Important!

Please give copies to all your VW Technicians

Subject:

Technical Bulletin
Group: 01 Number: 0005 Date: Aug.

Side Airbag, On Board Diagnostic (OBD) All 2000, 2001

Model(s):

22, 2000

Service
Additional diagnostic procedures have been established to prevent improper replacement of airbag components. In addition, certain airbag wiring harness terminals and connectors can now be repaired using VAS 1978 Wire Harness Repair Kit. Follow all diagnostic procedures in this bulletin and Repair Manual before beginning repair. Subject Airbag On Board Diagnostic (OBD) Airbag Diagnostic Trouble Code (DTC) Table Measuring value block, reading Display group 005 Evaluating display group 005 VAS 5056 test box VAS 5056 test box, components Airbag, connecting test box to side airbag components, example Wire harness, repair Terminal, inspection Technical Repair Bulletin Page Manual Page 2 3 5 7 8 15 15 16 17 18

(Cont. on Page 2)

C 010005
E 2000 Volkswagen of America, Inc.

Important!
Please give copies to all your VW Technicians

Technical Bulletin
CAUTION! ALWAYS review and follow all CAUTIONS and WARNINGS in the Repair Manual regarding Airbags!

Airbag On Board Diagnostic (OBD)

For diagnosis using VAS 5051, see VAS 5051 Tester. For additional VAG 1551 information, see Repair Manual, Body On Board Diagnostic (OBD), Repair Group 01. Rapid Data Transfer Enter address word XX HELP Indicated on display Note: With the address word 00 the automatic test sequence is carried out i.e., the DTC memories of all systems in the vehicle capable of On Board Diagnostic (OBD) are checked via the rapid data transfer. Press buttons -1- and -5- to insert Airbag address word 15. Rapid Data Transfer 15 - Airbag V03 Q Indicated on display

Press -Q- button to confirm input.

Indicated on display

1J0 909 608 D AIRBAG VW 3S Coding 0068 Rapid Data Transfer Select function XX

WSC12345

Press button.
Q Indicated on display

(Cont. on Page 3)

C 010005
E 2000 Volkswagen of America, Inc.

Important!
Please give copies to all your VW Technicians

Technical Bulletin
Press buttons -0- and -2- to select Check DTC Memory function 02. Q Indicated on display Press -Q- button to confirm input. Indicated on display (number of DTCs recognized) The stored DTCs are displayed and printed out one after the other. Eliminate DTCs by referencing DTC table. See page 4.

Rapid Data Transfer 02 Check DTC Memory X DTC Recognized

Airbag Diagnostic Trouble Code (DTC) Table

VAG 1551 Scan Tool Display 01217 Igniter for side airbag, drivers side -N199Resistance value too large Resistance value too small Short circuit to B+ Short circuit to Ground (GND) Improper or damaged connection - Read Measuring Value Block. See page 5. Faulty wiring or connections Igniter for side airbag, drivers side N199 faulty 01218 Igniter for side airbag, passengers side -N200Resistance value too large Resistance value too small Short circuit to B+ Short circuit to Ground (GND) Improper or damaged connection - Read Measuring Value Block. See page 5. Faulty wiring or connection Igniter for side airbag, passengers side -N200- faulty (Cont. on Page 4) Possible cause Corrective Action

C 010005
E 2000 Volkswagen of America, Inc.

Important!
Please give copies to all your VW Technicians VAG 1551 Scan Tool Display 01221 Crash sensor for side airbag, drivers side -G179Resistance value too large Resistance value too small Short circuit Open circuit Faulty Not authorized

Technical Bulletin
Possible cause Corrective Action - Check terminals in both connectors are fully seated. If damaged, repair or replace using VAS 1978 Repair Kit. - Check connectors. If damaged, repair using VAS 1978 Repair Kit. - Replace damaged component. - Replace crash sensor or control module. - Check terminals in both connectors are fully seated. If damaged, repair or replace using VAS 1978 Repair Kit. - Check connectors. If damaged, repair using VAS 1978 Repair Kit. - Replace damaged component. - Replace crash sensor or control module.

Faulty wiring or connections

Crash sensor faulty Control module faulty Crash sensor and control module do not match 01222 Crash sensor for side airbag, passengers side -G180Resistance value too large Resistance value too small Short circuit Open circuit Faulty Not authorized Faulty wiring or connections

Crash sensor faulty Control module faulty Crash sensor and control module do not match 65535

Control module malfunctioning Electrical interference as a - Test wiring and connections result of external sources, to control module according poor Ground (GND) to wiring diagram1) connections or Positive connections to control module -J234Control module -J234- faulty
1) Replace

- Replace control module.1)

control module only if DTC 65535 is displayed or vehicle has been involved in an acci(Cont. on Page 5)

dent.

C 010005
E 2000 Volkswagen of America, Inc.

Important!
Please give copies to all your VW Technicians

Technical Bulletin
Measuring value block, reading
WARNING! Check wiring via visual inspection only. Do not check continuity or resistance of airbag igniter circuits. Only check wiring with ignition switched off.

Rapid data transfer Select function XX

HELP

Indicated on display. If VAG 1551 is still in another function:

Press buttons -0- and -6- to select End

Output function. Rapid data transfer 06 End output Rapid Data Transfer Enter address word XX HELP HELP Indicated on display:

Press -Q- button to confirm entry.

Indicated on display

Press buttons -1- and -5- to insert Airbag

address word 15.

Rapid Data Transfer 15 - Airbag

Indicated on display

Press -Q- button to confirm input.

V03 Indicated on display

1J0 909 608 D AIRBAG VW 3S Coding 0068

WSC12345

Press button.

(Cont. on Page 6)

C 010005
E 2000 Volkswagen of America, Inc.

Important!
Please give copies to all your VW Technicians

Technical Bulletin
HELP Indicated on display.

Rapid data transfer Select function XX

Press buttons -0- and -8- to select Read

Measuring Value Block function.

Rapid data transfer 08 Read measuring value block

Indicated on display

Press -Q- button to confirm entry.

Indicated on display

Read measured value block Input display group number XXX 4

Press buttons -0-, -0- and -5- to select display

group 005 and confirm entry with -Q- button. Indicated on display (1-4 = Display Fields) Explanation of individual display fields on display is found in evaluation of display group numbers. If displayed values in all display fields are Correct:

Read measured value block 1 2 3

Press button.
Note: To change to another display group, proceed as follows: Display Group Higher Lower Skip VAG 1551 Press button -3Press button -1Press button -CVAG 1552 Press button Press button Press button -C-

(Cont. on Page 7)

C 010005
E 2000 Volkswagen of America, Inc.

Important!
Please give copies to all your VW Technicians

Technical Bulletin
Note: Check DTC memory after completing Read Measuring Value Block function 08. For additional information, see Repair Manual, Body On Board Diagnostic (OBD), Repair Group 01.

Display group 005

Display group 005 Read Measuring Value Block 5 xxxx 1 xxx 2 xxx 3 xxxx 4 A Display field Specification Not Applicable Not Applicable Igniter for side airbag, passengers side -N200Igniter for side airbag, drivers side -N199Correct Correct Evaluation See Page 8 A Indicated on display

(Cont. on Page 8)

C 010005
E 2000 Volkswagen of America, Inc.

Important!
Please give copies to all your VW Technicians

Technical Bulletin
Evaluating display group 005
Display contents Correct too small to Ground to Positive Corrective action - No malfunctions or DTCs present. - Visually check wiring (for damage) and connectors for correct engagement and tight fit. - While observing display, move seat back and forth, fold seats, (2 door models), move wiring up, down, back and forth in different areas. If display changes from too small, this indicates wiring repairs are necessary. If display remains on too small - Separate yellow 3-pin connector from side airbag adapter harness under seat. Display remains on too small: - Repair wiring between control module and 3-pin connector using VAS 1978 Repair Kit. Display changes to too large: - Remove seat (Remember to connect airbag adapter VAS 5094 as directed) See Repair Manual, Body-Interior, Repair Group 72. - Pull back seat back cover. See Repair Manual, Body-Interior, Repair Group 74.

Display Designation field 1 Igniter for side airbag, drivers id N199 d i side -N199-

(Cont. on Page 9)

C 010005
E 2000 Volkswagen of America, Inc.

Important!
Please give copies to all your VW Technicians

Technical Bulletin
Display contents too small to Ground to Positive Corrective action - Temporarily reinstall seat , remove VAS 5094 and reconnect 3-pin connector. - Separate igniter connector -N199from airbag unit. Display reads too small: - Replace adapter harness between igniter and 3-pin connector. Display reads too large - Reconnect igniter connector. Display reads too small: - Replace airbag unit and adapter harness (if harness has not already been replaced in previous steps).

Display Designation field 1 Igniter for side airbag, drivers side -N199-

(Cont. on Page 10)

C 010005
E 2000 Volkswagen of America, Inc.

Important!
Please give copies to all your VW Technicians

Technical Bulletin
Display contents too large to Ground to positive Corrective action - Visually check wiring (for damage) and connectors for correct engagement and tight fit. - While observing display, move seat back and forth, fold seats, (2 door models), move wiring up, down, back and forth in different areas. If display changes from too large this indicates wiring repairs are necessary. If display remains on too large: - Separate 3-pin yellow connector from side airbag adapter harness under seat (Display should remain too large). - Connect inert igniter #2 on VAS 5056 (see Page 16 to 3-pin yellow connector. Display should change to correct: Display remains on too large: - Press button on VAS 5056 to simulate short circuit. Display remains on too large: - Repair wiring between control module and 3-pin connector using VAS 1978 Repair Kit.

Display Designation field 1 Igniter for side airbag, drivers side -N199-

(Cont. on Page 11)

C 010005
E 2000 Volkswagen of America, Inc.

10

Important!
Please give copies to all your VW Technicians

Technical Bulletin
Display contents too large Corrective action Display changes to too small: - Remove VAS 5056, remove seat. Remember to connect airbag adapter VAS 5094 as directed. See Repair Manual, Body-Interior, Repair Group 72. - Pull back seat cover. See Repair Manual, Body-Interior, Repair Group 74. - Temporarily reinstall seat, remove VAS 5094 and reconnect 3-pin connector. - Separate igniter connector -N199from airbag unit. - Bridge ignitor connector -N199- ON ADAPTER WIRE HARNESS with small gauge wire. Display changes to too small: - Replace airbag unit and adapter harness. Display remains on too large: - Remove wire bridge from adapter harness. - Check adapter harness and connectors for damage, i.e., kinked or pinched wire near tiewrap. - Replace adapter harness between igniter and 3-pin connector. - Reconnect igniter connector. Display remains on too large: - Replace airbag unit and adapter harness (if not previously replaced).

Display Designation field 1 Igniter for side airbag, drivers side -N199-

(Cont. on Page 12)

C 010005
E 2000 Volkswagen of America, Inc.

11

Important!
Please give copies to all your VW Technicians

Technical Bulletin
Display contents Correct too small to Ground to Positive Corrective action - No malfunctions or DTCs present. - Visually check wiring (for damage) and connectors for correct engagement and tight fit. - While observing display, move seat back and forth, fold seats, (2 door models), move wiring up, down, back and forth in different areas. If display changes from too small, this indicates wiring repairs are necessary. If display remains on too small - Separate yellow 3-pin connector from side airbag adapter harness under seat. Display remains on too small: - Repair wiring between control module and 3-pin connector using VAS 1978 Repair Kit. Display changes to too large: - Remove seat (Remember to connect airbag adapter VAS 5094 as directed) See Repair Manual, Body-Interior, Repair Group 72. - Pull back seat back cover. See Repair Manual, Body-Interior, Repair Group 74.

Display Designation field 2 Igniter for side airbag, drivers id N200 d i side -N200-

(Cont. on Page 13)

C 010005
E 2000 Volkswagen of America, Inc.

12

Important!
Please give copies to all your VW Technicians Display Designation field 2 Igniter for side airbag, drivers side -N200-

Technical Bulletin
Display contents too large to Ground to positive Corrective action - Visually check wiring (for damage) and connectors for correct engagement and tight fit. - While observing display, move seat back and forth, fold seats, (2 door models), move wiring up, down, back and forth in different areas. If display changes from too large this indicates wiring repairs are necessary. If display remains on too large: - Separate 3-pin yellow connector from side airbag adapter harness under seat (Display should remain too large). - Connect inert igniter #2 on VAS 5056 (see page 16 ) to 3-pin yellow connector. Display should change to correct: Display remains on too large: - Press button on VAS 5056 to simulate short circuit. Display remains on too large: - Repair wiring between control module and 3-pin connector using VAS 1978 Repair Kit.

(Cont. on Page 14)

C 010005
E 2000 Volkswagen of America, Inc.

13

Important!
Please give copies to all your VW Technicians

Technical Bulletin
Display contents too large Corrective action Display changes to too small: - Remove VAS 5056, remove seat. Remember to connect airbag adapter VAS 5094 as directed. See Repair Manual, Body-Interior, Repair Group 72. - Pull back seat cover. See Repair Manual, Body-Interior, Repair Group 74. - Temporarily reinstall seat, remove VAS 5094 and reconnect 3-pin connector. - Separate igniter connector -N200from airbag unit. - Bridge ignitor connector -N200- ON ADAPTER WIRE HARNESS with small gauge wire. Display changes to too small: - Replace airbag unit and adapter harness. Display remains on too large: - Remove wire bridge from adapter harness. - Check adapter harness and connectors for damage, i.e., kinked or pinched wire near tiewrap. - Replace adapter harness between igniter and 3-pin connector. - Reconnect igniter connector. Display remains on too large: - Replace airbag unit and adapter harness (if not previously replaced).

Display Designation field 2 Igniter for side airbag, drivers side -N200-

3 4

Not applicable Not applicable

Correct Correct

(Cont. on Page 15)

C 010005
E 2000 Volkswagen of America, Inc.

14

Important!
Please give copies to all your VW Technicians

Technical Bulletin
VAS 5056 test box
It is possible to use VAS 5056 in conjunction with VAG 1551/1552 or VAS 5051 to diagnose airbag system faults. WARNING! Check wiring via visual inspection only. Do not check continuity or resistance of airbag igniter circuits. Only check wiring with ignition switched off.

VAS 5056 test box, components

1 - Igniter connector on inert igniter #1.

Used to simulate correct resistance of igniter

at airbag or seat belt. 2 - Adapter harness with connectors for inert igniter #2 (VAS 5056/2).

Used to connect inert igniter #2 to airbag

1 3
01-A018

harness 3 - Button

Used to simulate short circuit in harness

through connectors.

(Cont. on Page 16)

C 010005
E 2000 Volkswagen of America, Inc.

15

Important!
Please give copies to all your VW Technicians

Technical Bulletin
Airbag, connecting test box to side airbag components, example
Connect adapter harness with connectors
for inert igniter #2 (VAS 5056/2) to airbag harness connector underneath seat. See Evaluating display group 005 for specific diagnostic instructions. If diagnosis is not completed, proceed to next step.

Press button to simulate short circuit in

airbag harness through connectors. Repair as directed. If diagnosis is not completed, proceed to next step.

Remove seat -1-.

Note: When removing seat, always connect airbag adapter VAS 5094 as directed. See Repair Manual, Body-Interior, Repair Group 72.

Pull back seatback cover to expose side

airbag unit -2-. See Repair Body-Interior, Repair Group 74. Manual,

Remove connector -3- from airbag igniter. Check airbag igniter connector -3- for
damage.

1 3

Temporarily reinstall seat, remove VAS 5094

and reconnect 3-pin connector.

Bridge ignitor connector -N199- or -N200ON ADAPTER WIRE HARNESS with small gauge wire.

If concern still exists, replace side air bag unit

-2- and adapter harness. See Repair Manual, Body-Interior, Repair Group 69.

2
69-A010

(Cont. on Page 17)

C 010005
E 2000 Volkswagen of America, Inc.

16

Important!
Please give copies to all your VW Technicians

Technical Bulletin
Wire harness, repair
Note: No other procedure or materials, other than those in VAS 1978, may be used for wire harness repairs, specifically soldering, wire nuts, generic repair kits, etc. Always review Safety Precautions in the VAS 1978 Instruction Manual prior to performing any wiring harness repairs. CAUTION! Wiring that is part of the ABS system and shielded wiring for components, such as speed sensors or knock sensors, may not be repaired, but must ALWAYS be replaced. DO NOT use solder wire when repairing a wiring harness. Only use approved methods and materials if wiring harness repairs are required.

If wiring harness repairs are required:

Use only VAS 1978 Wire Harness Repair Kit. If wire harness cannot be repaired using this
procedure and materials contained in VAS 1978, replace wire harness.

N97-0027

(Cont. on Page 18)

C 010005
E 2000 Volkswagen of America, Inc.

17

Important!
Please give copies to all your VW Technicians

Technical Bulletin
Terminal, inspection
Replace terminal when one of following conditions occur:

C B

Terminal is bent or unintentionally deformed. Terminal is cracked or torn at crimped areas -Band -C-. Wire insulation has been drawn into core crimp -B-. Material is cracked at transition bend -D-. Terminal coating shows signs of moisture or greasy coating. Terminal surface should be bright and shiny. Primary lock tab(s) -A- should be straight and stand away from terminal. Note: During terminal extraction, primary lock tab(s) may have been pressed into terminal. Straighten using sharp edge to carefully lift tab.

0.64 mm Receptacle Terminal Gold Plated Contact Surfaces

97-A524

C 010005
E 2000 Volkswagen of America, Inc.

18