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  #1  
Old 08-27-2018, 09:10 PM
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ROLLGUY
 
Join Date: Oct 2007
Posts: 7,229
Replacing airbags- E320 CDI

As some of you know, the blue CDI I sold to my brother, was wrecked recently. (photos here: http://www.peachparts.com/shopforum/diesel-discussion/394294-feasability-cdi-drivetrain-swapped-into-e320-wagon.html )
Parts car photos on post #24.
I bought the car back, and was planning to use it to make an E320 CDI wagon (I bought an '04 wagon). I decided to hold off on the engine swap project, and get the CDI back on the road. I also bought another E320 for parts (same color interior and exterior). Today I removed the right front fender, right front door, airbag module, side curtain airbag, seat airbag, rear door airbag, and other parts from the parts car. It just so happens that the parts car had damage as well, but in different places from the CDI. The bumper on the CDI is slightly damaged, but still usable. I got all the airbags installed today. I thought I might have to remove the entire headliner, but as it turned out, just the items fastened to the right edge needed to be removed (A & B pillar trim, grab handles, sail panel). I used a 1/4" drive 10mm socket to remove the three nuts holding the airbag assembly under the headliner. The airbag is attached to a long piece of black plastic, which was easily un-clipped from the body. The curtain airbag goes all the way from the dash to the sail panel (about 7' long).

Not knowing, I removed the parts car seat, and almost totally disassembled it, thinking I was going to use the entire seat back. Figuring out an easier way, I just moved the seat all the way back, and tilted the seatback all the way back. I was able to drill out the rivets, and install the bag without removing the seat. The rear door bag was easy as well, just three rivets, and put the door panel back on. I installed the airbag module, and will power it up another day (maybe tomorrow?).



I also removed the front right door and fender, and installed them on the CDI. I still need to install the rocker panel cover (photos later).

Attached Thumbnails
Replacing airbags- E320 CDI-0827181527.jpg   Replacing airbags- E320 CDI-0827181531a.jpg   Replacing airbags- E320 CDI-0827181531b.jpg   Replacing airbags- E320 CDI-0827181528.jpg   Replacing airbags- E320 CDI-0827181531.jpg  


Last edited by ROLLGUY; 08-27-2018 at 09:27 PM.
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  #2  
Old 08-27-2018, 09:12 PM
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ROLLGUY
 
Join Date: Oct 2007
Posts: 7,229
Seat airbag replacement

As explained above. I removed the rear panel while the seat was forward. This one was quite easy. Also, a photo of the "B" pillar pulled back for access.
Attached Thumbnails
Replacing airbags- E320 CDI-0827181636.jpg   Replacing airbags- E320 CDI-0827181639.jpg   Replacing airbags- E320 CDI-0827181641.jpg   Replacing airbags- E320 CDI-0827181527a.jpg  

Last edited by ROLLGUY; 08-27-2018 at 09:25 PM.
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  #3  
Old 08-27-2018, 09:22 PM
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Join Date: Oct 2007
Posts: 7,229
Body parts replacement

Photos of the door and fender replacement. I still have to attach the bumper to the fender, and install the rocker panel cover. I think I need new clips for it.
Attached Thumbnails
Replacing airbags- E320 CDI-0827181308a.jpg   Replacing airbags- E320 CDI-cdi-door.jpg   Replacing airbags- E320 CDI-0827181913.jpg  

Last edited by ROLLGUY; 08-27-2018 at 11:16 PM.
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  #4  
Old 08-27-2018, 11:20 PM
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Join Date: Oct 2007
Posts: 7,229
Scanned codes, five airbag DTC's

I scanned the airbag system for fault codes, and there are five. #3 is because of the airbag control module VIN does not match the car. I think I may have to send in the bad module for repair.
Attached Thumbnails
Replacing airbags- E320 CDI-0827181926.jpg   Replacing airbags- E320 CDI-0827181926a.jpg   Replacing airbags- E320 CDI-0827181927.jpg   Replacing airbags- E320 CDI-0827181927a.jpg   Replacing airbags- E320 CDI-0827181927b.jpg  

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  #5  
Old 09-15-2018, 04:21 PM
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Join Date: Oct 2007
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Airbag system fixed!

One of the challenges was to get the airbag module repaired, and I found a place to do it. Airbag Master Tech (Riverside CA) did it while I waited, and it cost $40. I then had a few codes that were current. I had a WSS (Weight Sensing System) code, and two "Ignition Squib" codes (first two photos above). I went to P-Y-P and got a seat base, replaced it and put the seat back in the car, and that fixed that problem. I had no idea what an ignition squib was, so I did some research. I found that the charge that tensions the seat belt is a "squib". I found that the rear left passenger seat belt was tight. I removed everything to gain access to the seat belt retracter. Once the rear seat and sail panel are removed, the antenna module (not sure exactly what it is called) needs to be removed to gain access to the seat belt holder bolt. A piece of foam under the hat tray needs to be pushed back to gain access to the seat belt retracter bolt. I found out the hard way: When using a unit from a parts car, you MUST tie a knot in the belt so it will NOT roll all the way in. If the belt is allowed to retract all the way, you will not be able to pull it back out again without taking it all apart. There are little plastic gears and other pieces that had to be re-timed in order to get the belt out to tie a knot in it. Once I got the retracter fixed, it was installed with no issues. I had to do the driver seat belt as well, as it's squib was activated as well. Once both belts were replaced, the codes were cleared and the SRS light is out! Hooray!
Attached Thumbnails
Replacing airbags- E320 CDI-20180914_094411.jpg   Replacing airbags- E320 CDI-20180914_094430.jpg   Replacing airbags- E320 CDI-20180914_102948.jpg  

Last edited by ROLLGUY; 09-15-2018 at 04:44 PM.
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  #6  
Old 11-28-2018, 11:27 AM
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Join Date: Oct 2007
Posts: 7,229
The car is finally finished!

I finally got everything repaired. I had to get the lights, brakes, and smog inspected in order to get it back on the road (my niece is buying it). The smog passed no problem. I had to replace the rear brakes, as they were very worn out. The rotors and pads on my parts car looked fairly new, so they got swapped over. The Zenon headlights had to be replaced because of broken mounts on the housings, and they could not be adjusted. I used a set of halogen headlights I had. The problem now, is that it gives a "headlight cornering" message every time the car is started. I am assuming it wants to see the electronics for the Zenon bulbs, but none of that is there. Even with the message, the light inspection passed anyway. I had to replace both lower control arms to get it good enough to align properly. The front bumper on the parts car was worse, so I repaired the existing bumper and replaced the corner light with the one from the parts car. I am happy with the way it turned out, and my niece is excited to trade up from her '85 300D.

The car before:
The car after:
Attached Thumbnails
Replacing airbags- E320 CDI-20181126_154441.jpg  

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