Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2002 Freightliner Sprinter 2500 L5-2.7L DSL TurboFACTORY OEM SERVICE PROCEDURE
General Notes
Risk of injury
Injuries may result when performing testing or repair work on airbag or emergency tensioning retractor units.
Store airbag unit with the deployment face up, do not subject to temperatures above 100 degrees. When working on these units, disconnect power supply.
Danger!
Injuries may be caused by flying objects if an airbag or emergency tensioning retractor (ETR) unit is triggered accidentally or if an airbag unit is stored with its deployment face down.
Safety instructions/precautions
- Always store removed airbag units with the deployment face up.
- The procurement, transport, storage, testing and installation of these units must be performed or supervised by specially trained personnel.
- Install airbag and ETR units immediately following retrieval from storage.
- Protect airbag and ETR units from sparks, open flames and temperatures above 100 degrees.
- Do not transport airbag or ETR units in the passenger compartment, pack in original replacement part packaging only and secure tightly in the load compartment of the vehicle.
- Do not allow grease, oil or cleaning agents to come into contact with airbag or ETR units.
- Perform system tests using approved testing equipment only (e.g. Star Diagnosis) and only when the units are properly installed and the vehicle is unoccupied.
- Initial hook-up of the battery of an external power supply may only be done when the ignition is switched on and when the vehicle is unoccupied.
- If an airbag or ETR unit falls from a height of more than 0.5 m, it must be replaced.
For proper and safe scrapping, airbag and ETR units must be sent in their original packaging for disposal via the established MeRSy disposal system (Renz company).
- In all countries proper and safe scrapping shall be done in compliance with the applicable regulations of the country concerned.
The following steps must be taken before performing body work or retrofitting operations, work on airbag or ETR units, or work on components connected to airbag or ETR units or that involves the airbag or ETR circuitry (e.g. removal of the steering wheel):
- Remove key from starter switch.
- Disconnect and isolate the battery ground cable.
- Disconnect any external power sources (e.g. charging equipment).
- Pull plug from control module prior to performing work inside the passenger compartment and prior to any welding work.
Important instructions for performing repair, body work and welding on vehicles with airbags or belt tensioner units Models 901, 902, 903, 904
Models WD1, WD2, WD3, WD6, WD741, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7
Before beginning with
- body work,
- work on airbag or emergency tensioning retractor units (removal, installation).
- Work on components which are connected to the airbag and ETR units or necessitate an intervention in the circuit, e.g. when removing the steering wheel
Withdraw the ignition key.
On models 901, 902, 903, 904 and models WD2.YD141/YD241/YD341/ YD441/ YD541, WD5.WD141/WD241/WD341
you must also disconnect/isolate the ground lead of the battery.
Before commencing welding work
- remove the starter key and disconnect/insulate the battery ground line.
- Disconnect coupling from airbag control module with ETR units.
On model 414 you must also disconnect the positive lead, bridge the ground and positive leads with a metal drift, and then unplug the airbag connector from the airbag control module.
During painting work
involving force drying, there are no special safety regulations to observe. Airbag and emergency tensioning retractor units can withstand temperatures of up to 100 degrees without sustaining any damage.
Before starting up
When connecting up the positive and ground leads in model 414, make sure that nobody is inside the vehicle.
- Turn the ignition key to circuit 15 position(ignition on).
- Connect positive and ground lines.
After finishing work on the airbag and emergency tensioning retractor units
the restraint system is always to be checked with the hand-held tester/STAR DIAGNOSIS according to the diagnostics literature.
Injuries may result when performing testing or repair work on airbag or emergency tensioning retractor units.
Store airbag unit with the deployment face up, do not subject to temperatures above 100 degrees. When working on these units, disconnect power supply.
Danger!
Injuries may be caused by flying objects if an airbag or emergency tensioning retractor (ETR) unit is triggered accidentally or if an airbag unit is stored with its deployment face down.
Safety instructions/precautions
- Always store removed airbag units with the deployment face up.
- The procurement, transport, storage, testing and installation of these units must be performed or supervised by specially trained personnel.
- Install airbag and ETR units immediately following retrieval from storage.
- Protect airbag and ETR units from sparks, open flames and temperatures above 100 degrees.
- Do not transport airbag or ETR units in the passenger compartment, pack in original replacement part packaging only and secure tightly in the load compartment of the vehicle.
- Do not allow grease, oil or cleaning agents to come into contact with airbag or ETR units.
- Perform system tests using approved testing equipment only (e.g. Star Diagnosis) and only when the units are properly installed and the vehicle is unoccupied.
- Initial hook-up of the battery of an external power supply may only be done when the ignition is switched on and when the vehicle is unoccupied.
- If an airbag or ETR unit falls from a height of more than 0.5 m, it must be replaced.
For proper and safe scrapping, airbag and ETR units must be sent in their original packaging for disposal via the established MeRSy disposal system (Renz company).
- In all countries proper and safe scrapping shall be done in compliance with the applicable regulations of the country concerned.
The following steps must be taken before performing body work or retrofitting operations, work on airbag or ETR units, or work on components connected to airbag or ETR units or that involves the airbag or ETR circuitry (e.g. removal of the steering wheel):
- Remove key from starter switch.
- Disconnect and isolate the battery ground cable.
- Disconnect any external power sources (e.g. charging equipment).
- Pull plug from control module prior to performing work inside the passenger compartment and prior to any welding work.
Important instructions for performing repair, body work and welding on vehicles with airbags or belt tensioner units Models 901, 902, 903, 904
Models WD1, WD2, WD3, WD6, WD741, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7
Before beginning with
- body work,
- work on airbag or emergency tensioning retractor units (removal, installation).
- Work on components which are connected to the airbag and ETR units or necessitate an intervention in the circuit, e.g. when removing the steering wheel
Withdraw the ignition key.
On models 901, 902, 903, 904 and models WD2.YD141/YD241/YD341/ YD441/ YD541, WD5.WD141/WD241/WD341
you must also disconnect/isolate the ground lead of the battery.
Before commencing welding work
- remove the starter key and disconnect/insulate the battery ground line.
- Disconnect coupling from airbag control module with ETR units.
On model 414 you must also disconnect the positive lead, bridge the ground and positive leads with a metal drift, and then unplug the airbag connector from the airbag control module.
During painting work
involving force drying, there are no special safety regulations to observe. Airbag and emergency tensioning retractor units can withstand temperatures of up to 100 degrees without sustaining any damage.
Before starting up
When connecting up the positive and ground leads in model 414, make sure that nobody is inside the vehicle.
- Turn the ignition key to circuit 15 position(ignition on).
- Connect positive and ground lines.
After finishing work on the airbag and emergency tensioning retractor units
the restraint system is always to be checked with the hand-held tester/STAR DIAGNOSIS according to the diagnostics literature.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.