Volkswagen Transporter 2016 Instruction manual

Workshop Manual

Transporter 2016 ➤

General body repairs, interior

Edition 03.2020

Service

Service Department. Technical Information

List of Workshop Manual Repair Groups

Repair Group

00 - Technical data

68 - Interior equipment

69 - Passenger protection

70 - Trim, insulation

72 - Seat frames

74 - Seat - padding, covers

Technical information should always be available to the foremen and mechanics, because their

careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and

safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a

matter of course, be observed.

Service

No reproduction without prior agreement from publisher.

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2

1.2 Safety precautions when using testers and measuring instruments during a road test . . . . 3

1.3 Safety measures when working with pyrotechnic components . . . . . . . . . . . . . . . . . . . . . . 3

1.4 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units

(pyrotechnic components) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5 Additional safety regulations for side airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.6 Safety instructions for airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.7 Additional safety instructions for curtain airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.8 Deactivating the airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.9 Safety regulations for crash sensors (pressure sensors) for front side airbags . . . . . . . . . . 7

1.10 Additional safety instructions for repair work on seat occupied recognition for front passenger

airbag deactivation - country-specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.11 Measures for seat occupied recognition for front passenger airbag deactivation following an

accident - country-specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.12 Renewing pyrotechnic, electrical and mechanical components of the restraint system after

an accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.13 Checking airbag securing parts after an accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.14 Accident without airbag triggering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.15 Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.16 Checking seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.17 Check belt webbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.18 Checking inertia reel (locking mechanism) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.19 Visually checking belt buckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.20 Check operation of belt buckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.21 Checking belt relays, and buckle tongues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.22 Checking securing parts and anchorage points after an accident . . . . . . . . . . . . . . . . . . . . 14

1.23 Checking seat belt restraint function of seat belt for holding additional child seats (not for

driver seat belt) - country-specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.24 Checking child seat anchors after an accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.25 Safety instructions for automatic anti-dazzle interior mirror . . . . . . . . . . . . . . . . . . . . . . . . 15

1.26 Safety precautions when working in vicinity of high-voltage components . . . . . . . . . . . . . . 15

1.27 Safety precautions when working on a high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . 15

2 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3 Hazard classification of high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

68 - Interior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1 Compartments/covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.1 Overview of fitting locations - storage compartments/covers . . . . . . . . . . . . . . . . . . . . . . . . 20

1.2 Assembly overview - driver side dash panel cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.3 Assembly overview - steering column trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.4 Assembly overview - glove compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.5 Assembly overview - storage compartment in headliner . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.6 Removing and installing dash panel cover on driver side . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.7 Removing and installing dash panel insert trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.8 Removing and installing upper steering column trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.9 Removing and installing lower steering column trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.10 Removing and installing footwell cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.11 Removing and installing glove compartment opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.12 Removing and installing glove compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Transporter 2016 ➤

General body repairs, interior - Edition 03.2020

Contents i

1.13 Removing and installing dash panel compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.14 Removing and installing headliner storage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.1 Assembly overview - partition, panel van . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.2 Assembly overview - grab handles on pillar trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.3 Assembly overview – ashtray/cup holder, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.4 Assembly overview - sun blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.5 Removing and installing bracket for net partition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.6 Removing and installing sun visor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.7 Removing and installing roof grab handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

2.8 Removing and installing grab handles on pillar trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.9 Removing and installing partition, panel van . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.10 Removing and installing ashtray/cup holder, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.11 Removing and installing sun blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3 Centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.1 Assembly overview - centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.2 Removing and installing centre console cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.3 Removing and installing centre console insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3.4 Removing and installing centre console front storage compartment . . . . . . . . . . . . . . . . . . 63

3.5 Removing and installing centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.6 Removing and installing cup holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

4 Front centre armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4.1 Removing and installing front centre armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5 On inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

5.1 Assembly overview - interior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

5.2 Removing and installing interior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6 Table modules, Multivan/Business . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

6.1 Assembly overview - table modules, table module in seat rails . . . . . . . . . . . . . . . . . . . . . . 76

6.2 Assembly overview - table modules, table module in side panel . . . . . . . . . . . . . . . . . . . . 79

6.3 Table module in seat rails, removing and installing table module . . . . . . . . . . . . . . . . . . . . 80

6.4 Table module in seat rails, removing and installing table top . . . . . . . . . . . . . . . . . . . . . . . . 82

6.5 Table module in seat rails, removing and installing cup holder . . . . . . . . . . . . . . . . . . . . . . 83

6.6 Table module in seat rails, removing and installing ashtray . . . . . . . . . . . . . . . . . . . . . . . . 84

6.7 Table module in seat rails, removing and installing drawer . . . . . . . . . . . . . . . . . . . . . . . . 85

6.8 Table module in seat rails, removing and installing front trim . . . . . . . . . . . . . . . . . . . . . . 86

6.9 Table module in seat rails, removing and installing rear trim . . . . . . . . . . . . . . . . . . . . . . . . 87

6.10 Table module in seat rails, removing and installing side trim with magazine rack . . . . . . . . 87

6.11 Table module in seat rails, removing and installing rollers and support . . . . . . . . . . . . . . . . 89

6.12 Removing and installing table module in sidewall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

7 Seat rail systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

7.1 Assembly overview - seat rail systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

7.2 Removing and installing seat rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

69 - Passenger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

1 Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

1.1 Assembly overview - front three-point seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

1.2 Assembly overview - rear outer three-point seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

1.3 Removing and installing front three-point seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

1.4 Removing and installing rear three-point seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1.5 Removing and installing rear outer belt end fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1.6 Removing and installing belt height adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1.7 Removing and installing front belt buckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

1.8 Removing and installing rear belt buckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

2 Child seat anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

2.1 Assembly overview - front child seat anchors, Multivan/Business . . . . . . . . . . . . . . . . . . . . 142

Transporter 2016 ➤

General body repairs, interior - Edition 03.2020

ii Contents

2.2 Assembly overview - rear child seat anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

3 Airbag system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

3.1 Overview of fitting locations - airbag system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

4 Airbag control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

4.1 Assembly overview - airbag control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

4.2 Removing and installing airbag control unit J234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

5 Driver's airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

5.1 Removing and installing airbag unit with igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

5.2 Removing and installing return spring with slip ring (coil connector) . . . . . . . . . . . . . . . . . . 153

6 Front passenger side airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

6.1 Removing and installing front passenger side airbag unit with igniter . . . . . . . . . . . . . . . . 154

6.2 Removing and installing key-operated switch to deactivate front passenger side airbag . . 156

7 Side airbags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

7.1 Removing and installing front side airbag with igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

8 Curtain airbags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

8.1 Removing and installing curtain airbag with igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

9 Airbag crash sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

9.1 Overview of fitting locations - airbag crash sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

9.2 Removing and installing side airbag crash sensors on driver side G179 / G180 . . . . . . . . 173

9.3 Removing and installing rear side airbag crash sensors on driver side G256 / G257 . . . . 174

70 - Trim, insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

1 Front door trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

1.1 Assembly overview - front door trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

1.2 Removing and installing front door trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

2 Rear door trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

2.1 Assembly overview - rear door trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

2.2 Assembly overview - sun blind for door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

2.3 Removing and installing rear door trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

2.4 Removing and installing sun blind for door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

3 Dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

3.1 Assembly overview - dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

3.2 Assembly overview - auxiliary console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

3.3 Removing and installing dash panel end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

3.4 Removing and installing dash panel trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

3.5 Removing and installing dash panel insert trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

3.6 Removing and installing loudspeaker trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

3.7 Removing and installing light switch trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

3.8 Removing and installing radio/navigation system mounting frame . . . . . . . . . . . . . . . . . . 205

3.9 Removing and installing mounting frame of operating unit of heater and air conditioning

unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

3.10 Removing and installing dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

3.11 Removing and installing loudspeaker mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

3.12 Removing and installing cup holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

3.13 Removing and installing dash panel vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

3.14 Removing and installing auxiliary console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

3.15 Installing “No Airbag” sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

4 Central tube for dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

4.1 Assembly overview - central tube for dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

4.2 Removing and installing central tube for dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

5 Interior trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

5.1 Removing and installing sill panel moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

5.2 Removing and installing A-pillar trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

5.3 Removing and installing B-pillar trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

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5.4 Removing and installing C-pillar trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

5.5 Removing and installing D-pillar trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

5.6 Removing and installing side trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

5.7 Removing and installing floor covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

6 Luggage compartment trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

6.1 Assembly overview - lower rear lid trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

6.2 Assembly overview - upper rear lid trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

6.3 Removing and installing lower rear lid trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

6.4 Removing and installing upper rear lid trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

6.5 Removing and installing luggage compartment side trim . . . . . . . . . . . . . . . . . . . . . . . . . . 259

6.6 Removing and installing luggage compartment floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

6.7 Removing and installing lock carrier trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

6.8 Removing and installing fastening rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

7 Roof trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

7.1 Assembly overview – moulded headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

7.2 Removing and installing roof end strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

7.3 Removing and installing moulded headlining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

72 - Seat frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

1 Overview of seat variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

1.1 Overview of fitting locations - seat variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

2 Front seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

2.1 Overview of fitting locations - electrical and electronic components . . . . . . . . . . . . . . . . . . 287

2.2 Assembly overview - front seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

2.3 Assembly overview – front backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

2.4 Assembly overview - head restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

2.5 Assembly overview - seat pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

2.6 Removing and installing front seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

2.7 Retrofitting double bench seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

2.8 Connecting and disconnecting airbag adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

2.9 Removing and installing handle for seat height adjustment . . . . . . . . . . . . . . . . . . . . . . . . 318

2.10 Removing and installing seat height adjustment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

2.11 Removing and installing trim, front seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

2.12 Removing and installing lumbar support adjustment unit . . . . . . . . . . . . . . . . . . . . . . . . . . 331

2.13 Removing and installing lumbar support adjustment motor V125 / V126 / V129 / V130 . . 333

2.14 Removing and installing backrest adjustment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

2.15 Removing and handle for installing backrest adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 335

2.16 Removing and installing front backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

2.17 Removing and installing head restraint guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

2.18 Removing and installing seat adjustment operating unit, memory setting, lumbar support

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

2.19 Removing and installing seat and steering column adjustment control unit with memory J136

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

3 Rear seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

3.1 Assembly overview - bench seat/individual seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

3.2 Assembly overview - head restraint, Multivan/Business . . . . . . . . . . . . . . . . . . . . . . . . . . 360

3.3 Removing and installing bench seat/individual seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

3.4 Removing and installing rear seat backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

3.5 Removing and installing centre armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380

3.6 Trims of individual seat in 2nd row, Multivan/Business . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

4 Rear seats, Business . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394

4.1 Assembly overview - pneumatic lumbar support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394

4.2 Removing and installing bench seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396

4.3 Removing and installing seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

4.4 Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

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4.5 Removing and installing head restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

4.6 Removing and installing trim for head restraint adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . 408

4.7 Removing and installing backrest trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411

4.8 Removing and installing upper trim of front bench seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

4.9 Removing and installing lower trim of front bench seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414

4.10 Removing and installing upper trim of rear bench seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415

4.11 Removing and installing lower trim of rear bench seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

4.12 Removing and installing seat adjustment control element . . . . . . . . . . . . . . . . . . . . . . . . . . 418

4.13 Removing and installing control element bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424

4.14 Removing and installing seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426

4.15 Removing and installing belt buckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

4.16 Removing and installing centre console cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431

74 - Seat - padding, covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

1 Front seat covers and padding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

1.1 Assembly overview - seat heating element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

1.2 Assembly overview - backrest heater element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435

1.3 Removing and installing cover and padding for seat pan . . . . . . . . . . . . . . . . . . . . . . . . . . 436

1.4 Removing and installing backrest cover and backrest padding . . . . . . . . . . . . . . . . . . . . . . 444

1.5 Separating cover and padding on seat pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450

1.6 Separating cover and padding on backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450

1.7 Removing and installing seat heating element Z6 / Z8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452

1.8 Removing and installing backrest heating element Z7 / Z9 . . . . . . . . . . . . . . . . . . . . . . . . 455

2 Rear seat covers and padding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460

2.1 Removing and installing covers and padding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460

2.2 Separating cover and padding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477

3 Rear seat covers and padding, Business . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513

3.1 Removing and installing seat cover and padding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513

3.2 Removing and installing backrest cover and padding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518

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vi Contents

00 – Technical data

1 Safety information

(VRL014087; Edition 03.2020)

WARNING

If the vehicle has been converted by ABT e-Line, it is possible

that the repair instructions provided below are no longer valid.

• In this case, please always refer to the repair instructions

from ABT e-Line, available in ElsaPro in the tab “Super‐

structures and modifications”.

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1. Safety information 1

⇒ “1.1 Safety measures when working on vehicles with a start/

stop system”, page 2

⇒ “1.2 Safety precautions when using testers and measuring in‐

struments during a road test”, page 3

⇒ “1.3 Safety measures when working with pyrotechnic compo‐

nents”, page 3

⇒ “1.27 Safety precautions when working on a high-voltage sys‐

tem”, page 15

⇒ “1.26 Safety precautions when working in vicinity of high-volt‐

age components”, page 15

⇒ “1.4 Storage, transportation and disposal of airbag, belt ten‐

sioner and battery isolator units (pyrotechnic components)”, page

⇒ “1.5 Additional safety regulations for side airbag”, page 5

⇒ “1.6 Safety instructions for airbag”, page 6

⇒ “1.7 Additional safety instructions for curtain airbag”,

page 6

⇒ “1.8 Deactivating the airbag”, page 7

⇒ “1.9 Safety regulations for crash sensors (pressure sensors) for

front side airbags”, page 7

⇒ “1.10 Additional safety instructions for repair work on seat oc‐

cupied recognition for front passenger airbag deactivation - coun‐

try-specific”, page 8

⇒ “1.11 Measures for seat occupied recognition for front passen‐

ger airbag deactivation following an accident - country-specific”,

page 9

⇒ “1.12 Renewing pyrotechnic, electrical and mechanical com‐

ponents of the restraint system after an accident”, page 9

⇒ “1.13 Checking airbag securing parts after an accident”,

page 10

⇒ “1.14 Accident without airbag triggering”, page 11

⇒ “1.15 Seat belts”, page 11

⇒ “1.16 Checking seat belts”, page 11

⇒ “1.17 Check belt webbing”, page 12

⇒ “1.18 Checking inertia reel (locking mechanism)”, page 12

⇒ “1.19 Visually checking belt buckle”, page 13

⇒ “1.20 Check operation of belt buckle”, page 13

⇒ “1.21 Checking belt relays, and buckle tongues”, page 13

⇒ “1.22 Checking securing parts and anchorage points after an

accident”, page 14

⇒ “1.23 Checking seat belt restraint function of seat belt for hold‐

ing additional child seats (not for driver seat belt) - country-

specific”, page 14

⇒ “1.24 Checking child seat anchors after an accident”,

page 14

⇒ “1.25 Safety instructions for automatic anti-dazzle interior mir‐

ror”, page 15

1.1 Safety measures when working on ve‐

hicles with a start/stop system

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2 Rep. gr.00 - Technical data

Observe the following when working on vehicles with a start/stop

system:

WARNING

Injury hazard as a result of automatic engine start in vehicles

with start/stop system

♦ In vehicles with an activated start/stop system (indicated

by a message in the dash panel insert), the engine may

start automatically.

♦ When working on the vehicle, always make sure that the

start/stop system is deactivated (switch off the ignition;

switch the ignition on again if necessary).

1.2 Safety precautions when using testers

and measuring instruments during a

road test

WARNING

Risk of injury from unsecured testing and measuring instru‐

ments

When the front passenger airbag is triggered in an accident,

insufficiently secured testing and measuring instruments be‐

come dangerous projectiles.

♦ Secure testing and measuring instruments on the rear

seat or

♦ have a second person operate the test and measuring

equipment on the rear seat.

1.3 Safety measures when working with py‐

rotechnic components

WARNING

Pyrotechnic components can trigger unintentionally.

♦ Risk of injury.

♦ Discharge any static electricity in body by briefly touching

door striker plate.

The following are pyrotechnic components:

♦ Airbag units

♦ Belt tensioner

♦ Belt force limiters (depending on vehicle equipment level)

♦ Battery isolation elements (depending on vehicle equipment

level)

♦ Trigger for pedestrian protection

General notes

♦ Testing, removing, installing and repair work may only be per‐

formed by qualified personnel.

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1. Safety information 3

♦ There are no replacement intervals for airbag units.

♦ Under no circumstances should checks be carried out with a

test lamp, voltmeter or ohmmeter.

♦ Pyrotechnic components may only be checked in installed

state and with vehicle diagnosis, testing and information sys‐

tems approved by the manufacturer.

♦ When working on pyrotechnic components and airbag control

unit - J234- , battery earth strap must be disconnected with

ignition switched ON. Then, cover the negative terminal.

♦ A waiting time of 10 seconds is necessary after disconnecting

the battery.

♦ Battery must be connected with ignition SWITCHED ON.

When doing this, there should be no-one inside the vehicle.

♦ If the ignition is not switched on after reconnecting the battery,

the ignition may only be switched on (key/button) from the

driver's seat with the seat set in the rearmost position.

♦ Observe required procedures after connecting battery ⇒ Elec‐

trical system; Rep. gr. 27 ; Battery; Disconnecting and con‐

necting battery .

♦ Before handling pyrotechnic components of the restraint sys‐

tem, for example before separating an electrical connection,

the mechanic must electrostatically discharge himself/herself.

Electrostatic discharge is achieved by touching earthed met‐

allic parts, such as the door striker plate.

♦ Wash hands after coming into contact with triggered pyrotech‐

nic components of restraint system.

♦ Pyrotechnic components must not be opened or repaired; al‐

ways use new parts (risk of injury).

♦ Pyrotechnic components that have been dropped onto a hard

surface or show signs of damage must not be installed in a

vehicle.

♦ Pyrotechnic components must be installed immediately after

they have been removed from their packaging.

♦ If work is interrupted, the pyrotechnic component must be

stored back in its packaging.

♦ Leaving the pyrotechnic component unattended is prohibited.

♦ When connecting pyrotechnic components of the restraint

system, only the person carrying out the work may be inside

the vehicle.

♦ Pyrotechnic components must not come into contact with

grease, cleaning solution or similar.

♦ The airbag unit must be renewed if any contamination such as

oil, grease, paint or solvent penetrates the fabric.

♦ Pyrotechnic components must not be subjected to tempera‐

tures above 100°C, even for short periods.

Special instructions for driver and front passenger airbags

♦ Removed driver and front passenger airbag units must be

stored with padded side upwards.

It is essential to carry out work in the following sequence when

renewing airbag units:

1 - Remove old airbag unit and place to one side with padded

side upwards.

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4 Rep. gr.00 - Technical data

2 - Remove new airbag unit from transport packaging and place

to one side with padded side upwards.

3 - Immediately place old airbag unit in transport packaging.

4 - Install new airbag unit in vehicle.

Special instructions for belt tensioners

♦ Belt tensioner units must be handled with extreme caution

during removal and installation. If handled incorrectly, there is

a high risk of injury and damage in relation to the belt tensioner

units.

♦ Belt tensioner units which are mechanically damaged (dents,

fractures) must be renewed.

♦ Never point open end of belt tensioner at another person.

♦ When connecting the belt tensioner unit, all mechanical parts

(including those of the 3-point seat belt) must be properly at‐

tached. If connection of the belt tensioner unit is hindered due

to tight conditions, the belt strap must be rolled up completely

before connecting. In this case there is no heightened risk of

safety as long as the additional safety instructions are heeded.

Essentially this is aimed at battery disconnection and electro‐

static discharge of the fitter prior to connection of the belt

tensioner unit.

♦ Depending on the crash intensity, it is possible that the belt

tensioner was triggered but the belt force limiter did NOT ig‐

nite. These parts are to be treated as unignited components!

1.4 Storage, transportation and disposal of

airbag, belt tensioner and battery isola‐

tor units (pyrotechnic components)

♦ Storage must comply with the relevant national legislation.

♦ Transportation is subject to national and international regula‐

tions that govern packaging, marking, labelling and freight

documentation in detail.

♦ Untriggered pyrotechnic components must be disposed of

correctly in the original packaging in accordance with national

legislation. Contact your importer if in any doubt.

♦ Only completely ignited pyrotechnic components may be dis‐

posed of through the commercial waste system.

WARNING

♦ This does not apply to belt tensioners which are operated

by a Wankel type pump. Those must be disposed of like

pyrotechnic components which were not triggered (e.g.

airbags, seat belts, pyrotechnic battery isolators).

♦ Reason: On belt tensioners which are operated by a Wan‐

kel type pump it is not possible to verify, using workshop

means, if all igniters have been triggered.

1.5 Additional safety regulations for side air‐

bag

♦ The use of genuine seat covers is recommended.

♦ Under no circumstances may seat covers be fitted which have

not been specifically approved for use on Volkswagen seats

with side airbags.

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1. Safety information 5

♦ The foam padding in the seat backrest must not be cut away

in the vicinity of the side airbag.

♦ When installing, make sure the seam for the side airbag is

straight.

♦ All upholstery clips (metal and plastic clips) must be renewed.

♦ The use of genuine upholstery clips is recommended.

♦ When installing, all upholstery clips must be fitted in the same

positions as the original ones.

♦ If the seat cover fabric is damaged (tears, burn marks, etc.) in

the vicinity of the side airbag, the cover must always be re‐

placed for safety reasons, as otherwise the side airbag will not

inflate properly.

♦ Repairs may not be carried out on the backrest cover in the

area of the side airbag (because of the special thread and

precisely defined seam).

♦ Always renew the backrest padding after the side airbags have

been triggered.

♦ All damaged components must be renewed after an accident.

The original airbag unit can still be used if no signs of damage

are found.

♦ If side airbag units are renewed, the sticker for the airbag

number must be removed from the new side airbag unit and

stuck over the old sticker on the seat pan.

♦ Never poke upholstery needles or any other sharp objects

through the seat cover fabric in the vicinity of the airbag, seat

occupied sensor, front passenger side - G128- and the seat

occupied sensor mat.

1.6 Safety instructions for airbag

♦ Removed driver and front passenger airbag units must be

stored with padded side upwards.

It is essential to carry out work in the following sequence when

renewing airbag units:

1 - Remove old airbag unit and place to one side with padded

side upwards.

2 - Remove new airbag unit from transport packaging and place

to one side with padded side upwards.

3 - Immediately place old airbag unit in transport packaging.

4 - Install new airbag unit in vehicle.

1.7 Additional safety instructions for curtain

airbag

♦ Inspect trims for damage prior to installing them.

♦ Repair work on trims is not permissible (upper A-pillar trim, B-

pillar trim, C-pillar trim and D-pillar trim).

♦ Ensure proper seating of trims when installing them.

♦ When performing repair work behind the curtain airbag, al‐

ways remove the entire module.

♦ To prevent any potential damage during removal and instal‐

lation, curtain airbags must be handled with extreme caution.

♦ Place removed curtain airbag modules in packaging or on a

clean, flat surface on a cover.

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6 Rep. gr.00 - Technical data

♦ After body repairs in vicinity of curtain airbag, check body for

weld spray droplets, deformations and areas of chafing (com‐

pare with opposite side if necessary).

♦ Until gas generator is screwed in place, always hold it firmly

by hand when handling (transportation, removal and installa‐

tion etc.).

♦ Never twist, kink, throw, shake, pull, hang, squeeze, press,

pinch or clamp any curtain airbag modules.

♦ Folding is acceptable as long as no damage is caused (in par‐

ticular to the protective sleeve).

1.8 Deactivating the airbag

WARNING

The prerequisites for deactivating one or more airbag units

have been published in the “Technical Service Handbook”.

Airbags and belt tensioners are important elements of a

vehicle’s safety concept. These systems should therefore only

be switched off in exceptional circumstances.

A DISS request must always be created for any deactivation.

Any deactivation of the airbag units is subject to compulsory

registration.

Failure to comply means that the workshop responsible will

bear full responsibility for subsequent damage and costs.

Ensure when deactivating that the customer is made aware of

the vehicle’s status. The customer must also be informed that

he will be unable to claim against the manufacturer for dam‐

ages resulting from accidents in which injuries could have been

prevented with the airbags. The customer bears sole respon‐

sibility for the conversion.

Please observe the procedure in the workshop manual in all

instances.

In the “Technical Service Handbook”, the “Procedure ID” or the

“Technical solution number” for the deactivation of airbag units is:

“2022327/2”.

Or search for “Deactivating airbag units” or “Deactivating airbag”.

ElsaPro:

- Technical service handbook

- Service information

- Passenger protection, pedestrian protection

- Deactivation of airbag units/child seat, seat installation etc.

1.9 Safety regulations for crash sensors

(pressure sensors) for front side airbags

The side airbag crash sensors respond to changes in pressure

and must therefore be treated with particular caution. Observe the

following:

♦ The correct installation position is vitally important: install only

in the specified location in the doors.

♦ Protect the crash sensor against mechanical shocks and im‐

pacts: any crash sensors which have been dropped must no

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longer be used. Remove the crash sensor when carrying out

bodywork on the door.

♦ The crash sensor is matched to the volume of air inside the

door: deformation of the door, resulting in a reduction in the

air space in the door, impairs the function of the crash sensor.

♦ Avoid any major soiling of the crash sensor: do not use com‐

pressed air in the vicinity of the crash sensor. Protect the crash

sensor against swarf from filing or drilling (example, during

retrofitting of door speakers). Do not use cavity sealants or

spray oil in the vicinity of the crash sensor.

♦ Protect against heat/cold: avoid heat effects, for example dur‐

ing spray painting or other body shop operations. The crash

sensors must not be exposed to temperatures below -40°C

(for example in non-air-conditioned aircraft holds).

♦ The crash sensor must be protected against humidity during

storage and installation.

For the crash sensor to function properly, it is vital to ensure that

the door forms an effective seal after being fitted. Observe the

following:

♦ All components (e.g. cover, speakers, door trim) must be cor‐

rectly fitted.

♦ The door trim retaining clips seal the system. If necessary, re‐

new retaining clips.

1.10 Additional safety instructions for repair

work on seat occupied recognition for

front passenger airbag deactivation -

country-specific

♦ Basic setting of seat occupied recognition control unit must be

performed after each repair to front passenger seat in which

the seat and/or the backrest cover was »detached« ⇒ Vehicle

diagnostic tester.

♦ The mat of the seat recognition sensor must not be kinked.

♦ A leaky mat must be renewed (repair kit).

♦ The pressure hose of the mat must not be kinked.

♦ The components of the seat occupied recognition (repair kit)

must not fall on hard surfaces, come into contact with grease

or be damaged by pointed/sharp objects.

♦ The mat, the fleece and all other covers must fitted without

folds/creases.

♦ During installation, care must be taken to install seat padding

and seat cover in correct installation position.

♦ Renew all upholstery clips or other clips and ensure they are

positioned correctly on the seat.

♦ The basic setting of the system is only possible between tem‐

peratures of 0°C and +40°C for the airbags 8.R and 9.*. For

airbag 10.* the basic setting of the system is only possible be‐

tween temperatures of 5°C and 35°C.

♦ Ensure that no object is on the seat before and/or during the

basic settings.

♦ The use of additional items on the seat, such as cushions or

similar, impairs the functioning of the seat occupied recogni‐

tion system and can therefore prevent the airbag system from

functioning correctly.

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1.11 Measures for seat occupied recognition

for front passenger airbag deactivation

following an accident - country-specific

♦ Whenever an airbag or belt tensioner has been triggered, ba‐

sic setting of seat occupied recognition control unit must al‐

ways be performed ⇒ Vehicle diagnostic tester.

♦ If the seat rail and/or seat pan are replaced due to deformation

after an accident, the seat occupied recognition system must

be replaced by the “seat occupied recognition repair kit”. After

that, perform “basic settings” of seat occupied recognition con‐

trol unit ⇒ Vehicle diagnostic tester.

1.12 Renewing pyrotechnic, electrical and

mechanical components of the restraint

system after an accident

Special tools and workshop equipment required

♦ Vehicle diagnostic tester

The airbag control unit must be renewed:

♦ In the event of a front passenger airbag deployment.

♦ After side airbag, driver/front passenger airbag or belt ten‐

sioner deployments

♦ In the event of damage to the housing

♦ In the event of deformation to the tunnel within a 200 mm ra‐

dius of the control unit

Always renew the following:

♦ All triggered airbag units.

♦ Battery isolation igniter - N253-

Additionally, in the event of the front passenger airbag being trig‐

gered:

♦ Dash panel

♦ Supports for front passenger airbag unit which have been bent

out of shape (must not be bent back into shape)

♦ All sensors for front airbag at front end

♦ Remaining sensors for lateral acceleration in event of defor‐

mation of attachment points in vicinity of sensors

Additionally, in the event of the driver airbag being triggered:

♦ Return spring with slip ring

♦ All sensors for front airbag at front end

♦ Remaining sensors for lateral acceleration in event of defor‐

mation of attachment points in vicinity of sensors

Additionally, in the event of the side airbag being triggered:

♦ Pressure sensors on the triggered side

♦ Lateral acceleration sensors on the side affected

♦ Seat cover

♦ Padding

♦ In case of foldable backrest: padding of lateral seat bolster (if

fitted)

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♦ Remaining sensors for lateral acceleration in event of defor‐

mation of attachment points in vicinity of sensors

Additionally:

♦ All belt inertia reels with triggered belt tensioners

♦ Belt buckles for all belt inertia reels with triggered belt ten‐

sioners

♦ Belt adjuster (mechanical and electrical) for all belt inertia reels

with triggered belt tensioners

– If you suspect that belt tensioners or belt force limiters have

been triggered, connect a vehicle diagnostic tester .

– Under “15 - Airbag” in »Guided Fault Finding« check whether

there is a crash entry logged for the airbag control unit.

– At the same time check whether the “Resistance too high” fault

is also logged for belt tensioners and/or belt force limiters.

Triggered belt tensioners and/or belt force limiters have to

meet both conditions. “Prerequisite: The airbag control unit

has not yet been renewed”.

Note

♦

The “Resistance too high” fault can also be logged in the event

of a cable break. Under normal circumstances, no crash entry

is then logged.

♦

Depending on the crash intensity, it is possible that the belt

tensioner was triggered but not the belt force limiter. In this

case, observe notes on disposal of pyrotechnic components

⇒ page 5 .

♦

In addition, note the section: Checking seat belts

⇒ page 12 .

♦

Deployed belt force limiters can be identified by the following

features:

♦

The pin -1- and lug -3- have popped out of the belt force limiter

housing on the belt inertia reel.

♦

The strap -2- is no longer vertical but is pointing diagonally

outwards.

– If parts of the belt system are removed because of an accident,

the belt system bolts must be renewed.

– In addition, the following must also be replaced if necessary

(visual check): all damaged components.

1.13 Checking airbag securing parts after an

accident

All damaged securing parts must always be renewed. It is not

permissible to bend the components back into shape or »make

them fit«.

The following components must be checked after the relevant

airbag has been triggered.

In the event of the front passenger airbag being triggered:

♦ Central tube for dash panel; it must be possible to install the

supports for the front passenger airbag and front passenger

airbag unit tension-free. Otherwise the central tube must also

be renewed.

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♦ Check the glove compartment for damage. If damaged, it must

be renewed.

In the event of the driver airbag being triggered:

♦ Steering wheel: remove the steering wheel and place on a flat

surface together with the steering collar. The full face of the

steering collar must be in contact with the flat surface. Other‐

wise the steering wheel must be renewed.

♦ Check steering wheel for smoke residue. If any smoke resi‐

dues are found, the steering wheel must be renewed.

1.14 Accident without airbag triggering

♦ If the airbag warning lamp - K75- does not indicate a fault,

there is no requirement to replace pyrotechnic components.

The seat belts should be checked separately.

1.15 Seat belts

♦ Belt tensioner units must be handled with extreme caution

during removal and installation. If handled incorrectly, there is

a high risk of injury and damage in relation to the belt tensioner

units.

♦ Belt tensioner units which are mechanically damaged (dents,

fractures) always must be renewed.