Passive Occupant Detection System (PODS) (USA)

Airbag

CAUTION!
• Advanced airbags of passenger side in New Beetle sedan or convertible which only partially deployed, can cause severe injuries when second stage suddenly deploys.

• When working with airbag systems and transporting airbag units that have not deployed or have not completely deployed, strictly follow safety precautions.

• Never dispose of advanced passenger side airbag units of New Beetle sedan or convertible in waste or together with other materials to be scrapped.

Passive Occupant Detection System (PODS) (USA)

Removal

• All wires disconnected when removing the PODS must be reconnected correctly during installation.

• Before beginning work on the PODS, note how all wires are connected and routed.

- Disconnect the battery ground cable.

- Remove the front passenger seat (install the airbag adapter (VAS 5094)).

- Remove bolt on inside of seat - arrow -.

- Remove plastic rivet - 1 - at front part of seat.

- Remove plastic cover - 2 - by unhooking at the lower part of seat - 3 -.

- Remove the bolt - arrow -.

- Unhook the plastic part from the seat - arrow -

- Press the seat cover as depicted and pull off from the seat frame - arrow -

- Pull cover off from seat. To do this, remove the cover - arrow -.

• In this case, seat cover can be removed without removing backrest.

• Fold down backrest if necessary.

- Cut white plastic strap - 1 - on seat cushion.

• On replacement part, same strap must not be separated from cushion under any circumstance.

• To ease reassembly, note how heating element wires are routed.

- Remove heating element from seat cushion. Carefully separate both parts.

- Cut the clips - arrow -

- Disconnect sensor harness connector - 1 -

- Disconnect harness connector for belt tensioner sensor. Press connector downward and then inward to do so - arrow -

- Disconnect harness connector - 2 - and loosen from holding position.

- Remove the wires from the securing clips if necessary - 3 -

• Loosen locking mechanism on upper side of harness connector - 1 - of control module to reconnect replacement part.

• Before removing the wires from securing clips - 3 -, note the routing and connection.

- Remove the wires from the securing clips if necessary.

• Before removing the wires from the securing clips, note the routing and connection.

- Loosen the hose clips - arrows - from the bracket.

• Before loosening the clips, check whether the replacement part includes clips, otherwise reuse the clips.

• If the hose clips are missing, attach the replacement hose properly to route the hose as depicted in the figure.

- Remove Torx bolts - 1 -.

- Remove nuts - 2 -.

- Remove bolt - 4 -.

- Remove control module - 5 - from bracket - 3 -.

- Remove bracket - 3 -.

• Metal brackets must only be removed when damaged or the PODS and the pressure sensor do not fit through the opening.

- Pass control module and pressure sensor through hole - arrow -

• Illustration shows metal bracket after installation on seat.

- Remove sensor mat from seat shell.

Installation

Before installing, observe the following notes:

• Replacement mat must not be damaged when installing.

• Labels with notes and warnings on harness connectors must not be damaged or removed.

• Make sure that no connections from replacement kit are disconnected while installing.

• When reinstalling heating element in seat cushion, make sure secure seating.

• When reinstalling seat cover to seat cushion, make sure that velcro pads adhere firmly to each other.

• On replacement part, strap that connects sensor mat to seat cushion must not be damaged under any circumstance.

• After installing PODS, check with the help of (VAS 5051/5052 ) in instructions, if "basic setting for seat occupant detection " was performed on seat in order to match airbag ECU and seat sensor ECU, as well as "seat sensor for seat occupant detection on rear seats " and if empty seat parameters are set for seat sensor ECU.

- Further installation is performed in the reverse order of removal.

- Switch ignition on after installing all components.

- Close doors.

- Connect the battery ground cable.