122-E7M2M-09

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Replacing Airbag Sensor
Subject:
Replacing airbag sensor during repairs
Model Year:
As of 1990 up to 1994
Information:
Old airbag sensor no longer available.
Note:
During repairs, the faulty airbag sensor will be replaced by a new electronic airbag sensor. The new
airbag sensor is the same size as the airbag sensor that is installed as standard but needs an additional
power supply (terminal 15) from the fuse box in the luggage compartment.
Recommendation: Always replace the component in pairs.
Pars Info:
964.613.221.03
 Airbag sensor, set
Parts list:
Figure 1
———
1x
Airbag sensor  Figure 1 -1-
———
1x
Power supply line  Figure 1 -2-
———
2x
Shear-off nut  Figure 1 -3-
———
2x
Socket contact (not shown)
———
1x
Insulation tube (not shown)
———
6x
Tie-wrap (not shown)
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Tools:
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9259 - Socket-wrench insert
Work Procedure: 1
Component overview:
1
2
3
4
5
6
2
–
–
–
–
–
–
Right airbag sensor
Connection point for right airbag sensor
Relay/fuse carrier
Rubber sleeve in cross panel
Connection point for left airbag sensor
Left airbag sensor
Preparatory work:
2.1
Open front lid.
2.2
Remove cover on front lock lower part and
front-compartment carpet.
2.3
Only if replacing left airbag sensor or both
airbag sensors.
Remove cowl panel.
2.3.1
Unscrew screws  Figure 3 -1-.
2.3.2
Remove cowl panel  Figure 3 -2with piping  Figure 3 -3-.
2.4
Disconnect the battery.
2.5
Loosen relay/fuse carrier.
2.5.1
Figure 2
Open cover on relay/fuse carrier.
Figure 3
2.5.2
Unscrew screws  Figure 4 -1- and
remove filler plate  Figure 4 -2-.
Figure 4
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Unscrew screws  Figure 5 -1/2-.
Lift up the relay/fuse carrier 
Figure 5 -arrow- and set it aside.
3
Install power supply lines at the right and/or left.
3.1
Install power supply line at the right.
Figure 5
3.1.1
Open tie-wrap  Figure 6 -1-.
Unclip connection point for right
airbag sensor  Figure 6 -2from holder  Figure 6 -3- and
disconnect plug connection.
Figure 6
3.1.2
Carefully pull rubber sleeve 
Figure 7 -1- out of the body
(relay/fuse carrier housing) 
Figure 7 -a-.
Expose wire harness for airbag
sensor  Figure 7 -2-.
3.1.3
Guide power supply line through the
insulation tube.
Figure 7
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3.1.4
Guide power supply line  Figure
8 -1- through the rubber sleeve 
Figure 8 -2- ( Figure 8 -a-)
Figure 8
until the power supply line
connector  Figure 9 -1- is
touching the airbag sensor wire
harness connector  Figure 9 -2-.
Figure 9
3.1.5
Route airbag sensor wire harness
 Figure 10 -1- and power supply
line  Figure 10 -2- through
the bore to the airbag sensor
connection point holder  Figure
10 -3-.
Fit rubber sleeve  Figure 10 -4-.
Figure 10
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3.2
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Route power supply line  Figure
11 -1- further on to the relay/fuse
carrier.
Install power supply line at the left.
3.2.1
Open tie-wrap. Unclip connection
point from holder and disconnect
plug connection for airbag sensor.
Figure 11
3.2.2
Press rubber sleeve  Figure 12
-1- out of the cross panel  Figure
12 -3- ( Figure 12 -arrow-).
Expose wire harness for airbag
sensor  Figure 12 -2-.
3.2.3
Guide power supply line through the
insulation tube.
Figure 12
3.2.4
Guide power supply line  Figure
13 -1- through the rubber sleeve 
Figure 13 -2- ( Figure 13 -a-)
until the power supply line
connector  Figure 13 -b- is
touching the airbag sensor wire
harness connector  Figure 13
-4-.
3.2.5
Guide airbag sensor wire harness
and power supply line through the
cross panel and fit rubber sleeve.
Figure 13
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3.2.6
3.3
Route power supply line  Figure
14 -1- in the plenum panel  Figure
14 -2- to the relay/fuse carrier.
Connect power supply line at the right and/or
power supply line at the left.
Figure 14
3.3.1
Pull out locking mechanism
 Figure 15 -1- ( Figure 15
-arrow-).
Information
The connector is identified by the
letter K (Fig. 15 -inset-) on the side
of the relay/fuse carrier.
Disconnect connector K  Figure
15 -2 - from the relay/fuse carrier.
Figure 15
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The plug socket (row 1.1 – 1.5) is
not marked.
Only the related pin contacts on the
relay/fuse carrier are marked.
Relay/fuse carrier
3.3.2
Insert a small screwdriver  Figure
16 -1- into connector K  Figure
16 -a-.
Disconnect plug socket (row 1.1 –
1.5) from connector K  Figure 16
-b-.
3.3.3
Crimp power supply line at the right
and/or power supply line at the
left together using a new socket
contact.
Figure 16
3.3.4
Insert socket contact into chamber
1.2  Figure 16 -arrow-.
Assemble plug socket (row 1.1 –
1.5) and connector K.
Figure 17
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3.3.5
Connect connector K  Figure
18 -1- to the relay/fuse carrier 
Figure 18 -a-.
Close the locking mechanism 
Figure 18 -b-.
3.3.6
Secure lines to the standard wire
harness with a tie-wrap.
Figure 18
4
Replace airbag sensor at the right and/or left.
4.1
Unscrew shear-off nuts using 9259 - socketwrench insert  Figure 19 -2- and remove
airbag sensor  Figure 19 -1-.
4.2
Clean sealing surfaces  Figure 19 -3- until
bare metal is exposed using a brass brush.
4.3
Position airbag sensor. Tighten shear-off nuts
 Figure 19 -4-.
4.4
Connect airbag sensor connection point 
Figure 19 -5- and fit it in the holder.
Connect power supply connection point 
Figure 19 -6-.
5
Concluding work:
5.1
Install relay/fuse carrier.
Figure 19
Install filler plate.
Close cover on relay/fuse carrier.
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5.2
Only if left airbag sensor or both airbag sensors were replaced.
Install cowl panel.
5.3
Connect the battery.
5.4
Install front-compartment carpet and cover on front lock lower part.
5.5
Erase fault memory.
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68645540:
Airbag sensor replaced
Labor time: 90 TU
68645640:
Airbag sensors replaced
Labor time: 119 TU
03350000:
On-board diagnosis (OBD)
Labor time: 20 TU
Important Notice: Technical Bulletins issued by Porsche Cars North America, Inc. are intended only for use by professional automotive technicians who have attended Porsche service training
courses. They are written to inform those technicians of conditions that may occur on some Porsche vehicles, or to provide information that could assist in the proper servicing of a vehicle. Porsche special
tools may be necessary in order to perform certain operations identified in these bulletins. Use of tools and procedures other than those Porsche recommends in these bulletins may be detrimental to the
safe operation of your vehicle, and may endanger the people working on it. Properly trained Porsche technicians have the equipment, tools, safety instructions, and know-how to do the job properly and
safely. If a particular condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your authorized Porsche Dealer for the latest information
about whether a particular technical bulletin applies to your vehicle. Part numbers listed in these bulletins are for reference only. Always check with your authorized Porsche dealer to verify the current and
correct part numbers. The work procedures updated electronically in the Porsche PIWIS diagnostic and testing device take precedence and, in the event of a discrepancy, the work procedures in the PIWIS
Tester are the ones that must be followed.
© Porsche Cars North America, Inc.
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Porsche Cars North America, Inc. believes the specifications to be correct at the time of printing. However, specifications, standard equipment and options are subject to change without notice. Some
options may be unavailable when a car is built. Some vehicles may be shown with non-U.S. equipment. Please ask your authorized Porsche dealer for advice concerning the current availability of options
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