Golf 5 -> VW Rabbit GTI 2006

Transcription

Volkswagen Golf 5 2004-> VW Rabbit GTI 2006->
(A5)
Seat belts
Safety regulations for belt tensioners

Testing, removing, installing and repair work may
only be performed by qualified personnel.

Belt tensioner components may not be opened nor
repaired; always use new parts (risk of injury).

Belt tensioners that were subject to hard blows or
have been dropped on the floor, must not be
installed in a vehicle.

Belt tensioners that are mechanically damaged
(dents, cracks) must always be replaced.

Storage and transport is subject to laws governing
explosive materials.

Belt tensioners should be installed immediately after
removing them from the shipping package.

An impact wrench may not be used to remove the
belt tensioner.

Belt tensioner is to be returned to shipping package
when work is interrupted.

It is not acceptable to leave belt tensioner
unattended.

The belt tensioner may not be treated with grease,
cleaning agents, or similar materials, and may not be
exposed, even briefly, to temperatures above 212
F (100 C)

The pyrotechnic propellant has no expiration date,
i.e. it has unlimited service life and is maintenancefree.
Seat belts
Page 2 / 22
Disposing of belt tensioner units

Make sure that your dealership complies with
federal, state and local regulations for explosive
substances.

Deployed airbags and pyrotechnic seatbelts can be
disposed of as normal scrap.

Undeployed airbags and pyrotechnic seatbelts are
considered to be hazardous materials. When
disposing of an undeployed airbag or pyrotechnic
seatbelt that is either defective or expired, use the
appropriate repair information and Airbag
Deployment Device J-44210. DO NOT deploy
airbags and pyrotechnic seatbelts in the vehicle

All airbags and pyrotechnic seatbelts of a vehicle
scheduled to be scrapped must be deployed using
the Airbag Deployment Device J-44210.

When using Airbag Deployment Device J-44210,
wear appropriate eye and ear protection.

If the airbag or pyrotechnic seatbelt cannot be safely
deployed or removed from the vehicle, contact the
Volkswagen Dealer Technicians Helpline.

Shipment of active airbag gas generators and
pyrotechnic seatbelt retractors must be in
accordance with the regulations published in the
latest edition of the Code of Federal Regulations #49
(49 CFR). Shipment must be initiated and received
by certified individuals. The penalties for
noncompliance are severe. Civil penalties range the
$250 to $27,500 per violation, per day. Criminal
penalties, for willfully violating the regulations, range
up to $250,000 for individuals and $500,000 for
corporations.
Front seat belts (2-door), removing and installing
Assembly overview
Seat belts

Page 3 / 22
Screw

20 Nm
Screw

40 Nm

Window

Anchor rail

Screw

40 Nm

B-pillar belt retractor

Wiring harness
Seat belts

Page 4 / 22
Bolts

Qty. 2

4.5 Nm

Belt guide

Screw

40 Nm

Belt guide ring

Belt latch

Removing 69-1, Belt latch
(2-door), removing and
installing
Removing
Note:

Removal and installation is described for the lefthand side of the vehicle. Removal and installation for
the right-hand side is performed in the same
manner.
Warning!
Observe safety precautions for belt tensioners
Safety regulations for belt tensioners .
69-1,
- Disconnect vehicle battery
Repair Manual, Electrical Equipment, Repair Group 27,
.
- Remove upper B-pillar trim
removing and installing
- Remove seat bench
and installing .
- Remove backrest
installing
70-3, Upper B-pillar trim,
72-2, Rear seat bench, removing
72-2, Backrest, removing and
Seat belts
Page 5 / 22
- Remove 2-door sill panel trim
door), removing and installing
- Remove side trim
and installing
- Remove screw
68-3, Sill panel trim (2-
70-3, Side trim (2-door), removing
Item - 1 - (20 Nm).
- Remove screw Item - 2 - (40 Nm)
and remove window Item - 3 - .
- Remove anchor rail Item - 4 through loop in belt webbing.
and remove belt retractor Item - 6 from B-pillar.
Warning!
Electrostatic charges may result in
involuntary deployment of the belt
tensioner. Therefore the technician
must discharge static electricity from
the body before separating the
ignition and ground wiring. This is
done e.g. by briefly touching the body
or the door striker or pin.
- Disconnect wiring harness
.
Item - 7 -
- Remove screws Item - 8 - (4.5 Nm)
and remove belt guide Item - 9 - .
Seat belts
and remove belt relay Item - 11 - from
belt height adjuster.
Installing
- Installation is performed in the reverse order of removal.
- Connect vehicle battery
.
Front seat belts (4-door), removing and installing
Assembly overview
Page 6 / 22
Seat belts

Page 7 / 22
Screw

40 Nm

Micro-encapsulated

Belt anchor

Screw

40 Nm

B-pillar belt retractor

Wiring harness

Bolts

Qty. 2

4.5 Nm
Seat belts
Page 8 / 22

Belt guide

Screw

40 Nm

Belt guide ring

Belt latch

Removing 69-1, Belt latch
(4-door) removing and
installing
Removing
Note:

manner.
Warning!
Observe safety precautions for belt tensioners
Safety regulations for belt tensioners .
69-1,
- Remove lower B-pillar trim
70-3, Lower B-pillar trim,
and remove belt anchor
Item - 2 - from
body.
Caution!
Screw Item - 1 - is microencapsulated. For this reason, it must
always be warmed with hot air gun
before loosening. While doing this,
protect the neighboring seatbelt
Seat belts
Page 9 / 22
against excessive heat with a moist
towel.
Note :

The bolt is micro-encapsulated and must be
replaced every time it is loosened.

Before installing the new screw, threads on nut must
be cleaned, re-cut if necessary.
and remove belt retractor Item - 4 from B-pillar.
Warning!
Electrostatic charges may result in
involuntary deployment of the belt
tensioner. Therefore the technician
must discharge static electricity from
the body before separating the
ignition and ground wiring. This is
done e.g. by briefly touching the body
or the door striker or pin.
- Disconnect wiring harness
.
Item - 5 -
- Remove screws Item - 6 - (2 Nm)
and remove belt guide Item - 7 - .
Seat belts
Page 10 / 22
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi
and remove belt relay Item - 9 - from
belt height adjuster.
Installing
.
Front seatbelt height adjuster, removing and installing
Note:

Removal and installation is described for the left-
Seat belts
Page 11 / 22
hand side of the vehicle. Removal and installation for
manner.
Removing
Note:

Belt anchor or anchor rail does not need to be
removed on seat belt.
- Remove bolt - 1 - (40 Nm) and remove
belt relay - 2 - from belt height adjuster.
- Remove bolt - 3 - (20 Nm) and
separate belt height adjuster - 4 - from
mounting in carrier plate.
Seat belts
Page 12 / 22
Installing
Belt latch (2-door), removing and installing
Note:

Removal and installation is described for belt latch of
left seat. The same instructions apply for removal
and installation for belt latch of right seat.
Removing
- Remove front seat
installing
72-1, Front seat, removing and
- Position seat as far forward as possible.
- If present, disconnect wiring harness 1 - from seat frame.
Seat belts
Page 13 / 22
- Remove bolt - 2 - (20 Nm).
Note :

The screw is micro-encapsulated and must be

Before new bolts are installed, the thread of the
corresponding nut must be cleaned.
- Turn belt latch 90
A - .
clockwise - arrow
- Swivel belt latch toward outside - arrow
B - .
- Remove belt latch from mount in seat
rail - arrow C - .
Installing
Belt latch (4-door) removing and installing
Note:

Removal and installation is described for belt latch of
left seat. The same instructions apply for removal
and installation for belt latch of right seat.
Removing
- Remove front seat
installing
- Position seat as far forward as possible.
- If present, disconnect wiring harness
from seat frame.
Note :

The screw is micro-encapsulated and must be

Before new bolts are installed, the thread of the
corresponding nut must be cleaned.
Seat belts
- Remove belt latch - 2 - from mount in
seat rail - arrow - .
Installing
Rear outer seatbelts, removing and installing
Assembly overview
Page 14 / 22
Seat belts

Page 15 / 22
Screw

40 Nm

Belt anchor

Wiring harness

Screw

40 Nm

Automatic belt retractor with belt
tensioner

Screw

40 Nm
Automatic belt retractor without
Seat belts
Page 16 / 22
belt tensioner
Removing
Note:

manner.
2-door vehicles
- Remove seat bench
and installing .
- Remove backrest
installing
- Remove side trim
and installing
- Remove luggage compartment cover side compartment
70-5, Luggage compartment cover side storage
compartment, removing and installing
- Remove roof end strip
and installing
- Remove C-pillar trim
installing
70-6, Roof end strip, removing
70-3, C-pillar trim, removing and
4-door vehicles
- Remove seat bench
and installing .
- Remove 4-door side upholstery:

with rear side airbags 72-2, Side upholstery with
side airbag (4-door), removing and installing

without rear side airbags 72-2, Side upholstery (4door,), removing and installing
Seat belts
Page 17 / 22
and installing
- Remove C-pillar trim
installing
70-3, C-pillar trim, removing and
- Unscrew bolt - 1 - (40 Nm) and remove
seatbelt guide - 2 - from body.
Vehicles with belt tensioner
Repair Manual, Electrical Equipment,
Repair Group 27,
Warning!
Electrostatic discharges can lead to
an unintended deployment of the
airbag. Therefore the technician must
discharge static electricity from the
body before separating the ignition
and ground wiring. This is done e.g.
by briefly touching the body or the
door striker or pin.
- Disconnect wiring harness - 3 - .
- Remove screw - 4 - (40 Nm) and
remove automatic belt retractors - 5 from body - arrow A - .
Vehicles without belt tensioner
Seat belts
remove automatic belt retractors - 7 from body - arrow B - .
Installing
Rear center 3-point seatbelt, removing and installing
Assembly overview
Page 18 / 22
Seat belts
Page 19 / 22

Screw

Belt latch

Hex nut

40 Nm

Automatic belt retractor

Console
Removing
- Remove seat bench
and installing .
- Remove backrest
installing
- Remove cover and upholstery from backrest
74-2,
Seat belts
Page 20 / 22
Cover and cushion for backrest, removing and installing
remove belt latch - 2 - from body.
- Remove hex nut - 3 - (40 Nm) and
remove automatic belt retractors - 4 from console - 5 - .
- Guide belt latch - 2 - through console 5- .
Installing
Center rear lap belt, removing and installing
Removing
- Remove seat bench
Seat belts
Page 21 / 22
and installing .
- Remove backrest
installing
remove lap belt - 2 - from body.
Installing
Rear double belt latch, removing and installing
Removing
- Remove seat bench
and installing .
- Remove backrest
installing
Seat belts
remove double belt latch - 2 - from
body.
Installing
Page 22 / 22
Seat belts, inspecting
Page 1 / 5
69 - 2
Warning!
After every accident the seat belt system must be
inspected systematically! If damage is determined
when inspecting the check points, customer must be
informed regarding necessity of changing belts.
Check points:

Check belt webbing

Check retractor (locking function)

Visually check belt latch

Check belt latch function

Check belt guide rings and locking tongue

Check securing components and anchorage points
Check points
Check belt webbing
- Pull belt completely out of retractor or lap belt adjustment
tongue.
- Inspect belt webbing for contamination and, if necessary,
wash with mild soap solution also refer to Operating
Manual.

If any of the following illustrated damage examples
(1 and 2) are discovered on an accident vehicle replace complete seat belt with belt latch and belt
height adjuster.

If one kind of damage under points 1, 2, 3 and 4 is
detected on a vehicle which has not been in an
accident, only the damaged seatbelt needs to be
replaced.

Belt webbing cut, torn or chafed.

Webbing loops on belt edge torn.

Burn marks from cigarettes or similar.
Page 2 / 5

One side of belt edge deformed or area of belt edge
is wavy.
Check retractor (locking function)
The belt retractor has two locking functions.

The first locking function is initiated by belt being
jerked out of the retractor (belt extraction
acceleration).
Checking
- Pull belt webbing out of retractor with a firm jerk.

No locking function - replace compete seat belt with
belt latch.

If difficulties are experienced when pulling out or
retracting belt, first check whether position of
retractor has been altered.

The second locking function is initiated by change in
vehicle velocity (vehicle-dependent locking function).
For this, the vehicle must be moved on a level
surface.
Checking
- Fasten seat belt.
- Accelerate vehicle to 12 mph (20 km/h) and then perform
a full braking maneuver with foot brake.

If the locking mechanism does not lock the seat belt
during the braking maneuver, the complete seat belt
with belt latch must be replaced.
Page 3 / 5
Warning!
For safety reasons, road test should be carried out on
traffic-free stretch to ensure that other
motorists/pedestrians etc. are not endangered.
Visually check belt latch
- Inspect belt latch for cracks and chipping.

If damage is discovered, replace complete seat belt
with belt latch.
Check belt latch function
Check belt latch:
- Insert locking tongue into belt latch until it audibly
engages. Check whether locking mechanism is properly
engaged by giving belt webbing a firm jerk.

If locking tongue fails to engage properly in belt latch
even once during at least 5 tests, replace complete
seat belt with belt latch.
Check release mechanism:
- Release seat belt by pressing button on belt latch with
finger pressure.
- When belt is slack, locking tongue must spring out of belt
latch on its own.

Perform test at least 5 times. If locking tongue fails
even once to spring out, replace complete seat belt
with belt latch.
Warning!
Under no circumstances may grease be used to
eliminate noise or stiffness at belt buckle buttons.
Check belt guide rings and locking tongue
The plastic-covered guides show fine parallel scoring after
straining belt system (belt was fastened during accident).
(Wear which has been brought about by frequent belt use
can be identified by smooth signs of wear which are free of
scoring.)
Page 4 / 5
- Inspect for deformation, chipping and cracks in plastic.

If scoring and/or damage is discovered, replace
complete seat belt with belt latch.
Check securing components and anchorage points

Latch bracket deformed (stretched)

Height adjuster not functional

Anchorage points (seat, pillar, vehicle floor) distorted
or thread damaged

If damage is discovered on these components,
replace complete seat belt with belt latch.

Replace anchorage points.
Note:

In damage is discovered that is not accident-related,
e.g. wear, replace the particular part which is
damaged.
Page 5 / 5
Inspecting child seat anchors (LATCH system "Lower Anchors and Tethers for CHildr...
Page 1 / 1
69 - 3
Inspecting child seat anchors (LATCH system
"Lower Anchors and Tethers for CHildren"), after
accident
Check points

After an accident, child seat anchors must be
inspected for damage and deformation.

Child seat anchors that are welded into the body
cannot be repaired or corrected.

Child seat anchors that are bolted to the body must
be replaced if damaged or deformed.
Airbag
Page 1 / 29
69 - 4
Airbag
Airbag components, Location overview,

Driver airbag unit

Removing 69-4, Driver
airbag module, removing
and installing

Airbag malfunction indicator
lamp (MIL) K75

Front passenger airbag module

Removing 69-4,
Passengers side airbag
module, removing and
installing
Airbag

Page 2 / 29
Side airbag, driver side

Side airbag, front passenger
side

Removing 69-4, Side
airbags for driver and front
passenger, removing and
installing
Removing 69-4, Side
airbags for driver and front
passenger, removing and
installing
Rear driver-side side airbag

4-door only

Removing 69-4, Rear side
airbag (4-door), removing
and installing
Rear side-airbag, front
passengers side

4-door only

Removing 69-4, Rear side
airbag (4-door), removing
and installing
Airbag Control Module J234

Removing 69-4, Airbag
control module J234 ,

Adapting components
(coding) 69-4,
Components, adapting
Diagnostic connector
Airbag
Page 3 / 29
10 - Front passenger-side side curtain
airbag

removing 69-4, Driver and
passenger side curtain airbags,
11 - Driver-side side curtain airbag

removing 69-4, Driver and
passenger side curtain airbags,
Safety precautions for work on airbags

Testing, removing, installing and repair work may
only be performed by qualified personnel.

When working on the airbag system, the battery
Ground (GND) strap must be disconnected. No
waiting time is necessary after disconnecting battery.
Airbag
Page 4 / 29
When connecting the airbag system to a voltage
source, there must be no person present inside the
vehicle.

Before picking up (touching) the airbag unit, the
technician must electrostatically discharge
him/herself. This is achieved by touching a suitable
metal part, for example, a water pipe, heater pipe or
metal frame.

Airbag units should be installed immediately upon
removal from shipping package.

Airbag unit is to be returned to shipping package
when there is an interruption in work.

It is not acceptable to leave airbag unit unattended.

Airbag units which have been removed should be
stored so that padded side is facing up.

Airbag units that have fallen onto a hard surface or
show signs of damage must not be installed in
vehicle.
Additional safety precautions for side curtain airbag

Always replace damaged pillar trim panels, never
repair.

Head curtain airbags must not be kinked or twisted.

After body repairs, inspect the body for weld splatter,
deformations and chafing areas near the head
curtain airbag (compare with opposite side if
necessary).

If a deployed side curtain airbag is replaced, the
headliner, door seals with weather stripping, curtain
airbag guides, grab handle brackets, and the A, B, C
and (if equipped) D-pillar trim must be replaced. If
damaged, the rear interior lights, the roof grab
handles and the roof close-out molding must be
replaced.
Airbag
Page 5 / 29
Disposing airbag units

Make sure that your dealership complies with
federal, state and local regulations for explosive
substances.

Deployed airbags and pyrotechnic seatbelts can be
disposed of as normal scrap.

Undeployed airbags and pyrotechnic seatbelts are
considered to be hazardous materials. When
disposing of an undeployed airbag or pyrotechnic
seatbelt that is either defective or expired, use the
appropriate repair information and Airbag
Deployment Device J-44210. DO NOT deploy
airbags and pyrotechnic seatbelts in the vehicle

All airbags and pyrotechnic seatbelts of a vehicle
scheduled to be scrapped must be deployed using
the Airbag Deployment Device J-44210.

When using Airbag Deployment Device J-44210,
wear appropriate eye and ear protection.

If the airbag or pyrotechnic seatbelt cannot be safely
deployed or removed from the vehicle, contact the
Volkswagen Dealer Technicians Helpline.

Shipment of active airbag gas generators and
pyrotechnic seatbelt retractors must be in
accordance with the regulations published in the
latest edition of the Code of Federal Regulations #49
(49 CFR). Shipment must be initiated and received
by certified individuals. The penalties for
noncompliance are severe. Civil penalties range the
$250 to $27,500 per violation, per day. Criminal
penalties, for willfully violating the regulations, range
up to $250,000 for individuals and $500,000 for
corporations.
Airbag units, replacing after an accident
Accident with airbag deployment
Note:

The airbag control module does not need to be
replaced after deployment unless "Control module
Airbag
Page 6 / 29
faulty" DTC is set in the control module, or the
control module is physically damaged.
Always replace the following components after an
accident when airbag has deployed:

All deployed airbag units.

Supports and bracket from passenger module with a
deployed passenger airbag.

Return ring with slip ring, if drivers side airbag
deployed.

All seat belts with deployed seat belt tensioners.

If necessary (visual check) also replace the
following: All damaged components.
Accident without airbag deployment

The airbag control module does not need to be
replaced after deployment unless "Control module
faulty" DTC is set in the control module, or the
control module is physically damaged.

If the airbag malfunction indicator lamp (MIL) K 75
does not indicate a malfunction, it is not necessary
to replace any of the airbag components. Seat belts
must be inspected separately.
Airbag control module J234 , removing and installing
Warning!
Observe safety precautions for working on airbags
69-4, Safety precautions for work on airbags .
Removing
- Remove right and left footwell trim from center console
Airbag
Page 7 / 29
(other center console components do not need to be
removed):

Front center console without adjustable/folding
armrest with storage compartment 68-2, Front
center console without adjustable/folding armrest
with storage compartment, removing and installing

Front center console with adjustable/folding armrest
with storage compartment 68-2, Front center
armrest adjustable/folding with storage
Note :

For the sake of illustration, center console is not
depicted in the illustration.
- Open locking mechanism of connector 1 - and disconnect wiring harness from
control module - 2 - .
- Remove three nuts - 3 - (9 Nm).
Airbag
- Remove the control module from the
vehicle.
Installing
- Switch on ignition.
Warning!
Make sure that no persons are in the vehicle.
.
- If the control module was replaced, it must be coded.
Page 8 / 29
Airbag
Adapting components (coding)
adapting
Page 9 / 29
69-4, Components,
Driver airbag module, removing and installing
Note:

Removal and installation of airbag unit is described
for multi-function steering wheel.

The screwdriver mentioned in the following should
be about 175 mm long and have a blade width of 7
mm.
Removing
Warning!
- Adjust steering wheel height so that it is located in the
highest position.
- Adjust steering wheel depth (reach) so it is in the fully
extended position.
- Turn steering wheel into the position
depicted.
- Insert a screwdriver into hole on rear
side of steering wheel until it stops
(approx. 8 mm).
- Turn the screwdriver in the direction of
passengers side door - arrow - ; this
unlocks the airbag unit locking frame on
the right side of the steering wheel.
- Turn steering wheel 180 and
disengage airbag unit locking mechanism
on left side of steering wheel as
described.
- Turn steering wheel back 90
center position.
into
Airbag
- Remove airbag unit from steering
wheel.
Warning!
- Press connector lock and disconnect
connector - 1 - .
Note :

This connector is only installed with multifunction
steering wheel.
Page 10 / 29
Airbag
- Release connector lock in - direction
of arrow - and disconnect airbag
connector - 2 - .
Installing
- Check whether wiring harness - 3 - is
routed as shown in the illustration.
- Insert airbag connector - 2 - into
connector coupling. Airbag connector
must engage audibly.
- Insert connector - 1 - into connector
coupling.
- Push airbag unit into steering wheel.
Page 11 / 29
Airbag
- Check whether airbag unit is engaged
on the left and right-hand side of the
steering wheel.
Warning!
Make sure that no one is in the vehicle.
.
Steering wheel, removing and installing
Removing
Page 12 / 29
Airbag
Page 13 / 29
- Remove driver-side airbag unit
module, removing and installing
69-4, Driver airbag
- Turn steering wheel into center position
(wheels in straight ahead position).
- Remove bolt - 1 - and pull steering
wheel off of steering column.
Installing
- Place steering wheel onto steering
column.
- Center markings for steering wheel and
steering column - arrows - must align.
Airbag
- The coil spring connector socket and
pin must be positioned in the openings
provided at the base of the steering
wheel.
- Fasten steering wheel with bolt - 1 - ;
torque is 50 Nm.
Airbag Spiral Spring/Return Spring With Slip Ring F138 ,
Airbag spiral spring/return spring with slip ring is a
component of steering column switch, depending on
construction type.
Repair Manual, Electrical equipment, Repair Group 94,
Steering column switch
Page 14 / 29
Airbag
Page 15 / 29
Passengers side airbag module, removing and installing
Removing
Warning!
- Remove side instrument panel cover 68-2, Instrument
panel side covers, removing and installing
- Remove center cover
and installing
68-2, Center cover, removing
- Remove glove compartment 68-2, Glove
Warning!
- Disconnect wiring harness from front
passengers side airbag.
- Remove the two bolts - 1 - (9 Nm).
- Remove the two sets of bolts - 2 - and
- 3 - (9 Nm).
Airbag
- Remove front passengers airbag and
brackets - 4 - and - 5 - from mounts.
Installing
Warning!
Make sure that no one is in the vehicle.
.
Page 16 / 29
Airbag
Page 17 / 29
Side airbags for driver and front passenger, removing
and installing
Note:

manner.
Removing
Warning!
- Remove front seat
installing
- Remove front right seat trim
72-1, Right seat trim,
Vehicles with manual seat adjustment
- Remove front left seat trim
72-1, Left seat trim,
Vehicles with electric seat adjustment
- Remove left power seat trim
trim, removing and installing
72-1, Left power seat
All vehicles
- Remove front seat backrest
72-1, Front seat backrest,
- Remove cover and upholstery from front seat backrest
74-1, Front seat backrest cover and padding, removing and
installing
- Separate wiring harness - 1 - from
backrest frame.
Airbag
- Remove side airbag - 3 - from
mounting in backrest frame.
Installing
Warning!
.
Page 18 / 29
Airbag
Page 19 / 29
Rear side airbag (4-door), removing and installing
Note:

Removal and installation is described for the righthand side of the vehicle. Removal and installation for
the left-hand side is performed in the same manner.
Removing
Warning!
- Remove seat bench
and installing .
- Remove side upholstery with side
airbag (4-door), - 1 72-2, Side
upholstery with side airbag (4-door),
Note :

The bolts are microencapsulated and must therefore
be replaced after every removal.

Before installing the new bolts, the threads of the
corresponding nuts must be cleaned.
- Remove rear side airbag connector
coupling - 3 - from mount in side
upholstery - 1 - .
Airbag
- Remove rear side airbag - 3 - from
side upholstery.
Installing
Warning!
.
Page 20 / 29
Airbag
Page 21 / 29
Driver and passenger side curtain airbags, removing and
installing
Note:

Removal and installation for 4-door vehicle is
described. Removal and installation for 2-door
vehicle is identical.
Removing
Warning!
- If present, open sunroof.
- Remove sun visors
installing
68-2, Sun visor, removing and
- Remove roof grab handle
68-4, Grab handles (roof),
- Remove lights and switch in molded headliner
Repair Manual, Electrical Equipment, Repair Group 96.,
and installing
- Remove upper A-pillar trim
70-3, Upper A-pillar trim,
- Remove upper B-pillar trim. Belt anchors or front belt
anchor rails do not have to be removed 70-3, Upper Bpillar trim, removing and installing
2-door only
- Remove seat bench
and installing .
Airbag
Page 22 / 29
- Remove backrest
installing
- Remove side trim
and installing
4-door only
- Remove seat bench
and installing .

All vehicles
- Remove trim on C-pillars
and installing
- Remove molded headliner
and installing
70-3, C-pillar trim, removing
70-6, Headliner, removing
Warning!
- Disconnect wiring harness from side
curtain airbag
- Remove the four bolts - 1 - (4.5 Nm).
Note :

The four screws - 1 - must be replaced.
- Remove the two cap nuts - 2 - (9
Nm).
Airbag
- Remove all clips for curtain airbag from
body.
- Remove igniter - 3 - from threaded
pins - 4 - in body.
- Remove side curtain airbag from
vehicle via rear lid.
Installing
- After working on side curtain airbag,
ensure wiring harness - 1 - is routed as
shown.
Page 23 / 29
Airbag
- Wiring harness - 1 - must be secured
with cable guide - 2 - in C-pillar area.
Warning!
.
Front Passenger s Seat Occupied Sensor G128 ,
Warning!
Page 24 / 29
Airbag
Page 25 / 29
If Front Passenger s Seat Occupied Sensor G128 is
replaced, also the upholstery, front seat cushion must
always be replaced!
Removing
- Mount the fixture for seat repair VAS 6136 on the engine
and transmission holder VAS 6095 .
- Remove front seat
installing
- Attach the seat to the fixture for seat repair VAS 6136 .
- Remove front right seat trim
Vehicles with manual seat adjustment
- Remove front left seat trim
- Remove bracket and front seat operating lever 72-1,
Front seat bracket and operating lever, removing and
installing
Vehicles with electric seat adjustment
trim, removing and installing
- Remove retainer and power seat bracket 72-1,
Retainer and power seat bracket, removing and installing
All vehicles
- Remove front seat drawer mount
mount, removing and installing
72-1, Seat drawer
Note:

On vehicles with a luggage pass-through, it is
sufficient to fold the backrest forward, it does not
have to be removed.
- Remove cover and upholstery from front seat backrests
74-1, Front seat cushion cover and padding, removing
and installing
Warning!
Airbag
Page 26 / 29
Front Passenger s Seat Occupied
Sensor G128 - 1 - is secured with
seat cushion padding. It is not
possible to remove and install
separately, sensor must be replaced
with upholstery.
Installing
- Press wiring harness in positioning aid
area - 1 - in rear padding channel.
- Press wiring harness in area of arrows A and B - from padding.
- Align sensor positioning aid - 3 - with
padding positioning aid - 2 - .
Caution!
Ensure distance from sensor to
Airbag
positioning aids - 2 - is constant arrows - when doing this.
- Secure aligned sensor - 1 - with right
hand, remove adhesive tape strips - 2 and attach sensor to padding.
- Press wiring harness in rear area into
padding opening - arrow - .
Page 27 / 29
Airbag
- Connect wiring harness with vehicle
electrical system.
Installing of remaining components is reverse of removal.
- After installing, perform a function check with ignition on.
Components, adapting
Page 28 / 29
Airbag
Page 29 / 29

Vehicle Diagnosis, Testing and Information System
VAS 5051

Diagnostic cable VAS 5051/1 or VAS 5051/3
Note:

VAS 5051 A version shown as example only.
Select "Guided Fault Finding" on vehicle diagnosis, testing
and information system VAS 5051 .
After all control modules have been interrogated:
- Press "Go to" button
- Select "Function/Component selection"
- Select "Body"
- "Body Repairs"
- Select "01 - On Board Diagnostic (OBD) capable
systems"
- Select "Airbag"
- Select "Functions"
- Select "Action"
Passenger Occupant Detection System (PODS) (USA only)
Page 1 / 26
69 - 5
Passenger Occupant Detection System (PODS)
(USA only)
Note:

Passenger Occupant Detection System (PODS)
controls automatic passenger airbag deactivation.

This equipment is only installed on vehicles released
in the USA.
Safety measures when working on seat occupied
recognition

After every repair on the passenger seat in which the
seat and/or backrest cover was "disengaged" basic
setting on Seat Occupied Recognition Control
Module J706 must be performed. Perform basic
setting with a diagnostic tester that has "Guided
Fault Finding" .

The seat occupied recognition mat must not be
kinked.

A leaking mat must be replaced (repair kit).

The seat occupied recognition pressure hose must
not be kinked.

Seat occupied recognition (repair kit) components
must not fall on hard surfaces.

Seat occupied recognition components must not
come in contact with grease.

There is the danger that the pPassenger Occupant
Detection System (PODS) may be damaged by
sharp objects when working on the seat. It is
necessary to avoid this danger.

The mat, the crease and various covers must be
fitted to be free of folds.
Page 2 / 26

When installing, ensure upholstery and cover are
installed correctly.

Replace all upholstery clips and clip connectors from
cover, ensure it is positioned correctly on seat when
doing so.

System basic setting is only possible at
temperatures between 32 and 104 F (0
+40 C).
and

Make sure that no objects are placed on seat when
performing basic setting.

Use of seat covers, such as cushions or something
similar, impairs seat occupied recognition function
and airbag system effectiveness.
Procedure after an accident with belt pretensioner and/or
airbag deployment

Each time passenger airbag and/or belt pretensioner
on passenger side is deployed, Seat Occupied
Recognition Control Module J706 basic setting must
be performed. Perform basic setting with a
diagnostic tester that has "Guided Fault Finding" .

If the seat rails and/or seat pan must be replaced
after an accident due to deformation, seat occupied
recognition must also be replaced with "seat
occupied recognition repair kit" . Then, Seat
Occupied Recognition Control Module J706 basic
setting must be performed. Perform basic setting
with a diagnostic tester that has "Guided Fault
Finding" .
Passenger Occupant Detection System (PODS),
assembly overview (USA only)

Front seat wiring harness

Seat frame

Seat Occupied Recognition
Control Module J706

Upholstery of front seat cushion

Seat Occupied Recognition Mat

Must not be separated from
mat for seat occupied
recognition
Must not be removed from
pressure hose and
upholstery of front seat
cushion
Insertion profile
Page 3 / 26

Note location
Bracket

White
Repair set components for Passenger Occupant
Detection System (PODS)
If there is a malfunction on a part of the
system, it must be replaced with
components from the repair kit. Repair
set is already matched to characteristics
of vehicle to be repaired and contains the
following components.
Warning!
Never use repair set components
separately.
Page 4 / 26

Upholstery of front seat
cushion

Pressure hose

Seat Occupied Recognition Mat

Pressure Sensor G452

Control Module J706

Front seat wiring harness

Bracket

White
Warning!
Read and follow instructions for use
on package of repair set.
Page 5 / 26
Misapplication may lead to
malfunction of system.
Components of Passenger Occupant Detection System
(PODS), removing (vehicles with manual seat
adjustment)
Warning!
Observe safety precautions when working on seat
occupied recognition 69-5, Safety measures when
working on seat occupied recognition .
Note:

Seat cushion, mat for seat occupied recognition,
control module and pressure sensor must only be
replaced together. Components are complementary
and must not be separated!

Only disconnect wiring harnesses mentioned in the
following description!
- Remove front seat
installing .
- Remove front belt latch:

2-door 69-1, Belt latch (2-door), removing and
installing

4-door 69-1, Belt latch (4-door) removing and
installing
- Remove right trim on seat:

Seat without pass-through

Seat with pass-through 72-1, Right trim, removing
and installing (seat with pass-through)
Page 6 / 26
- Remove left trim on seat:

Seat without pass-through

Seat with pass-through 72-1, Left trim, removing
and installing (seat with pass-through)
- Remove bracket and front seat operating lever 72-1,
Front seat bracket and operating lever, removing and
installing .
- If present, remove mount for seat drawer
drawer mount, removing and installing .
- If present, remove connector - 1 - from
Front Passenger s Heated Seat Control
Module J132 .
- If equipped, remove retaining clip - 2 .
- Remove retaining clips - 3 - .
- If present, disconnect connector - 4 and remove connector from seat frame.
- Disconnect side airbag connector - 5 and remove connector from seat frame.
72-1, Seat
Page 7 / 26
- Remove line clip - 6 - and disconnect
backrest wiring harness from seat
frame.
removing and installing .
- Remove cover from upholstery of front seat cushion
(front seat cushion is not removed) 74-1, Front seat
cushion cover and padding, removing and installing .
- Unclip pressure hose - 6 - from
retainers.
- Unclip Seat Occupied Recognition
Pressure Sensor G452 - 5 - from
retainer, when doing this do not
disconnect harness connectors - 3 - or 4 - at Seat Occupied Recognition
Pressure Sensor G452 and similarly at
Seat Occupied Recognition Control
Page 8 / 26
Module J706 - 2 - .
- Remove bolts - 1 - (1.5 Nm).
- If present, disconnect front seat heating
connector - 3 - .
- Disconnect black Seat Occupied
Recognition Safety Belt Force Sensor
G453 connector - 5 - Disconnect yellow Front Passenger s
Safety Belt Switch E25 connector - 4 - .
- If present, disconnect front seat
backrest heating connector - 6 - .
- Cut wiring harness cable ties - 2 - .
- Slide white bracket - 1 - left and
remove from seat frame.
Page 9 / 26
- Remove all connectors from bracket.
Caution!
Do not disconnect connector from
Module J706 .
- Lift upholstery of front seat cushion - 1
- , when doing this do not separate
upholstery of front seat cushion from mat
for seat occupied recognition - 4 - .
- Remove clip - 2 - from seat frame - 5 , clip - 3 - must not be removed.
Warning!

Do not damage seals when assembling or
disassembling.
Page 10 / 26

pressure hose, Seat Occupied Recognition
Pressure Sensor G452 and Seat Occupied
Recognition Control Module J706 must not be
separated!
Page 11 / 26
- Remove screws - 1 - (2.5 Nm) and
remove Seat Occupied Recognition
Control Module J706 bracket.
- Remove upholstery of front seat
cushion - 1 - together with mat for seat
occupied recognition - 4 - .
Page 12 / 26
- Thread pressure hose - 6 - , Seat
Occupied Recognition Pressure Sensor
G452 - 7 - , Seat Occupied Recognition
Control Module J706 - 9 - and seat
wiring harness - 8 - through opening arrow - on seat frame - 5 - .
Repair set for Passenger Occupant Detection System
(PODS), installing (vehicles with manual seat
adjustment)
Note:

When installing, there must be no wiring harness of
seat heater between upholstery and mat for seat
occupied recognition.

Pressure hose must be routed without kinking.

Stickers with notes on harness connectors must not
Page 13 / 26
be damaged.

After being connected to the vehicle electrical
system, verify that the replaced components can
move easily by moving the seat.
After replacing seat occupied recognition, basic setting of
seat occupied recognition must be performed using
diagnostic tester containing "Guided Fault Finding" .
Warning!
Basic setting must be performed when seat is not
occupied.
Installation is reverse of removal, noting the following:
- Secure insertion profile - 2 - with double-sided tape - 3 on seat frame - 1 - as shown.
Page 14 / 26
- Clip pressure hose - 6 - into bracket.
Begin clipping into bracket near Seat
G452 - 5 - and end near connector - 3 .
Warning!

disassembling.
Page 15 / 26
.
Components of Passenger Occupant Detection System
(PODS), removing (vehicles with electric seat
adjustment)
Warning!
Observe safety precautions when working on seat
occupied recognition 69-5, Safety measures when
working on seat occupied recognition .
Note:

control module and pressure sensor must only be
replaced together. Components are complementary
and must not be separated!

Only disconnect wiring harnesses mentioned in the
following description!
- Remove front seat
installing .
- Remove front belt latch:

2-door 69-1, Belt latch (2-door), removing and
installing

4-door 69-1, Belt latch (4-door) removing and
installing
- Remove right trim on seat
trim, removing and installing .
- If present, remove seat drawer mount
drawer mount, removing and installing
72-1, Seat
- Remove retainer and power seat bracket 72-1,
Retainer and power seat bracket, removing and installing
Page 16 / 26
- Disconnect connector - 1 - from backrest adjustment
motor.
- Disconnect connector - 1 - from seat
adjustment motor.
- Remove cable brackets - 2 - and - 3 .
- Disconnect backrest adjustment
connector - 4 - and remove connector
from seat frame.
- Remove cable bracket - 5 - .
- If present, remove connector - 6 - from
Front Passenger s Heated Seat Control
Module J132 .
- If equipped, remove retaining clip - 7 .
- Disconnect side airbag connector - 8 .
- If present, disconnect front backrest
heating connector - 10 - and remove
yellow connector.
Note :

Do not remove white bracket.
Page 17 / 26
- Remove cover from upholstery of front seat cushion
(front seat cushion is not removed) 74-1, Front seat
cushion cover and padding, removing and installing .
Caution!
Do not disconnect connector from
Module J706 .
- Unclip pressure hose - 6 - from
retainers.
- Unclip Seat Occupied Recognition
Pressure Sensor G452 - 5 - from
retainer, when doing this do not
disconnect harness connectors - 3 - or -
Page 18 / 26
4 - at Seat Occupied Recognition
Pressure Sensor G452 and similarly at
Module J706 - 2 - .
- Remove bolts - 1 - (1.5 Nm).
- Disconnect black Seat Occupied
Recognition Safety Belt Force Sensor
G453 connector - 1 - Disconnect yellow Front Passenger s
Safety Belt Switch E25 connector - 2 - .
Page 19 / 26
- Remove white bracket - 3 - from seat
frame.
- If present, disconnect front seat heating
connector - 3 - .
- If present, disconnect front seat
backrest heating connector - 4 - .
- Cut wiring harness cable ties - 2 - .
- Slide white bracket - 1 - left and
remove from seat frame.
Page 20 / 26
- Remove all connectors from bracket.
- Lift upholstery of front seat cushion - 1
- , when doing this do not separate
upholstery of front seat cushion from mat
for seat occupied recognition - 4 - .
- Remove clip - 2 - from seat frame - 5 , clip - 3 - must not be removed.
Warning!
Seat cushion, mat for seat occupied
recognition, pressure hose, Seat
Occupied Recognition Pressure
Sensor G452 and Seat Occupied
Recognition Control Module J706
must not be separated!
Page 21 / 26
- Remove upholstery of front seat
cushion - 1 - together with mat for seat
occupied recognition - 4 - .
Page 22 / 26
Page 23 / 26
- Thread pressure hose - 6 - , Seat
G452 - 7 - , Seat Occupied Recognition
Control Module J706 - 9 - and seat
wiring harness - 8 - through opening arrow - on seat frame - 5 - .
Repair set for Passenger Occupant Detection System
(PODS), installing (vehicles with electric seat
adjustment)
Note:

When installing, there must be no wiring harness of
seat heater between upholstery and mat for seat
occupied recognition.

Pressure hose must be routed without kinking.

Stickers with notes on harness connectors must not
be damaged.

After being connected to the vehicle electrical
system, verify that the replaced components can
move easily by moving the seat.
After replacing seat occupied recognition, basic setting of
seat occupied recognition must be performed using
diagnostic tester containing "Guided Fault Finding" .
Warning!
Basic setting must be performed when seat is not
occupied.
Installation is reverse of removal, noting the following:
- Secure insertion profile - 2 - with double-sided tape - 3 on seat frame - 1 - as shown.
Page 24 / 26
- Connect pressure hose - 6 - . Brackets
must be reinstalled, from Seat Occupied
Recognition Pressure Sensor G452 - 5 to wiring harness connector - 3 - .
Warning!

disassembling.

Page 25 / 26
.
Page 26 / 26
Crash sensors
Page 1 / 6
69 - 6
Crash sensors
Front door crash sensors, removing and installing
Note:

Removing
Warning!
Observe safety precautions for working on airbags.
- Remove outer door panel
Repair Manual, Body Exterior, Repair Group 57,
- Separate wiring harness - 1 - from
crash sensor - 3 - .
Crash sensors
- Remove the two bolts - 2 - (2.5 Nm).
Installing
Warning!
.
Rear wheel housing crash sensors (2-door), removing
Page 2 / 6
Crash sensors
Page 3 / 6
and installing
Note:

Removing
Warning!
- Remove seat bench
and installing .
- Remove backrest
installing
- Remove side trim
and installing
- Press connector lock - 1 - toward rear arrow - and disconnect connector - 2 from crash sensor - 4 - .
Crash sensors
Installing
Warning!
.
Rear wheel housing crash sensors (4-door), removing
Page 4 / 6
Crash sensors
Page 5 / 6
and installing
Note:

Removing
Warning!
- Remove seat bench
and installing .

- Wheel housing trim, 4-door, removing
68-3, Wheel
housing trim (4-door), removing and installing
- Remove 4-door sill panel trim
door), removing and installing
68-3, Sill panel trim (4-
- Press connector lock - 1 - toward rear arrow - and disconnect connector - 2 from crash sensor - 4 - .
Crash sensors
Installing
Warning!
.
Page 6 / 6

Golf 5 -> VW Rabbit GTI 2006

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