gas is released.
- Irritation caused by breathing in fuel particles.
- Irritation caused by skin and eye contact with fuel particles.
- Airbag/belt tensioner components must not be opened nor repaired; always use only new parts.
- Injury caused by incorrect triggering due to tampering with the short circuit bridges.
Protective measures and rules of behaviour
NOTE:
- Protective measures and rules of behaviour
- Assembly work only by trained staff.
- Carry out tests only with the PIWIS Tester 97180 diagnostic module; do not use test lamps, voltmeters or ohmmeters.
- Do not bring into contact with grease, solvents, cleaning agents, or liquids.
- Do not expose to temperatures above 100 °C.
- Keep the unfolding area of the airbag clear; e.g. do not hang test devices over the steering wheel. When carrying, hold the airbag with the blow-out direction facing away from the body. Lay the airbag unit aside with the airbag pointing upwards.
- Electrostatic charge: In general, wear appropriate work clothing and footwear. Refer to Safety regulations for handling tools and materials for airbag and belt tensioner units
- Do not remove the short-circuit spring of the plug contacts.
- Never connect an airbag unit to electrical power sources not in accordance with regulations (danger of ignition). Only use testers prescribed by the manufacturer. Airbag diagnosis 6901.
- During installation/removal or work on the vehicle involving vibrations: switch off ignition, disconnect and cover negative terminal of the battery, wait 1 minute and only then disconnect the plug connection.
- Transport: In transport packaging. Forbidden in passenger compartment.
- Storage in the workshop: max. 10 kg (=100 driver's or 50 passenger's airbags); protect against theft.
- The installation of the airbag/belt tensioner unit must be carried out immediately after removal from the transport container.
- If work is interrupted, the airbag/belt tensioner unit must be stored in the transport container again.
- Leaving the airbag/belt tensioner unit unsupervised is not permitted.
Behaviour in cases of malfunction or danger
NOTE:
- Behaviour in cases of malfunction or danger
- Protect from flames and heat.
- In case of fire, inform the fire brigade on arrival about the units present.
- Do not install mechanically damaged units or units that have fallen, even from a low height.
- Always replace units that are mechanically damaged (bulges, cracks).
- Because of the irritating combustion residues, only handle triggered airbags with protective gloves and goggles.
- In the case of contact with combustion residues, wash the affected skin with soap and water.
- In the case of eye contact, wash the eyes out with water.
General information
NOTE: Airbags - general
- A period of 10 seconds is required to enable the triggering unit to identify all faults in the system.
- In order to guarantee that every possible fault source is checked during the vehicle test, the ignition must be switched on for at least 10 seconds.
- The fault memory must be cleared following a fault in the airbag system and after it has been remedied.
- The replacement of a component must be noted in the Guarantee and Maintenance booklet.
- To do this, attach the documentation number in a free panel intended for that purpose.
- The documentation number is attached to the replacement part as a tear-off sticker.
- Exchanged airbag units or airbag modules must be taken into possession by the Porsche Centre or by a dealer authorised by Porsche and must not be handed over to the customer (customer has no right to possess them). They must be destroyed, disposed of or returned to the manufacturer in accordance with the explosives ordinance and the hazardous materials ordinance.
- When the steering wheel is exchanged, e.g. to install a steering wheel from the Tequipment product range, the airbag unit of the replaced steering wheel must be removed and destroyed, disposed of or returned to the manufacturer before the steering wheel is handed over to the customer.
- The airbag system is constantly monitored by a diagnosis unit in the triggering unit. Any fault is signalled by a warning light. The warning light for the airbag system lights up in the event of a fault. The airbag warning light lights for approx. 3 seconds after the ignition is switched on and goes out if no fault has been entered in the fault memory. If it lights up again, this indicates a fault in the system. The fault can be read out with the PIWIS Tester 9718.
NOTE: If a new component (e.g. sensor, airbag control unit, airbag unit) of the airbag system has to be installed, the new component will be supplied with a barcode sticker (tear-off label).
- Tear off the tear-off label -2- on the new component -1- and stick it under the heading Proof of airbag system check/component replacement in the Guarantee and Maintenance booklet.
- The replacement date and mileage must be documented and the booklet must be stamped with the dealer's stamp.
Component exchange after airbag/belt tensioner triggering
The following components must be removed and replaced after the airbag system is triggered:
Airbag unit, driver's side:
1. Contact unit.
2. Airbag unit, driver's side.
3. Triggering unit after the third time the airbag is triggered.
Airbag unit, passenger's side:
1. Airbag unit, passenger's side.
2. Triggering unit after the third time the airbag is triggered.
3. Instrument panel.
4. Check instrument panel bracket for deformation and replace if necessary.
Side-airbag unit, seat:
1. Side-airbag unit, seat.
6. Seat covering, deformed seat components.
7. Sensor for the side-airbag unit after the third time the side-airbag is triggered
Head airbag unit, door:
1. Head airbag unit.
9. Check door unit carrier for deformation and replace if necessary.
10. Sensor for the side-airbag unit after the third time the side-airbag is triggered
Belt tensioner:
1. All belt tensioner units.
Because it is difficult to visually determine if one or more belt tensioners has been triggered, check the following points:
- Using the PIWIS Tester 9718, read out the fault memory.
- Check plug connection on the belt tensioner for damage.
- Pull out the belt strap as far as possible and check for wear.
- Perform a function test on the automatic belt device.