INTRODUCTION - AIR BAG SYSTEM

PRECAUTIONS

PRECAUTIONS

Work carefully on the fittings and use the recommended tools correctly to prevent damage.

SAFETY INSTRUCTIONS TO BE FOLLOWED FOR OPERATIONS ON VEHICLES FITTED WITH AIR BAG SYSTEMS

The following instructions MUST BE FOLLOWED during any operation involving vehicles equipped with Air Bags.

Preliminary instructions

It should be remembered that Air Bag modules should be handled with care. Their use, transportation and storage are regulated by the procedures for handling such components, which are given below.

Before carrying out any repair operations to the bodywork, welding or operations that involve removing the Air Bag modules or the control unit:

• Remove the key from the ignition switch.
• Always disconnect the battery, i.e.: disconnect the two leads from the pole and insulate them taping them carefully.
• Disconnect the electrical connection for the control unit waiting at least 10 minutes after disconnecting the battery.

Position the devices with the cover upwards in the lockable metal cupboard. This cupboard, especially designed for this purpose, should not, under any circumstances, be used to store any other types of material, particularly if they are flammable. The cupboard should be designed to store pyrotechnic charges (metal, impact resistant cupboard with grates to allow natural ventilation) and should have the markings required by law (DANGER EXPLOSIVES - NO NAKED FLAMES - NOT TO BE OPENED BY UNAUTHORIZED PERSONNEL).

All the connectors used and wired to the Air Bag modules contain a short circuit clip. Until the Air Bag modules are connected to an appropriate energy source there is no possibility of them being accidentally activated.

A system component that has not been activated during an accident is considered to still be "active". Therefore unexploded components that have to be removed from the vehicle (on account of defects or the warranty has expired, etc.) should be returned to the special centre following the procedure described below.

The safety system components should ONLY be fitted and dismantled by skilled, authorized personnel. Failure to follow the procedures described below could result in the accidental activation of the system, personal injury or repairs to the system that are not necessary. AIR BAG MODULES MUST NOT, UNDER ANY CIRCUMSTANCES, BE DISMANTLED.

All the system components have been specifically designed to work on a specific marque and type of vehicle, therefore Air Bags should not be adapted, reused or installed on other vehicles, only the ones for which they have been designed and produced.

Any attempt to resue, adapt or install one on a different type of vehicle could result in serious injury or even be fatal for the occupants of the vehicle in the case of an accident.

Interventions on system components

After every repair to the system it should be checked using the EXAMINER or other diagnostic equipment.

Module duration

The system pyrotechnic components have different life spans.

Therefore they must be replaced at the following intervals:

• Air Bag modules: 14 years
• Clock spring: 10 years
• Pretensioner: 10 years

Air bag module replacement (on account of defects or expiry of warranty)

If an Air Bag module is being replaced because it is defective or the warranty has expired:

• Remove the detachable part of the adhesive label from the new module and place it in the special folder containing the vehicle details (model, registration date, chassis number) and the serial number of the old module. The file should be kept for future checks.
• A new adhesive lable is supplied together with the module that should be stuck on top of the existing one. Beforehand, however, it should be perforated at the month and 14 years after the year in which the module is being fitted (e.g. 2003 for 2017).

Similarly, if the clock spring or a pretensioner is being replaced, remember that the recommended life of these components is 10 years.

Control unit replacement

The electronic control unit should ALWAYS be replaced after an impact that results in the entire system being activated (Air Bag and pretensioners).

If the control unit is being replaced, the detachable part of the adhesive label must also be removed and placed the special file mentioned above.

Replacing the clock spring

The clock spring for connecting the driver''s Air Bag module is equipped with a device that automatically stops it rotating when the steering wheel is removed. This is designed to prevent the upper plate, now no longer secured to the steering wheel, from turning freely and unwinding or winding the coil inside the device and possibly causing it to break.

The device is automatically released when refitting the steering wheel.

If the clock spring is removed and refitted, ensure it is refitted to the steering wheel stalk unit in the same position as before removal.

If, for any reason, the upper clock spring shim has rotated in relation to the lower to an extent that the position is unknown, the clock spring must be REPLACED.

In the case of replacement, the replacement clock spring is supplied separately from the steering column switch unit and it should be fitted with the wheels straight because this is the corresponding position for the new device. The new device is equipped with a safety tab that keeps it locked. This tab should be removed when fitting the steering wheel to allow the system to rotate correctly.

Interventions after an accident

If any of the safety system components is damaged following an accident it MUST be replaced.

Do not attempt to repair the control unit, clock spring or Air Bag modules.

Accidents with or without air bags activated

Several of the system components should be inspected after an accident whether the system has been activated or whether it has NOT been activated. These components are:

• Steering column;
• Steering column supports;
• Electronic control unit and modules mounting area;
• Clock spring;
• Dashboard (the area of the passenger Air Bag module).

If the component shows signs of distortion, breaks or bends it should be replaced.

Accidents with air bags activated

Several of the system components should be replaced if the vehicle is subject to a frontal impact that has fully or partly activated the system.

In the case of partial activation (pretensioners, Side Bags or Head Bags), these components are:

• Pretensioners, Side Bags or Head Bags
• Electronic control unit (only after the third activation of the pretensioners, Side Bags or Head Bags)

In the case of total activation (Air Bags, Side Bags, Head Bags and pretensioners), these components are:

• Front Air Bag modules
• Pretensioners, Side Bags or Head Bags
• Electronic control unit.

As far as the wiring and connectors are concerned, they should be inspected for any signs of burning, melting of the outside insulation or damage from excessive heat.

Any signs of damage to the clock spring or in the area where the electronic control unit and Air Bag modules are mounted means that the damaged components should be replaced.

Painting operations

There are no special safety regulations to follow for painting and subsequent drying operations in an oven because the modules in particular have been designed in such a way that the outside surfaces of the vehicle are not damaged when they get hot from normal paint drying systems.

It is forbidden to use naked flames near the modules.

All the electronic control units (including the Air Bag system) are always removed if the ambient temperature could reach or exceed 85°C.

Dangers to health

The following precautions should be observed when handling activated Air Bag modules:

• wear polythene protective gloves and safety goggles;
• wash your hands and other parts of the body exposed with soap and water after touching exploded Air Bag units.

Effects of overexposure

There is no potential danger of exposure to the propellants as the system is completely sealed.

The propellant mixture is in a solid state therefore it is impossible to inhale it even if the gas generator cartridge is broken.

There is no danger to human health if the gas escapes.

Contact with the skin should be avoided and the propellant should not be swallowed.

In the case of:

• Contact with skin: wash immediately with soap and water.
• Contact with eyes: wash eyes immediately with running water for at least 15 minutes.
• Inhalation: take the affected person into the open air immediately.
• Swallowing: induce vomiting if the person is conscious.

A doctor should always be called in these situations.

SAFETY INSTRUCTIONS FOR HANDLING AIR BAG MODULES

In normal conditions the driver''s and passenger Air Bags are activated by the electronic command during the impact. The gases that develop in these conditions are not toxic.

It is important that the personnel who carry out repairs to devices fitted on the vehicle follow the safety regulations listed below.

The personnel working on the devices should be trained and should observe the following precautions:

• When removing and replacing open (exploded) Air Bags, only move the modules one at a time and wear protective gloves and goggles for the removal.
• Always rest the Air Bag module with the opening flap and the pre-breaking splining facing upwards. Never place anything on top of this flap.
• At the end of the operations wash your hands thoroughly with soap and, if there is any contact with the residual powder and your eyes, rinse immediately with plenty of running water.
• On all versions with Air Bags it is forbidden to work from the front seats before having rendered the system inoperative by disconnecting the two battery leads and waiting at least 10 minutes
• The metal Air Bag components are very hot just after it has exploded. Avoid touching these components for 20 minutes after the Air Bag has been activated.
• Never carry out repair operations on Air Bag modules. Send all defective modules to the supplier.
• Never heat the Air Bag module (e.g. through welding, striking, drilling, mechanical machining, etc.);
• Never fit Air Bag units that have been dropped or show signs of any type of damage.
• The storage of Air Bag modules together with flammable or combustible materials is prohibited.
• Gas generators should not come into contact with acid, grease or heavy metal: contact with these substances could cause the formation of gases that are poisonous or harmful or explosive compounds.

Replacement parts should be stored in their original packaging and the same procedures as for Air Bag modules that have not been activated and have been removed from the vehicle should be followed for their temporary storage, i.e. in a specially designed, locked, metal cupboard (impact resistant metal cupboard with grates for natural ventilation) The cupboard should have special warning signs (DANGER: EXPLOSIVES - NO NAKED FLAMES - NOT TO BE OPENDED BY UNAUTHORIZED PERSONNEL).

SCRAPPING AIR BAG MODULES

The Air Bag modules fitted on the vehicle should not be scrapped with the actual vehicle, but removed first.

The Air Bag units cannot be scrapped unless they have been activated first.

If the Air Bag module has not been activated during an accident it should be considered as still charged.

All unexploded material SHOULD NOT BE ACTIVATED, but should be sent to a specialist centre with the following written on the accompanying docket: "AIR BAG CONTAINING PYROTECHNIC CHARGE TO BE DEACTIVATED".

The local laws in force must be observed.

The devices must be sent in the packaging that replacement components are received in and, if it is not available, the packaging only can be ordered from the PARTS DEPT.

Obviously, if Air Bags are being replaced, the original packaging should be kept intact for dispatching devices not activated.

Not following the procedures described here can cause the accidental activation of Air Bag units and result in personal injury. Air Bag units that have NOT been activated should be disposed of through normal methods. Air Bag units that have not bee activated contain substances that are dangerous to health and can cause personal injury if the sealed container is damaged during disposal. The disposal of Air Bag units not carried out in accordance with this procedure may be in violation of regulations in force on this subject.

ORDERING METHODS

If necessary, the devices can be ordered, as and when required, from the Aftersales Parts Department - Volvera through the V.O.R. procedure since the Network should not keep these parts in stock. In any case, a record should be kept of internal movements by recording the module identification numbers and vehicle details (chassis number, registration date, model, etc.).

PRECAUTIONS

PRECAUTIONS

Before working on the electrical system (connectors, electrical components, wiring, etc.) turn the ignition key OFF and DISCONNECT THE BATTERY.

Work carefully on the fittings and use the recommended tools correctly to prevent damage.

CODE - ALARM SYSTEM COMPONENT MANAGMENT

Data base for code and alarm system parts management

There is a centralized DATA BASE (for all markets) managed by the PARTS DIVISION for ordering all CODE system components and some of the alarm system components.

The production plant transfers all the necessary data into this data base together with the chassis number of the new vehicle.

This data base is then used for ordering components that need replacing by the Dealer Network.

The data base contains numerous pieces of information, such as:

• vehicle chassis no.;
• secret code;
• code for each key (transponder identification);
• remote control code;
• mechanical key code;
• programming data;

If one of the CODE - alarm system components needs replacing and is being ordered, follow the procedures described below.

Lost key/s (mechanical or key with remote control)

Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.

Deleting codes of lost keys from the body computer memory

Connect the Tester to the vehicle tester output and run the following procedure.

1. Set the Body Computer to "Code Acquisition" mode.

2. Insert the remaining keys into the ignition in sequence.

3. Exit "Code Acquisition" mode: The IDs of keys not inserted will be deleted from the Body Computer memory.

4. Set the Body Computer to "Remote Control Code Acquisition" mode.

5. Press the keys of the remaining remote control units in sequence.

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6. Exit "Remote Control Code Acquisition" mode: The IDs of remote control units not inserted will be deleted from the Body Computer memory.

All versions

At the end of the procedure, pring a table showing the identification code/s still enabled. If no printer is available, copy the codes from the screen onto the FIAT PARTS system form.

Only if the Body Computer already contains 8 keys, send the codes to Fiat Parts to update the DATABASE.

Requesting a new key

Use the Personal Computer supplied to log onto Fiat Parts. Enter the chassis no. of the customer''s car, the model code and set up a VOR order to request the key/s (entering the part number) and specify the quantity.

Note that the Body Computer is designed to store up to 8 keys. It is not therefore possible to accept orders when the sum of the number of existing keys and the number of keys ordered exceed this quantity. Keep a record of the form used to order the keys in order to monitor the situation.

Programming key codes into the body computer memory

Once the new key/s have been received from Fiat Parts, ensure that all the old keys in the customer''s possession are available.

Connect the Tester to the vehicle tester output and run the following procedure.

1. Set the Body Computer to "Code Acquisition" mode.

2. Insert all the keys (old and new) into the ignition in sequence.

3. Exit "Code Acquisition" mode.

4. Then set the Body Computer to "Remote Control Code Acquisition" mode.

5. Press all the remote control units, old and new, in sequence: it may take several seconds to initialise the new remote control units.

6. Exit "Remote Control Code Acquisition" mode:

7. Check system operation before returning the vehicle to the customer by starting it up using all the keys and opening/closing the doors using the remote control unit (if applicable).

Ordering a new key (mechanical or key with remote control)

Proceed as described above, but no deletion is necessary. Order a new key from Parts and store it (if it comes with a remote control unit, the SEED and ID must also be stored).

If the Body Computer memory already contains 8 stored keys, run the deletion procedure if keys have been lost.

Note that the Body Computer is designed to store up to 8 keys. It is not therefore possible to accept orders when the sum of the number of existing keys and the number of keys ordered exceed this quantity. Keep a record of the form used to order the keys in order to monitor the situation.

In the case of operating faults, it is possible to order spare parts only, but it is absolutely forbidden to exchange electronic control units and/or transponders between different keys because it will not be possible to service the vehicle in the future.

Replacing key lock barrels

This becomes necessary when one or more door lock barrels and/or the ignition key barrel are forced.

Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.

Use the Personal Computer supplied to log onto Fiat Parts. Enter the chassis no. of the customer''s car, the model code and set up a VOR order to order a single key kit (entering the part number) for the vehicle type and specification.

A single cylinder or a kit with the mechanical key code only cannot be ordered.

Programming key codes into the body computer memory

Once the new key kit is received from Fiat Parts, replace the barrels on the door locks and ignition key.

Connect the Tester to the vehicle tester output and run the following procedure.

1. Set the Body Computer to "Code Acquisition" mode.

2. Insert all the new keys into the ignition in order to recognise the new transponder ID codes.

3. Exit "Code Acquisition Mode". Keys not inserted will not be usable for start-up.

4. Then set the Body Computer to "Remote Control Code Acquisition" mode to recognise the SEEDs and IDs of the new remote control units.

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5. Press all the new remote control units in sequence: it may take several seconds to initialise the remote control units.

All versions

6. Exit "Remote Control Code Acquisition" mode:

7. Check system operation before returning the vehicle to the customer by starting it up using all the keys and opening/closing the doors using the remote control unit (if applicable).

If the customer already owns 2 keys prior to the loss, order further keys as indicated previously (ORDERING NEW KEYS) and remember to insert all keys by means of the appropriate procedure.

Lost code card

The Customer must prove that he or she is the owner of the vehicle by producing the registration document and identification data.

Use the Personal Computer supplied to log onto Fiat Parts. Enter the chassis no. of the customer''s car, the model code and set up a VOR order to order a single Code Card (entering the part number).

Once it has been received from Fiat Parts, deliver the new Code Card to the Customer.

Body computer operating fault

Ensure the fault reported by the Customer is due to a body computer malfunction.

Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.

Use the Personal Computer supplied to log onto Fiat Parts. Enter the chassis no. of the customer''s car, the model code and set up a VOR order to order a single Body Computer (entering the part number to identify the version).

Once the new programmed Body Computer has been received from Fiat Parts, proceed as follows:

1. Check the Body Computer serial number stamped on the plate applied to the order form corresponds to that shown on the Body Computer.

2. Check the vehicle chassis no. printed on the plate applied to the order form corresponds to the vehice chassis no.

3. If all codes correspond, install the Body Computer on the vehicle instead of the malfunctioning unit.

4. Connect the Tester to the tester output on the vehicle.

5. Set the Body Computer to "Code Acquisition" mode.

6. Insert all the keys in the customer''s possession into the ignition for recognition of the keys that are still enabled.

7. Exit "Code Acquisition" mode: The IDs of keys not inserted will be deleted from the Body Computer memory.

8. Set the Body Computer to "Remote Control Code Acquisition" mode.

9. Press the remote control units in the Customer''s possession in sequence in order to ensure the remote control units that are still enabled are recognised.

10. Exit "Remote Control Code Acquisition" mode: The IDs of remote control units not inserted will be deleted from the Body Computer memory.

11. Check system operation before returning the vehicle to the customer by starting it up using all the keys and opening/closing the doors using all the remote control units available (if applicable).

Engine control unit operating fault

A possible fault in the electronic injection control unit should always be confirmed through a thorough check using the Examiner or other diagnostic equipment.

Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.

Use the Personal Computer supplied to log onto Fiat Parts and set up a VOR order to request a single Engine Control Unit (entering the part no.).

Once a new blank Engine Control Unit has been received from Fiat Parts, install it on the vehicle in place of the malfunctioning unit.

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Initalise the Control unit by turning the ignition on with the enabled keys so that the FIX CODE resident in the Body Computer is transferred to the Engine Control Unit.