Attachment III - Technical Information
OVERVIEWThis program involves removing and partially disassembling the heated seats from the affected vehicles and inspecting the heater element pads to determine what level of repair is required.
^ All vehicles built from Job # 1 2003 through May 3, 2003 require lower seat cushion heater element pad replacement.
^ Any heater element pads that are found to be out of position and completely folded up or damaged must be replaced.
^ All other heater element pads must have additional adhesive applied.
SEAT ASSEMBLY REMOVAL
WARNING!
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE IMPACT SENSORS (IF EQUIPPED) ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLARS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE (1) MINUTE BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
1. Make sure all accessories are turned OFF.
2. Make sure the ignition switch is in the OFF position.
3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F2.60 (7.5A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. Disconnect the battery negative cable and wait at least one (1) minute.
7. Move the seat to its full rearward position.
8. Remove the seat track outer trim cover.
9. Remove the seat assembly front retaining bolts.
10. Move the seat to its full forward position.
11. Remove the seat track outer rear trim cover.
12. Remove the seat assembly rear retaining bolts.
13. Disconnect the underseat electrical connector. See Figure 1.
14. Remove the seat from the vehicle and position it on a suitable work surface.
SEAT CUSHION AND SEAT BACK DISASSEMBLY
1. CAUTION: Note the position and routing of the wiring harnesses to aid installation. An incorrectly routed wiring harness may lead to the wires becoming damaged on the seat mechanism.
Detach the safety belt buckle sensor and pretensioner wiring harnesses, if equipped, from the underside of the cushion. See Figure 2.
2. Detach the five (5) electrical harnesses from the retainer, then disconnect the five (5) electrical connectors from the underseat connector. See Figure 3.
3. Remove the four (4) bolts securing the cushion to the seat frame, then remove the seat cushion from the frame. See Figure 4.
4. Detach the heater element pad wiring harness from the retainers. See Figure 5.
5-DOOR
5. CAUTION: Do not cut or break the seat cover retaining cords.
Detach the two (2) retaining pins from the seat cushion frame to release the two (2) retaining cords and cut off the two (2) hog rings securing the corners of the seat cover. Be sure to remove the hog ring pieces that are left after cutting. See Figure 6.
4-DOOR AND WAGON
6. Detach the retaining strip along the front edge of the seat cover. See Figure 7.
7. Position the cover and cut off the hog rings as follows: See Figure 8.
A) Pull the cover up around the sides of the cushion to expose the side hog rings (three [3] each side), then cut the hog rings.
B) Lift the cover back to expose the three (3) hog rings along the top rear edge of the cover and cut those hog rings as well.
C) Pull the cover back further and cut off the remaining side hog rings (one [1] additional each side).
8. Remove the seat back lumbar support adjust lever (if equipped). See Figure 9.
9. Detach the seat back cover retaining strip from the underside of the seat back. See Figure 10.
10. Roll the seat back cover 50-75 mm (2-3 inches) up the seat back to access the lower ends of the tension rods and then detach the lower ends of the tension rods from the seat back. See Figure 11.
11. CAUTION: Do not bend the tension rods when handling the seat back cover.
Roll the seat back cover up to expose the entire seat back heater element pad. See Figure 12.
INSPECTION
1. Verify the vehicle build date.
^ If the vehicle was built from Job # 1 2003 through May 31, 2003, the lower seat cushion heater element pads must be replaced and the seat back heater element pads inspected. Proceed to the Heater Element Pad Replacement procedure after performing step 2 of this procedure for the seat back inspection.
^ If the vehicle was built on June 1, 2003 or later, continue with Step 2 of this procedure.
2. Inspect the heater element pads (both seat cushion and seat back) to see if they are loose (the original adhesive strips are not stuck to foam).
NOTE:
The seat cushion heater element pad has glue strips at the front and back edges.
The seat back heater element pad has adhesive strips along the top and bottom edges.
NOTE:
Some of the conditions that you may encounter include heater element pads that:
> may not have been properly assembled (the protective tape on the adhesive strip may never have been removed).
> the adhesive backing was removed, but the adhesive itself is contaminated so it did not adhere well to the foam.
> are partially folded together (having a small section of the heater element pad folded like an accordion). See Figure 13.
> are completely folded together (may be bunched together either toward the rear of the seat or at the bottom of the seat back). See Figure 13.
> are not loose.
^ If the heater element pad is loose and partially folded together, it can be smoothed out and re-adhered. Proceed to Heater Element Pad Repair.
^ If the heater element pad is loose and completely folded together or damaged, it must be replaced. Proceed to Heater Element Pad Replacement.
^ If the seat cushion and seat back do not show any concerns (not loose), proceed to Heater Element Pad Adhesion Reinforcement.
HEATER ELEMENT PAD REPAIR
NOTE:
This procedure applies only to seat cushion and seat back assemblies that are:
^ not adhered properly.
^ only partially folded.
CAUTION:
When adhering the heater element pad to the foam, be sure to position the pad so it is straight and free of any wrinkles that may show through the material once the seat cover is reinstalled.
NOTE:
During this procedure, you will be applying the adhesive to three (3) sides (front and both sides) of the seat cushion heater element pad, and to four (4) sides (bottom, top and both sides) of the seat back heater element pad.
1. Unfold and smooth out the heater element pad.
2. On the loose end of the heater element pad, check the adhesive strip to see if the backing was ever removed to expose the adhesive.
^ If the backing is still present, peel it off, position the pad in its original position and press down along the adhesive strip to secure the pad to the foam.
3. CAUTION: Apply only enough adhesive to properly bond the pad to the foam. Applying too much adhesive can result in adhesive bleeding through to the seat trim cover. Apply the adhesive in a strip no more than 25-mm (1-inch) wide along the outer edges of the heater element pad and on the mating surfaces of the foam to ensure no adhesive is applied under the heater element wire. Also, DO NOT apply adhesive to an existing adhesive strip on the element pad itself. Poor adhesion will result.
Neatly apply Motorcraft Trim and Weather Strip Adhesive (part number TA-14 or CTA-14 for Canadian dealers) on the entire front edge of the heater element pad forward of the adhesive strip and on the mating surface on the foam. Pull the heater element pad into position and press the leading edge down to adhere it to the foam. See Figure 14.
4. CAUTION: Apply only enough adhesive to properly bond the pad to the foam. Applying too much adhesive can result in adhesive bleeding through to the seat trim cover. Apply the adhesive in a strip no more than 25-mm (1-inch) wide along the outer edges of the heater element pad and on the mating surfaces of the foam to ensure no adhesive is applied under the heater element wire. Also, DO NOT apply adhesive to an existing adhesive strip on the element pad itself. Poor adhesion will result.
Neatly apply Motorcraft Trim and Weather Strip Adhesive (part number TA-14 or CTA-14 for Canadian dealers) on the side edges of the heater element pad and the mating surfaces on the foam. Press the edges down while smoothing the heater element pad down to avoid wrinkling or puckering. Allow the adhesive to dry for five (5) minutes before assembling the seat. Test the edges to make sure they adhere well enough to avoid pulling the heater element pad up when the trim cover is reinstalled. See Figure 15.
5. Proceed to the Seat Cushion and Seat Back Reassembly procedure in this Attachment III.
HEATER ELEMENT PAD REPLACEMENT
NOTE:
This repair applies to lower seat cushion heater element pads that:
^ are installed on vehicles built from Job # 1 2003 through May 31, 2003.
This repair also applies to both lower seat cushion and seat back heater element pads that:
^ are completely folded together or are damaged.
CAUTION:
When adhering the heater element pad to the foam, be sure to position the pad so it is straight and free of any wrinkles that may show through the material once the cover is reinstalled.
1. SLOWLY AND CAREFULLY peel the heater element pad adhesive strip from the foam. If the foam begins to tear or if the adhesive is not separating cleanly from the foam, stop and try to separate the other end of the adhesive strip from the foam. If necessary, use a razor or other sharp knife to trim the pad from the foam. See Figure 16.
2. For seat back heater element pad removal, detach the heater element pad harness from the seat frame harness retainer, then remove the heater element pad from the seat assembly.
3. Position the new heater element pad onto the foam, feeding the wire harness through the hole in the foam. Be sure the pad is properly positioned (straight and in the same footprint as the original).
4. CAUTION: Apply only enough adhesive to properly bond the pad to the foam. Applying too much adhesive can result in adhesive bleeding through to the seat trim cover. Apply the adhesive in a strip no more than 25-mm (1-inch) wide along the outer edges of the heater mat and on the mating surfaces of the foam to ensure no adhesive is applied under the heater element wire.
Neatly apply Motorcraft Trim and Weather Strip Adhesive (part number TA- 14 or CTA-14 for Canadian dealers) to all four (4) edges of the heater element pad and the mating surface on the foam. Press the edges down while smoothing the heater element pad down to avoid wrinkling or puckering. Allow the adhesive to dry for five (5) minutes before assembling the seat. Test the edges to make sure they adhere well enough to avoid pulling the heater element pad up when the trim cover is reinstalled.
5. Proceed to the Seat Cushion and Seat Back Reassembly procedure in this Attachment III.
HEATER ELEMENT PAD ADHESION REINFORCEMENT
NOTE:
This repair applies to both seat cushion and seat back assemblies that:
^ show no signs of damage.
^ do not require any parts replacement.
^ are not subject to any other repair.
CAUTION:
When adhering the heater element pad to the foam, be sure to position the pad so it is straight and free of any wrinkles that may show through the material once the cover is reinstalled.
1. CAUTION: Apply only enough adhesive to properly bond the pad to the foam. Applying too much adhesive can result in adhesive bleeding through to the seat trim cover. Apply the adhesive in a strip no more than 25-mm (1-inch) wide along the outer edges of the heater mat and on the mating surfaces of the foam to ensure no adhesive is applied under the heater element wire. Also, DO NOT apply adhesive to an existing adhesive strip on the pad itself. Poor adhesion will result.
Neatly apply Motorcraft Trim and Weather Strip Adhesive (part number TA-14 or CTA-14 for Canadian dealers) on the side edges of the heater element pad and the mating surface on the foam. Press the edges down while smoothing the heater element pad down to avoid wrinkling or puckering. Allow the adhesive to dry for five (5) minutes before assembling the seat. Test the edges to make sure they adhere well enough to avoid pulling the heater element pad up when the trim cover is reinstalled. See Figures 14 and 15.
2. Proceed to the Seat Cushion and Seat Back Reassembly procedure in this Attachment III.
SEAT CUSHION AND SEAT BACK REASSEMBLY
NOTE:
When installing the hog rings, locate the original holes in the fabric from where the hog rings were removed. This will help ensure the cover is properly positioned onto the cushion.
1. Position the seat back heater mat harness along the seat frame and secure in the harness retainer as shown. See Figure 17.
2. Attach the upper ends of the tension rods.
3. Roll the seat back cover down and attach the lower ends of the tension rods.
4. Attach the seat back cover retaining strip along the bottom of the seat back assembly.
5. Install the lumbar support adjustment lever (if equipped).
6. Position the seat cover onto the seat cushion.
4-DOOR AND WAGON
7. Attach the retaining strip along the front edge of the seat cover.
5-DOOR
8. Position the two (2) retaining cords and attach the two (2) push-type retaining pins into the seat cushion frame, then secure the seat cover straps with two (2) hog rings. See Figure 6.
ALL VEHICLES
9. Attach the heater element pad wiring harness to the retainers.
10. Position the seat cushion assembly onto the seat frame and install the retaining bolts. Tighten the bolts to 28 Nm (21 lb-ft).
11. Attach all electrical connectors to the underseat connector, then secure the harnesses in the harness retainer on the seat frame. See Figure 3.
12. Secure the safety belt buckle and pretensioner wiring harnesses, if equipped, to the underside of the cushion. See Figure 2.
SEAT ASSEMBLY INSTALLATION
1. Position the seat into the vehicle.
2. Install the rear retaining bolts. Tighten the bolts to 38 Nm (28 lb-ft).
3. Install the seat track rear outer trim cover.
4. Move the seat to its full rearward position and install the front retaining bolts. Tighten the bolts to 38 Nm (28 lb-ft).
5. Install the seat track front outer trim cover.
6. Connect the underseat electrical connector.
7. Repeat the repair procedure for the other seat.
8. Make sure all SRS components are connected.
9. Turn the ignition switch from OFF to ON.
10. Install the RCM fuse F2.60 into the CJB and install the cover.
11. Connect the battery negative cable.
12. Turn the ignition switch from ON to OFF, wait 10 seconds and turn the ignition switch to ON.
13. Visually monitor the air bag indicator. The indicator should light continuously for six (6) seconds and then turn off.
14. If the air bag indicator remains lit, fails to light or flashes, there is a fault present in the SRS.
15. Clear all continuous DTCs from the restraints control module (RCM) using a diagnostic tool.