CONSTRUCTION SPECIFICATIONS

Before working on the electrical system (connectors, electrical components, wiring, etc.), turn the ignition key to STOP and disconnect the battery.

SAFETY INSTRUCTIONS TO BE FOLLOWED FOR WORKING ON CARS FITTED WITH AIRBAG SYSTEMS AND PRETENSIONERS

The following instructions MUST BE FOLLOWED for any work on cars equipped with airbag safety systems with pretensioners.

PRELIMINARY INSTRUCTIONS

Remember that airbag modules and pretensioners must 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 repairs on the bodywork, welding or work that involves removing the airbag modules and/or pretensioners, or the control unit:

- Remove the key from the starter switch.

Always disconnect the battery, i.e. disconnect the two terminals from their respective poles and thoroughly insulate them with tape.

- Wait at least 10 minutes after disconnecting the battery and disconnect the electrical connection for the control unit.

Position the devices with the cover upwards in a locked metal cupboard. This cupboard, intended exclusively for this purpose, must not, under any circumstances, be used to store any other types of material, particularly if they are flammable.

The cupboard must be designed to store pyrotechnic charges (metal, impact resistant cupboard with grates to allow natural internal ventilation) and must 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 airbag modules and/or pretensioners contain a short circuit clip. Until the airbag modules and/or pretensioners are connected to an appropriate energy source there is no possibility of them being accidentally activated.

The continuity of the system wiring can only be measured after the modules have been replaced with specific dummy resistors.

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 car (on account of defects or other reasons) must be returned to the special centre, following the procedure described below.

The safety system components must ONLY be fitted and dismantled by skilled, authorised personnel. Failure to follow the procedures described below could result in the accidental activation of the system, personal injury or unnecessary repairs to the system. AIRBAG MODULES AND/OR PRETENSIONERS MUST NOT, UNDER ANY CIRCUMSTANCES, BE DISMANTLED.

All the system components have been specially designed to work on a specific make and type of vehicle, therefore airbag modules and/or pretensioners cannot be adapted, reused or installed on vehicles other than those for which they were designed and produced.

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

Interventions on system components

After any repair, the system must be checked using EXAMINER or other diagnosis equipment.

Airbag module and/or pretensioner replacement

To replace an airbag module and/or the pretensioners, it is necessary to:

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 folder must be kept for any checks necessary.

- A new sticker is supplied together with the module, which must be stuck over the one either in the driver side area (door or central pillar) or in the passenger side glove compartment. Before sticking it on, perforate it at the installation month and year of the new module.

This also applies when replacing the clock springs.

Control unit replacement

The electronic control unit must ALWAYS be replaced after an impact that results in the entire system being activated (airbag module and pretensioners).

Handle the control unit with extreme care during maintenance, do not drop it and do not knock it.

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

Replacing the clock spring

The clock spring for connecting the driver's airbag 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, no longer secured to the steering wheel, from turning freely and unwinding or winding the cables inside the device and possibly causing them to break. The device is automatically released when the steering wheel is refitted.

When removing/reattaching the steering wheel, if it is not necessary to remove the clock spring, use adhesive tape to block rotation of the two plates.

When replacing, if the clock spring is supplied separately from the steering column, it must be installed with the wheels straightas this is the corresponding position of the new device.

The new device is equipped with a safety tab that keeps it locked.

This tab must be removed when fitting the steering wheel to allow the system to rotate correctly.

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 they are not damaged when the outside surfaces of the vehicle get hot from normal paint drying systems.

In any case, the vehicle must not be exposed to temperatures above 93°C (200°F). If exposed to higher temperatures, remove the components to prevent damage or possible activation.

It is forbidden to use naked flames near the modules.

All the electronic control units (including the Air Bag system) need to be removed if their temperature in certain environments could reach or exceed 85°C.

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 airbag modules and/or pretensioners.

Accidents with or without activation of the airbags and/or pretensioners

Some of the system components must be inspected after an accident whether the system has been activated or it has NOT been activated.

These components are:

- Steering control shaft.

- Steering control shaft mount.

- Electronic control unit and module anchoring area.

- Clock spring.

- Dashboard (in the passenger airbag module area).

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

Accidents with activation of the airbags

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

In the event 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 event of total activation (airbags, side bags, head bags and pretensioners), these components are:

- Front airbag modules.

- Pretensioners, side bags or head bags.

- Electronic control unit.

As far as the wiring and connectors are concerned, they must 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 airbag modules are mounted means that the damaged components must be replaced.

Dangers to health

The following precautions should be observed when handling activated airbag modules and/or pretensioners:

- wear polythene protective gloves and safety goggles;

- wash your hands and other exposed parts of the body with soap and water after touching triggered airbag units and/or pretensioners.

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

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

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: immediately take the affected person into the open air.

- Swallowing: induce vomiting if the person is conscious.

A doctor must always be called in these situations.

SAFETY INSTRUCTIONS FOR HANDLING AIRBAG MODULES AND/OR PRETENSIONERS

In normal conditions the driver and passenger airbags and/or pretensioners 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 work on devices fitted on the car follow the obligatory safety regulations listed below.

The personnel working on the devices must have received suitable training and must observe the following precautions:

When removing and replacing open (exploded) airbags and/or pretensioners, move the modules one at a time and wear protective gloves and goggles for the removal.

- Always place the airbag module with the opening flap and the pre-breaking splines facing upwards. Never place anything on top of this flap.

- Do not use the rod to handle loose pretensioners or seats with pretensioners installed

- At the end of the operations, wash your hands thoroughly with mild soap and, if the residual dust from the device contacts the eyes, rinse immediately with plenty of running water.

- On all versions with airbags and/or pretensioners, it is forbidden to work from the front seats before having rendered the system inoperative by disconnecting the two battery cables and waiting 10 minutes.

- The metal airbag and/or pretensioner components are very hot just after it has been deployed. - Avoid touching these components for 10 minutes after the airbag and/or pretensioner has been activated.

- Do not carry out repairs on airbag modules and/or pretensioners.

- Do not heat the airbag module and/or pretensioners (e.g. by welding, striking, drilling, mechanical machining, etc.).

- Do not install airbag modules and/or pretensioners that have been dropped or show signs of any type of damage.

The storage of airbag modules together with flammable or combustible materials is prohibited.

Gas generators must 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 must be stored in their original packaging. For temporary storage, use the same procedures as for airbag modules and/or pretensioners that have not been activated and have been removed from the car, i.e. in a specially designed, locked, metal cupboard (impact resistant metal cupboard with grates for natural internal ventilation).

The cupboard must have special warning signs (DANGER: EXPLOSIVES - NO NAKED FLAMES - NOT TO BE OPENED BY UNAUTHORIZED PERSONNEL).

AIRBAG MODULE AND/OR PRETENSIONER REPLACEMENT

The airbag modules and/or pretensioners fitted on the car must not be scrapped with the car itself, but removed first.

The airbag modules and/or pretensioners cannot be scrapped unless they have been activated first. If the airbag module and/or pretensioners have 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: "AIRBAG MODULE AND/OR PRETENSIONER CONTAINING PYROTECHNIC CHARGE TO BE DEACTIVATED".

The local laws in force must be observed in all cases.

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

Obviously, if airbag modules and/or pretensioners are being replaced, the original packaging must be kept intact for dispatching the devices that have not been activated.

FAILURE to follow the procedures described here may cause the accidental activation of the airbag modules and/or pretensioners resulting in personal injury. Airbag units that have not been activated must NOT be disposed of through normal waste disposal methods. Airbag modules and/or pretensioners that have not been activated contain substances that are dangerous to health and can cause personal injury if the sealed container is damaged during disposal. Failure to comply with this procedure when disposing of airbag modules and/or pretensioners may violate the relevant laws in force.

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 Dealers do not keep these parts in stock.

In any case, a record should be kept of internal movements, recording the module identification numbers and vehicle details (chassis number, registration date, model, etc.).

TIGHTENING TORQUE VALUES

The values given refer to the material strength classes most used in production.

When tightening a "screw with nut", the torque values refer to the part being turned.