Procedure

The new, modified HPS head airbag gas generator (from 09/99 production) has two locating lugs (1) and an oval bore (2) as mounting point.

In order to replace the HPS airbag, remove dashboard and headliner (follow the repair manual RA 72 12 020).

To modify vehicle installation points:





Drill two holes in the support tube for the instrument cluster to accommodate the locating lugs of the new HPS generator.





1. Mark out the dimensions for both bores on the instrument panel support tube:

(A) = 25 mm; height measurement from the lower edge of support plate to the center of the lower hole.

(B) = 47 mm; height measurement from the lower edge of support plate to the center of the upper hole.





2. Mark out the dimensions for both holes on the instrument panel support tube:

(D) = 11.0 mm; side measurement from the inner edge of support plate to the center of lower hole.

(C) = 10.5 mm; side measurement from the inner edge of support plate to the center of the upper hole.





3. Drill two 8.5 mm holes (1, 2) at the marked points in the instrument panel support tube. Deburr bores, protect against rust, and remove (vacuum) metal chips which were generated by drilling.

Important:
Make sure that no electric wires or other equipment components are in the area of the marked holes.

Remove, or protect them if necessary.





4. Install the HPS generator. The two locating lugs (1) of the generator must be inserted into two corresponding holes (2) in the support tube for the instrument panel.





5. During installation, the HPS airbag gas generator does not rest flush on the support plate for the instrument panel; there is an intentional gap (A). Tightening the self-locking nut builds up a desired pretension, which provides additional security against release.