Warning - Airbags

PRELIMINARY INSTRUCTIONS

Before carrying out any repair operations on the bodywork, welding or operations that involve removing the airbag modules or the Occupant Restraint Controller (ORC) module:

• Remove the key from the ignition switch.
• Always disconnect the battery. Disconnect the two terminals from the respective poles and insulate by taping them carefully.
• Disconnect the electrical connection for the ORC, waiting at least 10 minutes after disconnecting the battery.

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 OPEN FLAMES - NOT TO BE OPENED BY UNAUTHORIZED PERSONNEL).

All the connectors used and wired to the airbag modules contain a short circuit clip. Until the airbag 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 car (on account of defects or other reasons) must be returned to the special center, following the procedure described below.

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

INTERVENTIONS ON SYSTEM COMPONENTS

After every repair to the system, it must be checked using a diagnostic scan tool or other diagnosis equipment.

AIRBAG MODULE REPLACEMENT (ON ACCOUNT OF DEFECTS OR ACTIVATION)

If an airbag module is replaced due to defects or activation, it is necessary to remove the detachable part of the adhesive label from the new module and place it in a suitable folder containing the car details (model, registration date, chassis number) and the serial number of the old module. The folder must be kept for any checks necessary.

This also applies to clocksprings and tensioners.

OCCUPANT RESTRAINT CONTROLLER (ORC) MODULE REPLACEMENT

The Occupant Restraint Controller (ORC) module must ALWAYS be replaced after an impact that results in the entire system being activated (airbags and tensioners). If the ORC is being replaced, the detachable part of the adhesive label must also be removed and placed in the file mentioned above.

REPLACING THE CLOCKSPRING

The clockspring for connecting the Driver AirBag (DAB) 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 reinstalled.

If replaced, the clockspring is supplied together with the steering wheel interface and must not be separated. Installation must be carried out with the wheels straight because 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 installing 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.

It is forbidden to use open flames near the modules.

All the electronic control units (including the Occupant Restraint Controller (ORC) module) must always be removed if the ambient temperature could reach or exceed 85° C (185° F).

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 Occupant Restraint Controller (ORC) module, clockspring or airbag modules.

ACCIDENTS WITH OR WITHOUT ACTIVATION OF THE AIRBAGS

Some of the system components must 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
• Occupant Restraint Controller (ORC) module and module mounting area
• Clockspring
• Instrument panel (the area of the Passenger AirBag/PAB module).

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

ACCIDENTS WITH ACTIVATION OF THE AIRBAGS

Some of the system components must 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 (tensioners, side bags or head bags), these components are:

• Tensioners, side bags or head bags
• Occupant Restraint Controller (ORC) module (only after the third activation of the tensioners, side bags or head bags)

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

• Front airbag modules
• Tensioners, side bags or head bags
• ORC module

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 clockspring or in the areas where the ORC 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:

• 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.

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 must always be called in these situations.

SAFETY INSTRUCTIONS FOR HANDLING AIRBAG MODULES

In normal conditions the driver and passenger airbags 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 installed 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, only move the modules one at a time and wear protective gloves and goggles for the removal.
• Always rest the airbag module with the opening flap and the predetermined breakout lines facing upwards. Never place anything on top of this flap.
• At the end of the operations wash your hands thoroughly with neutral soap and, if there is any contact between the residual powder from the device and your eyes, rinse immediately with plenty of running water.
• On all versions with airbags 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 components are very hot just after it has been deployed. Avoid touching these components for 20 minutes after the airbag has been activated.
• Never carry out repair operations on airbag modules. Send all defective modules to the supplier.
• Never heat the airbag module (e.g. through welding, striking, drilling, mechanical machining, etc.).
• Never install airbag units 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 and the same procedures as for airbag modules that have not been activated and have been removed from the car must be followed for their temporary storage, 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 OPEN FLAMES - NOT TO BE OPENED BY UNAUTHORIZED PERSONNEL).

SCRAPPING AIRBAG MODULES

The airbag modules installed on the car must not be scrapped with the car itself, but removed first.

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

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

NO unexploded material MUST BE ACTIVATED, but must be sent to a specialist center with the following written on the accompanying docket: "AIRBAG 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 airbags are being replaced, the original packaging must be kept intact for dispatching devices which have not been activated.

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.).