RE21 Airbag Systems - I-CAR Repairability Technical Support Portal
Contents
1. _1 Use the same box that the replacement airbag module was shipped in There may be shipping instructions with the replacement module L Make sure the package is properly labeled for hazardous materials Hazardous material shipping information is in HMO1 abs 8 Vehicle Protection 8 1 Electronic Parts To protect computers and other sensitive parts from damage _1 Follow the vehicle maker s recommendations for recording and resetting electronic memories L Ensure that the ignition switch is in the LOCK position and the key is removed L Disconnect and isolate the negative battery cable and disarm the passive restraint system Follow the vehicle maker s procedural and wait time recommendations m Carefully remove computer modules when welding or heating within 300 mm 12 ora greater distance when recommended by the vehicle maker _1 Protect computer modules connectors and wiring from dirt heat static electricity and moisture _1 Loosen or remove any wiring harnesses or electrical parts that could be damaged during the repair process To protect diagnostic or resistor modules Avoid touching electrical terminals Use a static grounding strap when handling the module Do not store modules near electric welders or other high energy electrical equipment Do not perform electrical tests unless directed by a service manual Do not open the package of the replacement module until it is to be installed on the vehicle2. Inspect replacement modules for the proper part number and visible damage before installation C C O L L cont d Copyright 1999 Inter Industry Conference On Auto Collision Repair v 4 0 RE21 6 eis 8 Vehicle Protection cont d 8 2 Replacing Airbag System Parts When replacing airbag system parts L1 Match parts identically to the vehicle and the location _1 Use all replacement fasteners that come with the part Do not reuse old fasteners or substitute other fasteners _1 Torque fasteners to the vehicle maker s recommendations _1 Obtain and follow the vehicle maker s service procedures P 9 Repair Procedure Do not attempt to repair airbag system parts unless recommended by the vehicle maker Repairs are generally limited to wiring harnesses Do not refinish airbag covers Do not plastic weld or perform adhesive repairs on the airbag cover 9 1 Cleanup After Deployment To clean the inside of the vehicle after an airbag deployment 1 Tape the airbag exhaust vents to contain the powder 2 Vacuum the vehicle interior working from the outside in 3 While vacuuming the vents briefly run the blower fan at low speed to remove powder from the vents 4 Vacuum the interior again 5 Wrap the deployed airbags in a plastic bag and dispose of as non hazardous material C O OO 9 2 Deployed System To service airbag systems following a deployment 1 Disarm the passive restraint system Follow the vehicl
3. Tungs Airbag Systems Procedures For Collision Repair Copyright 1999 Inter Industry Conference On Auto Collision Repair v 4 0 1 Description This procedure describes methods for the repair replacement inspection and testing of airbag systems A 2 Purpose The purpose of this procedure is to provide industry accepted requirements for performing high quality repair of airbag systems This procedure is intended for use by professionals who are qualified through training and experience l Referenced Documents The following documents are considered part of this procedure by reference 3 1 Procedures HM0O1 ME01 PS01 REO1 RE31 RE41 Hazardous Materials Three Dimensional Measuring Personnel Safety Seat Belt Tensioners Seat Belt Knee Bolster 3 2 Other Information Equipment specific information Vehicle specific diagnostic information Vehicle specific repair information I CAR information DN 4 Equipment And Material Requirements 4 1 Equipment The use of this equipment is included in this procedure _I digital volt ohm meter DVOM L jumper wires _1 electro static discharge ESD strap Caution Ensure that the DVOM has an output less than 10 mA 0 01 A on the lowest ohmmeter range with the probes shorted Various airbag systems may require these additional items C C C C L L airbag simulator or load tool shorting bar or connector universal or vehicle specific bre
4. aced external airbag sensors for these conditions sensor mounting locations at the proper dimensional specification mounting brackets properly positioned sensor arrows pointing forward fasteners torqued to the vehicle maker s recommendations proper ground connections proper routing of wire harnesses and pigtails O O C C O Correct any defects 11 2 System Operation Check To verify that an airbag system is operating properly 11 1 Install a scan tool or jumper wire to allow reading of current and history codes Follow the vehicle maker s recommendations 2 Turn the ignition switch ON Observe the operation of the airbag dash lamp Make sure the lamp is displaying the proper sequence 4 Ifthe dash lamp indicates a system problem follow the vehicle maker s diagnostic method using the chart in the service manual Not all systems use trouble codes A specialty tester or scan tool may be required for diagnosing the system 5 Make the necessary repairs and repeat steps 1 4 6 Clear all stored codes using the vehicle maker s recommended procedure and equipment Disarm the system following the vehicle maker s recommendations Remove the airbag simulator or load tool if installed 9 Install the airbag modules 10 Re activate the system following the vehicle maker s recommendations 11 Verify that the dash lamp goes out 12 Road test the vehicle to check the dash lamp and electrical accessories for
5. akout box universal or vehicle specific scan tool vehicle specific airbag system tester vehicle specific test harness special wire repair tools cont d Copyright 1999 Inter Industry Conference On Auto Collision Repair v 4 0 RE21 2 YY 4 Equipment And Material Requirements cont d Follow the vehicle maker s recommendations This equipment may be required for manually deploying airbag modules vehicle specific manual deployment tool switch or special deployment tool 6 m 20 ft wiring harness charged battery A 5 Damage Analysis 5 1 Airbag Parts Inspect these airbag system parts for damage C C L airbag module and trim cover airbag system labels clock spring diagnostic backup power and resistor modules and brackets sensors and sensor brackets wiring harnesses and connectors knee bolster or diverter see RE41 seat belts see RE01 seat belt tensioners if equipped see RE31 C C O O O O O C If an airbag deployment occurred refer to the vehicle maker s information for parts that must be inspected tested and replaced Vehicle makers may require replacement of all seat belts in use during a collision of specified severity or if there was an airbag deployment Follow the vehicle maker s recommendations Damaged airbag system parts must be replaced with new parts Vehicle makers may allow minor repairs of the wiring harness Follow the vehicle maker s recommendations 5 2 Rela
6. e maker s procedural and wait time recommendations 2 Clean the vehicle interior and dispose of the deployed airbags See 9 1 3 Install an airbag module simulator or load tool if necessary Follow the vehicle maker s recommendations Perform the necessary damage repairs Make sure the body structure and sensor mounting locations are properly restored 5 Follow the vehicle maker s recommendations for post deployment inspection and replacement of parts 6 Re activate the system Keep the simulator or load tool installed if applicable 7 Check the system operation See 11 2 Uo L L L L L aN cont d Copyright 1999 Inter Industry Conference On Auto Collision Repair v 4 0 RE21 7 p 9 Repair Procedure cont d 9 3 Undeployed System To service airbag systems when the airbags have not deployed m Oo O ih Disarm the passive restraint system Follow the vehicle maker s procedural and wait time recommendations Use an airbag module simulator or load tool if necessary Perform the necessary damage repairs Make sure the body structure and sensor mounting locations are restored Visually inspect airbag system parts for damage Replace the parts as required by the vehicle maker If a non deployed airbag will be replaced it must be manually deployed following the vehicle maker s recommendations See 9 4 Re activate the system Keep the simulator or load tool installed if applicable Check
7. es Always carry the airbag module with the trim cover facing away from your body Do not place an airbag module on the floor bench or storage shelves with the trim cover facing down Do not carry any system parts by the wiring harness or pigtail Avoid contact with sodium azide pellets Do not expose the pellets to sparks fire or moisture Dispose of the pellets as hazardous waste See HM01 _1 Follow the vehicle maker s recommendations if a part is dropped or shows visible signs of damage _1 Some airbag sensors and control modules contain mercury Dispose of these sensors as hazardous waste See HM01 C C L L 6 5 Safety With Sodium Hydroxide To prevent exposure to sodium hydroxide during airbag cleanup Wear rubber gloves safety glasses and a long sleeved shirt Avoid rubbing eyes eating or smoking until hands have been washed Wash hands with mild soap and water after cleanup Avoid kneeling or sitting on surfaces that have not been cleaned Wear the proper respirator when sodium hydroxide powder may be present C C C L Copyright 1999 Inter Industry Conference On Auto Collision Repair v 4 0 RE21 5 CJ 7 Environmental Safety 7 1 Hazardous Waste Hazardous waste safety information is in HM01 7 2 Shipping Undeployed Airbag Modules Do not dispose of an undeployed airbag If it cannot be manually deployed return the undeployed airbag module to the vehicle maker Follow these requirements
8. proper operation O oc w CUCC oo N If the dash lamp remains on or continues to flash there are still problems in the system This does NOT mean the system is disabled Make the necessary repairs and repeat steps 1 4 Copyright 1999 Inter Industry Conference On Auto Collision Repair v 4 0 RE21 9
9. ted And Adjacent Parts Inspect the following related and adjacent parts for damage dash panel and support brackets inner door trim panels instrument panel steering column braces seats and headrests C C L cont d Copyright 1999 Inter Industry Conference On Auto Collision Repair v 4 0 RE21 3 A 5 Damage Analysis cont d steering column steering column levers and switches steering wheel steering wheel mounted accessories such as horn etc windshield for damage and proper adhesion to the opening integrated child seat if equipped see RE51 sensor mounting locations C C O C L L Some vehicle makers require replacement of the steering wheel or the entire steering column following an airbag deployment 5 3 System Operation Check If there has not been an airbag deployment and there is no visible damage to the airbag system parts check the operation of the system See 11 2 6 Personnel Safety 6 1 General Safety General safety information is in PS01 6 2 Safety With Non Deployed Airbags Before working on a collision damaged vehicle with an undeployed airbag disarm the passive restraint system following the vehicle maker s procedure To prevent injury from an accidental deployment during repairs even if the system is disarmed Do not work in the area where the airbags would deploy Keep areas in front of the airbag modules clear of loose objects Use an airbag module simulator or load
10. the system operation See 11 2 9 4 Manual Deployment To manually deploy an airbag module outside of the vehicle o N UO OOC O l NONA o Follow the vehicle maker s recommendations for connecting the wiring harness and other special equipment to the airbag module Disconnect the wiring and remove the airbag module from the vehicle Place the airbag module with the trim cover facing up on a bench or other surface away from any loose objects or heat sources or secure the module with heavy wire to a spare tire to prevent recoil Clear a space at least 2 m 6 ft in diameter where the airbag module will be deployed Put on appropriate hearing and eye protection Stretch the wiring harness to its full length and reconnect the module to the harness Touch the two wiring harness leads to the power source The airbag should immediately deploy After the module has cooled dispose of it as non hazardous material If the module cannot be deployed ship it to the vehicle maker as described in 7 2 9 5 Wire Repair Some vehicle makers do not allow wires to be repaired Follow the vehicle maker s recommendations for making wire repairs Copyright 1999 Inter Industry Conference On Auto Collision Repair v 4 0 RE21 8 amp 10 Use Of Recycled Salvage Parts Do not install salvage airbag system parts eo 11 Inspection And Testing 11 1 Inspection Of Replaced External Sensors Inspect the repl
11. tool during testing if required by the vehicle maker Be aware that electronic memory savers supply enough power to deploy an airbag Do not apply electrical power to any part unless directed by a service manual This includes using an ohmmeter or other self powered test equipment C O C L cont d Copyright 1999 Inter Industry Conference On Auto Collision Repair v 4 0 RE21 4 6 Personnel Safety cont d 6 3 Safety When Manually Deploying Airbags To prevent injury when manually deploying an airbag _J Whenever possible deploy the airbag outside of the vehicle Follow the vehicle maker s recommendations When deploying the airbag inside the vehicle make sure personnel tools and equipment are removed from inside the vehicle Follow the vehicle maker s procedures and equipment recommendations Wear the proper hearing and eye protection Deploy the airbag with the trim cover facing up Stay at least 2 m 6 ft from the airbag Allow the airbag module to cool Do not deploy the airbag while it is attached to an unbolted steering column C C L L L If an undeployed airbag cannot be deployed using manual deployment procedures it may have to be returned to the vehicle maker See 7 2 6 4 Safety With Replacement Airbags To prevent injury when storing or handling replacement airbags Store a replacement airbag module in a clean dry place Make sure the module is not exposed to extreme temperatur
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