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Supplementary Restraint System Precautions

In document D2 Workshop Manual (Page 53-58)

General

The Supplementary Restraint System (SRS) provides active protection for vehicle occupants in the event of a serious collision. The system components include airbags and pretensioner seat belts which are automatically deployed when a severe frontal crash condition is detected.

In order to assure system integrity, it is essential that the SRS system is regularly checked and maintained so that it is ready for operation in the event of an accident.

The SRS system contains components which could be potentially hazardous to the service engineer if not serviced and handled correctly. The following guidelines are intended to alert the service engineer to potential sources of danger and emphasise the importance of ensuring integrity of the SRS components fitted to the vehicle.

Where necessary, additional specific precautions are detailed in the Restraint Systems section of this Manual which should be referred to prior to commencing repair operations.

It should be noted that these precautions are not restricted to operations performed when servicing the SRS system. The same care should be exercised when working on ancillary systems and components located in the vicinity of SRS components; these include but are not limited to steering system (driver's airbag), body and trim components (passenger's airbag and seat belt pretensioners) and electrical system components (SRS harnesses etc.).

WARNING: Do not use rear facing child seats in the front passenger seat if the vehicle is fitted with a passenger airbag.

WARNING: It is imperative that before any work is undertaken on the SRS system the appropriate information is read thoroughly.

WARNING: Replace the airbag every 10 years.

Do not install used SRS parts from another car.

When repairing an SRS system, always use approved new parts.

Carefully inspect the airbag module before installing it. Do not install an airbag module that shows signs of being dropped or improperly handled, such as dents, cracks or deformation.

Do not try to disassemble or tamper with the airbag module.

Special bolts are necessary for installing the airbag module. Do not use other bolts.

Preliminary procedures

The SRS system uses energy reserve capacitors that keep the system active in the event of electrical supply failure under crash conditions. It is necessary to allow the capacitors sufficient time to discharge in order to avoid the risk of accidental deployment.

Always remove the ignition key from the starter switch, disconnect the vehicle battery and wait 10 minutes before commencing work on the SRS system.

Carefully inspect any SRS component before installation. Do not install any SRS component that shows signs of damage such as dents, cracks or deformity.

Component handling

The SRS components are sensitive and potentially hazardous if not handled correctly; always comply with the following handling precautions:

l Never drop an SRS component. The airbag Diagnostic Control Unit (DCU) is a particularly shock sensitive device and must be handled with extreme care. Airbag modules and seat belt pretensioner units could deploy if subjected to a strong shock.

l Never wrap your arms around an airbag module. If an airbag module has to be carried, hold it by the cover, with the cover uppermost and the base away from your body.

l Never transport airbag modules or seat belt pretensioners in the cabin of a vehicle. Always use the luggage compartment of the vehicle for carrying airbag modules and seat belt

pretensioner units.

WARNING: The airbag module contains sodium azide which is poisonous and extremely

flammable. Contact with water, acid or heavy metals may produce harmful or explosive compounds. Do not dismantle, incinerate or bring into contact with electricity, before the unit has been deployed.

Storage

Airbag modules and seat belt pretensioners are classed as explosive devices. For overnight and longer term storage, they must be stored in a secure steel cabinet which has been approved as suitable for the purpose and has been registered by the local authority.

For the temporary storage of an airbag module or seat belt pretensioner during service, place in a designated storage area. If there is no designated storage area available, store in the luggage

compartment of the vehicle and inform the workshop supervisor. Always observe the following

precautions when temporarily storing an airbag module:

l Ensure the cover is facing upwards and the luggage compartment is secured.

l Always keep components cool, dry and free from contamination.

l Do not allow anything to rest on the airbag module.

l Store any removed airbag assembly on a secure flat surface away from electrical equipment and heat sources exceeding 85°C (185°F).

WARNING: Store the airbag module or seat belt pre-tensioner in a designated storage area. If there is no designated storage area available, store in the locked luggage compartment/

loadspace of the vehicle and inform the workshop supervisor.

Installation and testing precautions

The integrity of SRS system components are critical for safety reasons. Ensure the following precautions are always adhered to:

l Never install used SRS components from another vehicle or attempt to repair an SRS component.

l When repairing an SRS system, only use genuine new parts.

l Never apply electrical power to an SRS component unless instructed to do so as part of an approved test procedure.

l Special Torx bolts are necessary for installing the airbag assembly. Do not use other bolts.

Ensure bolts are tightened to the specified torque.

l Ensure that SRS component fixings are correctly positioned and torqued during service and repair.

l Always use new fixings when replacing an SRS component.

l Ensure the airbag DCU is always installed correctly. There must not be any gap between the DCU and the bracket to which it is mounted.

An incorrectly mounted unit could cause the system to malfunction.

l The airbag DCU is a non-serviceable

component and no attempt should be made to repair or modify the unit.

l Do not try to disassemble the airbag assembly.

It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused.

l If you suspect an airbag assembly could be defective, install a new unit and dispose of the old unit. Manually deploy the old unit before disposal.

WARNING: Keep clear of the deployment zone when working on or near an airbag module.

Accidental deployment could cause serious injury.

WARNING: Do not use a multimeter or other general purpose test equipment on SRS system components or accidental deployment may occur. Use only Testbook to diagnose system faults.

SRS harnesses and connectors

Always observe the following precautions with regard to SRS systems:

l Never attempt to modify, splice or repair SRS wiring. SRS wiring can be identified by a special yellow outer protective covering (black with yellow stripe protective coverings are sometimes used).

l Never install electronic equipment (such as a mobile telephone, two way radio or in-car entertainment system) in such a way that it could generate electrical interference in the airbag harness. Seek specialist advice when installing such equipment.

CAUTION: Always ensure the SRS harness is routed correctly. Avoid trapping or pinching the SRS harness. Look out for possible chafing points.

CAUTION: Ensure all SRS harness connectors are mated correctly and securely fastened. Do not leave the connectors hanging loose.

CAUTION: Do not allow the airbag module to hang by the airbag harness.

Rotary coupler

Always follow the Repair procedure for fitting the rotary coupler.

Comply with all safety and installation procedures to ensure the system functions correctly. Observe the following precautions:

l Do not install a rotary coupler if it is suspected to be defective.

l Do not attempt to service, modify or repair a rotary coupler.

l Do not cut, splice or modify the wires attached to yellow SRS connector and lead.

l Always ensure the rotary coupler connectors are mated correctly and securely fastened.

l Always ensure the battery is disconnected before working on the rotary coupler.

l Always ensure the rotary coupler is removed and installed in its centered position and with the front road wheels in the straight ahead position.

l If a new rotary coupler is being installed, ensure the locking tab holding the coupler's rotational position is not broken; units with a broken locking tab should not be used.

Warning labels

Warning symbols are displayed at various positions in the vehicle (either in a suitable prominent position such as driver and passenger side glass, or attached to the component itself) to indicate SRS items which must be treated with particular care. Exact positions of SRS warning labels may vary dependent on legislation and market trends.

WARNING: It is imperative that before any work is undertaken on the SRS system the appropriate information is read thoroughly.

Side window label

a The need for caution when working in close proximity to SRS components.

b Refer to the publication where the procedures, instructions and advice can be found (usually the Workshop Manual) for working on the SRS system.

c Do not use rear facing child seats in the front passenger seat if the vehicle is fitted with a passenger airbag.

Rotary coupler label

a Refer to the Workshop Manual for detailed instructions

b Ensure wheels are in the straight ahead position before removal and refitting c Part number/Bar code. The code must be

recorded and quoted for ordering purposes

Airbag and pretensioner deployment

Deployment procedures and precautions as detailed in this manual should be strictly adhered to. Only personnel who have undergone the appropriate training should undertake deployment of airbag and pretensioner modules. The following precautions must be complied with:

l Only use deployment equipment approved for the intended purpose.

l Before beginning deployment procedure, ensure deployment tool functions properly by performing the self test procedure detailed in SRS section of this manual.

l Deployment of airbag/ pretensioner modules should be performed in a well ventilated area which has been designated for the purpose.

l Ensure airbag/pretensioner modules are not damaged or ruptured before attempting to deploy.

l Notify the relevant authorities of intention to deploy airbag and pretensioner units.

l When deploying airbag pretensioner units, ensure that all personnel are at least 15 metres (45 feet) away from the deployment zone.

l Ensure deployment tool is connected correctly, in compliance with the instructions detailed in the SRS section of this manual. In particular, ensure deployment tool is NOT connected to battery supply before connecting to airbag module connector.

l When deploying seat belt pretensioners, ensure pretensioner unit is secured correctly to the seat.

l When removing deployed airbag modules and pretensioner units, wear protective clothing.

Use gloves and seal deployed units in a plastic bag.

l Following deployment of any component of the SRS system within the vehicle, all SRS

components must be replaced. DO NOT re-use or salvage any parts of the SRS system.

l Do not lean over airbag module when connecting deployment equipment.

If a vehicle is to be scrapped, undeployed airbag modules and pretensioner units must be manually deployed. In this case airbags can be deployed in the vehicle; before deployment, ensure the airbag module is secure within its correct mounting position.

Deployment of the driver's airbag in the vehicle may damage the steering wheel; if the vehicle is not being scrapped, deploy the module outside of the vehicle.

WARNING: During deployment parts of the

In document D2 Workshop Manual (Page 53-58)

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