airbag AUDI A4 1997 B5 / 1.G Airbag Service User Guide

69-47

Airbag system side airbags, safety
precautions


WARNING!

Checking, removing, installing and servicing
may ONLY be performed by qualified
personnel.
Following the same safety precautions as for
driver and passenger-side airbags.
Only use original equipment seat covers and
backrest covers that are approved for use
with side airbags (identified by a label on the
fabric).
Do not use extra seat covers over the seat as
they interfere with proper side airbag
operation.
Do not use seat cushion supports, mats or
similar since they impare seat occupant
sensor and airbags

Note:
The driver's seat does not have a seat occupant
sensor.
Pa
ge 12 of 75 Airba
gs, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD03.69.3

WARNING!

For vehicles without heated seats, a dummy
seat heating element is installed (heating
element without heating wire).
The seat backrest foam must not be cut out
in the area of the side airbag.
When installing, seam near side airbag must
be straight.
Pa
ge 13 of 75 Airba
gs, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD03.69.3

69-48

WARNING!

All upholstery clips must be replaced (metal
and plastic clips).
Only use genuine Audi replacement
upholstery clips.
When installing, all upholstery clips must be
installed at the same location from which
they were removed.
If the seat cover is damaged (rips, burn holes
etc) near the side airbag, always replace the
seat cover to ensure proper side airbag
inflation.
Seat cover may not be repaired in the area
near the side airbag (special thread and an
exact seam are used).
Always replace seat cover if side airbag has
deployed.
All damaged components must be replaced
after an accident. If no damage to the airbag
unit is found, the airbag unit can be reused.

Pa
ge 14 of 75 Airba
gs, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD03.69.3

Side airbag units have an expiration date
(see sticker on B-pillar). If side airbag units
are replaced, pull sticker with expiration date
off new side airbag unit and place it over old
sticker on B-pillar. Replace side airbag unit
and sticker after 14 years.
If there is no sticker on the B-pillar, airbag
change must be indicated in service plan.
If side airbag unit is replaced, pull airbag
number sticker off side airbag unit and stick
it to the seat pan.
Do not use a needle or other sharp objects to
poke around area near airbag and sensor
mat.
Pa
ge 15 of 75 Airba
gs, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD03.69.3

69-49

Additional safety precautions for side
curtain protection airbag


WARNING!

All safety precautions for the driver and
passenger-side airbags apply, as well as the
following:

Visually check the vehicle's trim panels for
damage before every installation.
Do not attempt any repair work on the
vehicle trim panels (top trim panels for A-
pillar, B-pillar, C-pillar and D-pillar).
Make sure the trim panel is securely fitted
during installation.
Side curtain airbags must only be folded at
its intended location (transition of roof to A-
pillar).
To carry out repairs behind the side curtain
airbag, always remove the entire unit first.
After removal, always carry the side curtain
airbag in the folded position.
Pa
ge 16 of 75 Airba
gs, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD03.69.3

69-50

WARNING!

After removal, place the side curtain airbag
into the transport container in the folded
position or lay on a clean, even surface (on a
blanket or in the luggage compartment).
After servicing the body of vehicle in vicinity
of airbag, check the body for welding beads,
deformations and chafe marks (compare to
opposite side of the vehicle).
Always hold the side curtain airbag
securely.
After removal, always fold the side curtain
airbag and grasp by the igniter (thumbs
toward E-connection).
Always keep one hand on the igniter.
Never twist, wind, bend, throw, spin, pull,
hang, squeeze, press, pinch or clamp the
side curtain airbag.
If any contamination penetrates into the
fabric (i.e. oil, grease, lacquer, paint or
solvent), the unit must always be replaced.
Pa
ge 17 of 75 Airba
gs, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD03.69.3

69-51


Airbag component locations, overview

Repair Manual, Body On Board Diagnostic
(OBD), Repair Group 01
1 -
Driver-side airbag unit
Removing m.y. 1998 page 69
-53
Removing m.y. 1998 page 69
-54
2 -
Driver-side airbag unit (sport steering
wheel)
Removing m.y. 1998 page 69
-58
Removing m.y. 1998 page 69
-61
3 -
Airbag control module -J234-
Removing and installing page 69
-74
4 -
Passenger-side airbag unit
Removing page 69
-70
Locking and activating (adaptation)
5 -
Seat occupant sensor
Removing and installing page 69
-83
Pa
ge 18 of 75 Airba
gs, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD03.69.3

69-52


6 -
Side airbag
Removing and installing page 69
-75
7 -
Crash sensor for side airbag
Removing and installing page 69
-85
8 -
Spiral spring
Removing and installing m.y. 1998
page 69
-64

Removing and installing from sport steering
wheel m.y. 1998 page 69
-67

Removing and installing m.y. 1998
page 69
-68

9 -
Data Link Connector (DLC)
Pa
ge 19 of 75 Airba
gs, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD03.69.3

69-53

Driver-side airbag unit ( m.y. 1998),
removing and installing


- Disconnect battery Ground (GND) strap.

Note:
Always follow airbag safety precautions when
working on airbag system components ( page
69
-40
).

-
Using T30 Torx bit, unbolt airbag unit on both left and right side of
steering wheel. Tightening torque: 6 Nm (53 in. lb)
- Carefully pull back airbag unit.
- Disconnect harness connector from airbag unit.

WARNING!
No one may be in vehicle when connecting battery Ground (GND)
strap. - Place airbag unit on suitable surface with impact padding facing up.
- When installing, make sure harness connector audibly engages
(clicks).
Pa
ge 20 of 75 Airba
gs, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD03.69.3

69-54


Driver-side airbag unit (m.y. 1998 ),
removing and installing

WARNING!
Follow all safety precautions when working on
the airbag page 69
-40
.
1 -
Steering wheel
Removing page 69
-57
- Secure loose cable at location indicated
by arrow -A-.
2 -
Harness connector for spiral spring
3 -
Harness connector for airbag unit
4 -
Multipoint socket
Always replace60 Nm (44 ft lb)
5 -
Airbag unit
6 -
Threaded bushing
7 -
Torx bolt (T30)
8 -
Torx wrench (T30)
Pa
ge 22 of 75 Airba
gs, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD03.69.3