2020 Volkswagen Passat Compliance Recall 69AY Passenger Airbag

SEOCONTENT-START

Repair Overview
• Replace passenger frontal airbag.
NOTE
• These repair instructions may differ from the labor operations and labor times listed in ELSA.
• Damages resulting from improper repair or failure to follow these work instructions are the dealer’s responsibility and are not eligible for reimbursement under this action.
• This procedure must be read in its entirety prior to performing the repair.
• Due to variations in vehicle equipment and options, the steps/illustrations in this work procedure may not identically match all affected vehicles.
• Diagnosis and repair of pre-existing conditions in the vehicle are not covered under this action.
• When working during extreme temperatures, it is recommended that the vehicle be allowed to acclimate inside the shop to avoid temperature-related component damage/breakage.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2020 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
October 2020 69AY Page 7 of 16
Required Tools
Trim Removal Wedge
-3409-
(or equivalent)
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2020 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
October 2020 69AY Page 8 of 16
Repair Instruction
Section A – Check for Previous Repair
TIP
If Campaign Completion label is present, no further work is required.
• Enter the VIN in Elsa and proceed to the “Campaign/Action” screen.
TIP
On the date of repair, print this screen and keep a copy with the repair order.
• Confirm the Campaign/Action is open <arrow 1>. If the status is closed, no further work is required.
• Note the Applicable Criteria ID <arrow 2> for use in determining the correct work to be done and corresponding parts associated.
CRITICAL REPAIR STEP
STOP!
If multiple software update Campaign/Actions are open, they must be performed in order of the Start date <arrow 3>. The oldest should be performed first.
• All Safety Recalls must be completed prior to completing this campaign.
• Proceed to Section B.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2020 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
October 2020 69AY Page 9 of 16
Section B – Repair Procedure
WARNING
Risk of injury. Refer to “Warning and Safety Precautions”, found in Appendix A at the end of this document.
Remove instrument panel side cover:
• Carefully fold the door seal molding outward in the instrument panel cover area.
• Pry out the instrument panel side cover <1> with the -3409- near the catches.
• Pull the cover toward the rear and remove it.
Remove passenger side instrument panel decorative trim:
• Using the full steering column adjustment range move the steering wheel as far to the rear and down as possible.
• Working from the outside inward, carefully detach the decorative trim <1> from the retainers <arrows> using the -3409-.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2020 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
October 2020 69AY Page 10 of 16
Remove passenger side center console trim:
• Remove screw <1>.
• Pull down the center console side trim <2> slightly, guide out of the front mount and remove from the center console.
Remove lamps and glove compartment screws:
• Carefully pry out and disconnect glove compartment light (if equipped).
• Carefully pry out and disconnect right footwell lamp <3>.
• Remove the screws <2> from the glove compartment <1>.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2020 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
October 2020 69AY Page 11 of 16
Remove glove compartment:
• Loosen glove compartment <1> from the instrument panel and lower to the side in the direction of <arrow A>.
• Remove the glove compartment guide <5> from the center console <4>.
NOTE
It is easier to guide the damping element <3> past the instrument panel crossmember <2> when the glove compartment lid is slightly open.
• Carefully guide the glove compartment damping element <3> past the instrument panel crossmember <2> in the direction of <arrow B>.
• At the same time, release and disconnect any wiring harnesses and connectors (depends on vehicle equipment).
• Lower the glove compartment <1> and remove from the vehicle in the direction of <arrow C>.
WARNING
Accident risk. When working on pyrotechnic components (such as airbags and belt tensioners), the battery must be disconnected with the ignition switched ON.
• Turn ON the ignition.
• Move the passenger seat to the most rearward position.
• Fully recline passenger seat.
CAUTION
Reclining the passenger seat before disconnecting the battery allows for additional safety in the event Terminal 15 power is not restored when reconnecting the battery at the end of the repair.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2020 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
October 2020 69AY Page 12 of 16
• Open the cover <1> over the battery ground terminal post.
• Loosen the nut <3>.
• Remove and isolate the battery ground cable <2> from the battery terminal.
Disconnect airbag connectors:
WARNING
Before handling pyrotechnic components (for example, disconnecting the connector), the person handling it must “discharge static electricity”. This can be done by touching the door striker, for example.
• Release the connector locks <2> with a small screwdriver <arrow>.
• Release and disconnect the connectors <1> from the Front Passenger Airbag Igniter 1 -N131- and Front Passenger Airbag Igniter 2 -N132-.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2020 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
October 2020 69AY Page 13 of 16
• Support the Front Passenger Airbag Unit <2> to prevent it from falling out.
TIP
Leaving one of the bolts <1 or 3> installed a few turns will help support the airbag while removing the remaining bolts.
• Remove the bolts <1 and 3>.
• Remove the Front Passenger Airbag Unit <2> downward.
WARNING
Lay the airbag so that the collision cushion faces upward.
• Clean the bolts and the threads in the instrument panel for bolts <1 and 3> with a 6 x 1.0 mm thread cleaner or tap.
• Apply high strength thread locking fluid (Loctite® 648™) on the bolts <1 and 3>.
• Install new Front Passenger Airbag Unit and torque bolts <1 and 3> to 8 Nm.
Part Number
Part Description
561-880-204-D
Passenger Airbag
Connect airbag igniter connectors:
o Connect the connector <1> to the airbag igniter in direction of <arrow A>.
o Press in the connector lock <2> in direction of <arrow B>. While doing this, the connector is pushed into the airbag igniter and locks into place.
Reinstall glove compartment and interior trim:
• Installation is the reverse order or removal.
• Ensure all electrical connectors are connected.
• Torque screws to 1.5 Nm.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2020 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
October 2020 69AY Page 14 of 16
Reconnect battery:
WARNING
Ignition must be ON when connecting battery. If pyrotechnic components (e.g. airbag, belt tensioner) are not repaired correctly, they may deploy unintentionally after connecting battery. There must not be anyone inside the vehicle when connecting the battery.
• Disconnect the connector <2> from the Battery Monitoring Control Module -J367- <3> (if equipped).
• Attach the battery ground cable clamp by hand to the battery negative terminal and torque the nut <1> to 6 Nm.
• Reconnect the connector to the Battery Monitoring Control Module -J367- (if equipped).
• Cycle the ignition off and back on.
• Bring passenger seat to an upright position.
• Set clock to local time.
• Activate the convenience open/close functions.
• Check the DTC memories of all the control units and erase under-voltage faults if necessary.
NOTE
• After connecting the battery and switching on the ignition, the ASR/ESP Control Lamp -K155- and Electromechanical Power Steering Indicator Lamp light up continuously. The indicator lamps switch off automatically after driving a short distance (less than 100 meters). This activates Steering Angle Sensor -G85-.
• Once -G85- is activated and the ignition is cycled, the Start/Stop function will also start working again and any faults related to the battery being disconnected should be able to be cleared.
Proceed to Section C.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2020 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
October 2020 69AY Page 15 of 16
Section C – Campaign Completion Label
Install Campaign Completion Label
• Fill out and affix Campaign Completion Label, part number CAMP 010 000, next to the vehicle emission control information label.
TIP
Ensure Campaign Completion Label does not cover any existing label(s).
Proceed to Section D
Section D – Parts Return/Disposal
Properly store (retain), destroy or dispose of removed parts in accordance with all state/province and local requirements, unless otherwise indicated and/or requested through the Warranty Parts Portal (WPP) for U.S. and the Part Destruction and Core Disposition Report for Canada.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2020 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
October 2020 69AY Page 16 of 16
Appendix A – Warning and Safety Precautions
WARNING
General Safety Precautions when Working with Pyrotechnic Components:
• Pyrotechnic components always contain propellant that generates a gas during combustion. In some components, there is also a supply of pressurized gas to ensure this gas is generated
• This pressurized gas is stored under high pressure in a compressed gas container. Pyrotechnic components are triggered by electrical/mechanical igniters.
• Only trained personnel should perform testing, assembly and servicing work. Airbags do not have a replacement interval.
• Never check with test lamps, voltmeter or ohmmeters.
• Only check pyrotechnic components when they are installed in the vehicle using vehicle diagnosis, testing and information systems approved by the manufacturer.
• When working on pyrotechnic components and the airbag control module, disconnect the battery ground strap while the ignition is switched on. Then cover the negative terminal.
• Wait 10 seconds after disconnecting the battery.
• The ignition must be SWITCHED ON when connecting the battery. There should not be anyone inside the vehicle when doing this.
• Exception: vehicles with batteries in the passenger compartment. In this case, stay outside the range of the airbags and seat belts.
• Wash your hands after touching ignited pyrotechnic components from the restraint system.
• Do not open or repair pyrotechnic components. Use only new components to reduce the risk of injury.
• Do not install pyrotechnic components that have fallen onto a hard surface or show signs of damage.
• Discharge static electricity before handling pyrotechnic components, for example before disconnecting the electrical connector. This can be done by touching grounded metal objects such as the door striker pin.
• Install pyrotechnic components immediately after removing them from their transport packaging. If you must stop working, store the pyrotechnic component in its original transport packaging.
• Do not leave pyrotechnic components lying in the open unattended.
• Do not treat pyrotechnic components with grease, cleaning solutions or similar products.
• Do not expose pyrotechnic components to temperatures above 100 ºC, even for brief periods of time.
• People in the immediate vicinity of the workplace must be protected from possible noise and projectiles.
• Pyrotechnic components can trigger unintentionally.
• In the event of unintentional deployment:
o Single-stage inflators: allow airbag to cool down completely. Wait at least 10 minutes before handling.
o Two-stage inflators: wait for second airbag ignition. Allow airbag to cool down completely. Wait at least 10 minutes before handling.

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VOLKSWAGEN DEALER COMMUNICATION
Ensure all dealership personnel are aware of this notice so they are able to address customer questions. Contact Warranty if you require
additional assistance. Direct press inquiries to Volkswagen Public Relations.
Volkswagen Customer Protection 69AY_DLR_LAUNCH
Repair Available – Compliance Recall 69AY / Passenger Airbag
This notice is for:  Dealer Principal
 General Manager
 Sales Managers
 Service Manager
 Parts Manager
 Service Consultant
 Warranty Administrator
 Technicians
Date: October 12, 2020
Issue: The passenger frontal airbag may not have been folded properly during airbag
production. Because of this, there is a potential that, in a crash with airbag deployment,
the passenger airbag may deploy too forcefully, increasing the risk of injury.
Repair:  REPAIR AVAILABLE – October 13, 2020 / Replace passenger frontal airbag.
 See ELSA/ServiceNet for complete repair & claiming instructions
 Check both the daily Campaign Open Inventory report and OMD for affected
vehicles in inventory. Verify OPEN status in ELSA on the day of repair.
 Repair every affected inventory vehicle before delivery to consumers.
Parts Department: There will be a parts allocation. Please reference the Repair Projection Tool in the
campaign circular to view your potential VIN population. Please coordinate with your
service department to ensure that parts are available for all scheduled appointments.
Affected Vehicles Country Beginning
Model Year
Ending Model
Year Vehicle Vehicle
Count
USA 2020 2020 PASSAT 1,829
CAN 2020 2020 PASSAT 290
*Counts reflect overall population; some vehicles may have already been repaired. Check Campaigns/Actions
screen in Elsa on the day of repair to verify that a VIN qualifies for repair under this action. Elsa is the only valid
campaign inquiry & verification source.
Notes:  Schedule owner repairs immediately
 Owner mailing – October 2020
U.S.A.: Loaner/rental coverage cannot be claimed under this action. However,
loaner/rental may be covered under the Alternate Transportation Program. Please refer
to the Volkswagen Warranty Policy and Procedures Manual for loaner claims information
and reimbursement details.
Canada: Loaner/rental coverage cannot be claimed under this action. Please refer to the
Volkswagen Service Loaner Program to determine loaner eligibility.
IMPORTANT REMINDER: VEHICLES AFFECTED BY SAFETY & COMPLIANCE RECALLS
New Vehicles in Dealer Inventory: It is a violation of federal law for a dealer to deliver a new
motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by
this notification under a sale or lease until the defect or noncompliance is remedied. By law,
dealers must correct, prior to delivery for sale or lease, any vehicle that fails to comply with an
applicable Federal Motor Vehicle Safety Standard or that contains a defect relating to motor
vehicle safety.
Pre-Owned Vehicles in Dealer Inventory: Dealers should not deliver any pre-owned vehicles in
their inventory which are involved in a safety or compliance recall until the defect has been
remedied.
-END OF MESSAGE

************************************************************************************************

VOLKSWAGEN DEALER COMMUNICATION
Ensure all dealership personnel are aware of this notice so they are able to address customer questions. Contact Warranty if you require
additional assistance. Direct press inquiries to Volkswagen Public Relations.
Volkswagen Customer Protection 69AY_DLR_ADV
Advance Notice – Compliance Recall 69AY / Passenger Airbag
This notice is for:  Dealer Principal
 General Manager
 Sales Managers
 Service Manager
 Parts Manager
 Service Consultant
 Warranty Administrator
 Technicians
Date: September 21, 2020
Issue: The passenger frontal airbag may not have been folded properly during airbag
production. Because of this, there is a potential that, in a crash with airbag deployment,
the passenger airbag may deploy too forcefully, increasing the risk of injury.
Repair:  REPAIR NOT YET AVAILABLE
 Check daily campaign open inventory report or OMD for affected vehicles in
inventory
 Repair every affected inventory vehicle before delivery to consumers.
Affected Vehicles Country
Beginning
Model
Year
Ending
Model
Year
Vehicle Vehicle
Count
USA 2020 2020 PASSAT 1,829
CAN 2020 2020 PASSAT 290
*Counts reflect overall population; some vehicles may have already been repaired. Check Campaigns/Actions
screen in Elsa on the day of repair to verify that a VIN qualifies for repair under this action. Elsa is the only valid
campaign inquiry & verification source.
Notes: IMPORTANT REMINDER: VEHICLES AFFECTED BY SAFETY & COMPLIANCE RECALLS
New Vehicles in Dealer Inventory: It is a violation of federal law for a dealer to deliver a new
motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by
this notification under a sale or lease until the defect or noncompliance is remedied. By law,
dealers must correct, prior to delivery for sale or lease, any vehicle that fails to comply with an
applicable Federal Motor Vehicle Safety Standard or that contains a defect relating to motor
vehicle safety.
Pre-Owned Vehicles in Dealer Inventory: Dealers should not deliver any pre-owned vehicles in
their inventory which are involved in a safety or compliance recall until the defect has been
remedied.
-END OF MESSAGE

SEOCONTENT-END