Service Procedure
Service ProcedureTools/Miscellaneous Materials Required
- Molex Hand Crimp Tool 63811-1000
- Service Crimp Tool J 38125-7
- Service Crimp Tool J 38125-6
- Butane Soldering Iron with:
- Standard Tip for Soldering
- Heat Deflector Tip for Heat Shrink Application
- High Flow Solder (Lead Free Only)
- Wire Cutters
- Wire Stripper - Knipex
- 10mm and 16mm Sockets and Driver
- T40 Torx Socket
- Headrest Removal Probe
- Scrivet Removal Tool
- Long Nosed Pliers
- 2.50mm Punch
- 1.40mm Precision Screw Driver
- Rivet Gun (Pneumatic or Easy Squeeze Type Recommended)
- Measuring Tape
- Electrical Tape
- Kent Automotive Coroplast 837 X Anti-Abrasive Tape
Service Kits
All parts required for this rework will be supplied as part of the following three kits:
Seat Kit (LH and RH) - Part Number 92457427
Body Harness Kit LH - Part Number 92457428
Body Harness Kit RH - Part Number 92457429
Crimp Tool Uses
The following details the crimp tools and associated jaws required for each terminal/seal crimp throughout the rework. These must be adhered to.
2-Way and 3-Way Connector Terminals and Seals (Common - Seat Side Only)
16-Way Connector Terminals and Seals (Seat Side Only)
Splice Terminals (Body Side Only)
Service Procedure
1. Using the vertical seat adjuster, raise both seats to their maximum vertical heights. Also tilt both seats backwards approximately 45 degrees using the electric tilt adjuster. Some vehicles may have a manual adjuster knob for tilt.
Note
Do not attempt any other reworks that require electrical power in parallel with this rework.
2. Disconnect both vehicle negative battery terminals using a 10mm socket. Both vehicle batteries are located in the vehicle's rear compartment (boot/trunk).
3. Remove the seat outer adjuster finish cover.
1. Remove the rear section first by sliding the seat all the way forward, unclipping the rear clip (1) and removing the trim.
2. To remove front section, unclip the rear trim clip first, then slide seat back, lever the rear of the front section in an upward direction until all clips are unsecured and slide forward (2).
3. Check for damaged clips on the removed trims. If broken clips are found, replace the affected component.
4. Locate and remove seat connectors.
1. Locate the group of four (five on the passenger side) connectors (1) at the base of the front outer seat rail housed within a carrier.
2. Carefully disconnect and remove the connectors (1) from the carrier (2) and discard the carrier.
5. Remove the front side door sill trim plate.
1. Unclip the front side door sill trim plate starting from the front and work back.
2. Check for damaged clips on the removed trim. If broken clips are found, replace the affected component.
6. Remove front seat.
1. Remove the front seat retaining bolts (1) using a 16mm socket. Bolts are located on the rear side of the seat. Access to the bolts is via the rear passenger door.
2. Fully extend head restraint (2) out of the head restraint guides (1).
3. Insert a suitably sized probe into the hole in the left-hand restraint guide (3).
4. Depress the right-hand head restraint sleeve height adjuster lock (4).
5. Remove the head restraint out of the guides. Note that the seat may need to be tilted so that the headrest can clear the headliner.
6. Remove the seat belt buckle latch located on the seat by sliding down the buckle cover (2) and using a T40 torx driver to loosen the screw (3).
7. Using a probe or punch, push the screw out from the opposite side (4) and pull the belt out of the latch (5).
8. Remove the front seat, by lifting and tilting the seat forward, and then lifting and pulling the seat rearwards to disengage the front hooks. The seat can be removed via the front door. Use caution not to scratch any trim upon removal of the seat.
9. Place the seat on an appropriate table with the seat airbag label facing towards the ceiling.
7. Free the seat harness.
1. Detach the two harness clips (1) retaining the airbag circuits to the seat as well as the single clip (2) retaining the remaining seat circuits.
2. Carefully cut the clips off the wires one at a time and replace each with the cable tray clips provided in the exact location as the clip that was removed. Make use of the visible crimp left behind by the removed tie to help locate the new tie.
8. Attach seat bracket.
1. Attach the correct sided seat bracket to the seat using the rivets provided. Note that the two safety circuit bracket clips (2) will always be located towards the front of the vehicle regardless of side.
2. Rivet (1) the bracket in the two locations shown.
9. Clip seat harnesses to bracket and cable tray.
1. Refit the harness retaining clips that were attached in Step 7 to the attached seat bracket in the following order:
- 2-way pretensioner harness (1) (closest to front of vehicle)
- 3-way SIAB harness (2) (2nd closest from front of vehicle)
- Remaining bundle (3) (3rd closest from front of vehicle)
Note
Attach clip (2) to cable tray hole bracket side.
2. Attach the supplied cable-tie clip over both safety circuit harnesses at a distance of 220mm (8.60 in) (1) from the pre-tensioner harness clip and press into the cable tray in the position shown.
10. Replace pre-tensioner (2P male) and SIAB (3P male) connectors.
Note
Cut both harnesses 76 mm (3 in) post retaining clip.
1. Using a measuring tape, measure 76 mm (3 in) of harness from the harness retaining clips towards the connectors and cut the harnesses off using wire cutters.
2. Strip back the black outer insulation of both leads 30.0mm (1.20 in) using a wire stripping tool to expose the 5 colored circuits (1).
3. Slide 0.50mm wire seals onto all 5 leads in the orientation shown and back enough to enable removal of the insulation (2).
4. Strip all wires back 4.0mm (0.16 in) (3).
5. Position the 0.50mm MALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using Molex Tool 63811-1000 Jaw 1.6mm.
Warning
To avoid personal injury or part damage, review the information below.
-
DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only a butane fueled soldering iron when working on SIR circuits.
-
Ensure that the wire seals are distant from the crimp before applying solder. This will avoid melting the seals.
-
When soldering, hold the iron tip on the underside of the terminal and allow solder to flow through the crimp from the top.
6. Solder all terminals at the wire crimp.
7. Position the wire seal to the terminal and crimp the seal and insulation using Service Tool J38125-6 Jaw #1.
8. Insert the terminals into the rear of the 2-way pre-tensioner housing as follows.
Listen for an audible "click" sound indicating that the terminals are inserted. Perform a push-pull test to ensure the terminals are fully inserted.
GN - PIN1
GY - PIN2
9. Using a 1.4mm precision screwdriver, push the internal purple locking tab (1) from left to right in the orientation shown to lock the terminals in.
10. 10 Insert the terminals into the 3-way SIAB housing as follows:
BK - PIN 1
BU - PIN2
BN - PIN3
11. Replace remaining circuits (combine into 16P male). The remaining circuits (large bundle) need to be combined into the 16P male connector as follows: Using a measuring tape, measure 110mm (4.30 in) of harness from the retaining clip towards the connector and cut it off using wire cutters. Strip the black outer harness tube back 70mm (2.75 in) to expose each circuit. Be extremely careful not to cut any of the individual wires.
Power and Ground Circuits (2.80 mm sq RD and BK)
The power and ground circuits have the smallest gauge (the power and ground circuits are the thickest or largest 2 wires in this bundle) and accordingly will be inserted into two of the larger cavities in the connector.
12. Slide 2.80mm wire seals onto both leads in the correct orientation and back enough to enable removal of the insulation.
1. Strip the insulation of both leads 5.0mm (0.20 in) using the specified wire stripping tool and align the seals with the wire insulation. Ensure no wire strands have been cut through following removal of the insulation.
2. Position both 2.00mm MALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using Service Tool J38125-6 Jaw #2.
Warning
To avoid personal injury or part damage review the information below.
-
DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only a butane fueled soldering iron when working on SIR circuits.
-
Ensure that the wire seals are distant from the crimp before applying solder. This will avoid melting the seals.
-
When soldering, hold the iron tip on the underside of the terminal and allow solder to flow through the crimp from the top.
3. Solder terminals at the wire crimp.
13. Insert the terminals into the rear of the connector as follows:
RD - PIN8
BK - PIN16
Listen for an audible "click" sound indicating that the terminals are inserted. Perform a push-pull test to ensure the terminals are fully home.
Remaining Circuits
Note
The remaining circuits do not require wire seals to be fitted as the connector is internally sealed for these circuits.
1. Strip back the insulation off all remaining circuits 5.0mm (0.20 in) using the specified wire stripping tool. Ensure no wire strands have been cut through following removal of the insulation
2. Crimp 0.50mm terminals to all remaining wires as previously detailed, (no wire seal crimping is required). Crimp the terminals onto the bare wire using the Molex Tool 63811-1000 Jaw 1.6mm.
3. Solder all crimped terminals as previously detailed using the appropriate butane fueled iron.
Note
All connector cavities that are not required will be pre-plugged. The connector with the most open cavities is used on the passenger side.
4. Insert the terminals into the rear of the connector as follows. Listen for an audible "click" sound indicating that the terminals are inserted. Perform a push-pull test to ensure the following terminals are fully inserted.
- BK - PIN2
- BK/WH - PIN10
- PK/BU - PIN4
- PU/WH - PIN12
- BK/GY - PIN15 (Passenger Side Only)
- GN/BN - PIN6 (Passenger Side Only)
- WH/PK - PIN7 (Passenger Side Only)
Attach Connectors to Seat Bracket
14. Now that all sealed seat connectors have been terminated, clip them onto the seat bracket as shown.
15. Repeat procedure for other seat. Once complete, commence work on the body harness side of the vehicle as detailed in the coming sections.
Replace Body Side Connectors
16. Remove electrical tape and pull harness out from under floor.
1. Remove all electrical tape from the body harness underneath the sill plate trim in the region shown (1). Include the breakout branch and any tape underneath the white plastic harness holders (2).
2. Pull the breakout harness (3) out from underneath the floor to free it up.
17. Splice the wires into the body harness.
1. Select the correct Body Template located in the Appendix 1 or Appendix 2. The body templates located in Appendix 1 and 2 are model year specific.
2. Select the first body harness wire in the "splice order" column. Measure and cut the dimension, example shown. The cut lengths given are from the tip of each connector as shown.
Caution
To avoid confusion, only cut, strip, and crimp 1 wire at a time. There are multiple wires on the body that are the same color so cutting 1 wire is imperative.
3. Splice the first wire to the corresponding pigtail wire as detailed in the Appendix 1 or 2. When splicing circuits, you must observe the following guidelines:
Splicing Guidelines:
- When cutting the matching body harness wires to the pigtail wires, you must ensure that an overlap - equivalent to the length of the stripped copper (approximately 8.0 mm or 0.30 in) - is allowed for. Refer to "A" portion of illustration. Specifically stripped wire overlap area (1) and terminal (2).
- Ensure that a section of heat-shrink is slid over the harness prior to crimping the two wires together in the splice terminals.
- Two different sized splice terminals are required for this rework. Larger terminals are required when splicing the power and ground circuits. When crimping, only use service tool J38125-7 Jaw B (large splice terminals) and Jaw C (small splice terminals).
- Solder needs to be applied to each crimp. When soldering, place the soldering tip at the underside of the terminal (3) and allow the solder to seep into the joint from the top of the terminal. Refer to "B" portion of the illustration
- Use a heat deflector heat shrink head only on the butane soldering iron to apply the heat shrink to the joints. Refer to "C" portion of illustration.
- The heat shrink (1) supplied has an adhesive on the inside which must be visibly oozing out from each end (2) to ensure that a proper seal has been created.
4. Following the order detailed in the Appendix, cut, strip, and splice all of the remaining circuits into the body harness one at a time.
18. Re-fit the body harnesses.
1. Tape the pigtail harnesses (1) using anti abrasive tape to where the wires break out into the body harness holder (2). Stretch the wires as you tape them.
2. Place the rest of the circuits (1) neatly within the harness holder. Some wires will need to be looped over.
3. Close the flap back over the body harness and apply electrical tape (1) to the areas shown in illustration. Also, ensure that the harness branch (2) running to the seat connectors is passed under the flooring.
Note
Cable tie the stand-off clip to the harness.
4. Attach the stand-off clip (2) to the harness running to the 16-way connector at a distance of 60mm (2.36 in) from the center (1) of the connector end.
19. Re-fit seats to vehicle. Do not bolt seats down.
Following the procedure detailed in Steps 6.0-6.9, but in reverse order, fit the seat and headrest back into the vehicle; however, DO NOT bolt the seat back in at this stage.
Caution
Be careful not to damage the seat bracket when placing the seat back into the vehicle.
20. Make the body and seat wire connections.
1. Connect each of the three body harness connectors (1) to the seat. You may need to tilt the seat forward to make these connections more easily.
2. Note that the RED locking tabs (1) on each connector must be pushed in fully to ensure a robust connection.
3. Ensure that the stand-off clip (1) that you previously cable tied to the harness is inserted into the seat bracket as shown.
4. Loosely attach the #2 bar cable-tie clip to the harness (1) at the #2 bar (2) and insert it into the #2 bar hole (3).
5. Ensure that there is a sufficient amount of slack on the harnesses (1) at the connector ends and pull the cable-tie tight (3).
6. Trim excess cable-tie length using wire cutters.
21. Repeat entire procedure on the other side of vehicle.
Perform the same rework to the body harness on the other side of the vehicle.
22. Once both sides have been reworked, reconnect both the primary and auxiliary negative battery terminals to 5 Nm (3.70 lb ft).
23. Plug in a Scan Tool and ensure that there are no new trouble codes present. Clear any diagnostic trouble codes, if required. Ensure no DTCs reset
24. Test all functions:
- Airbag warning - Turn vehicle ignition on. Check that the airbag telltale does not remain on.
- Lumbar support motor - Check lumbar in/out control for operation.
- Recline motor - Check recline fore/aft for operation.
- Front seat height motor - Check front seat motor raise/lower operation.
- Rear seat height motor - Check rear seat motor raise/lower operation.
- Passenger occupant detection, passenger belt buckle switch - Occupy passenger seat. Check that passenger seat belt reminder telltale is shown. Check that telltale clears when passenger seat belt is buckled.
- Driver buckle switch - Check that driver seat belt reminder telltale is illuminated when buckle is open and cleared when buckle is secured.
25. Bolt down seats and re-install trim pieces.
Once all checks have been made and all seat functions are working:
- Re-tighten all seat bolts (located on the rear of the seat) to 45 Nm (33 lb ft).
- Re-install the seat belt buckle latches to the seat to 6 Nm (4.4 lb ft).
- Re-fit the sill plate trims by simply pressing it on over the body harness.
- Re-fit the seat outer trim pieces in reverse order to those specified on trim removal section of this bulletin.
- Check over the vehicle and ensure no trim pieces have been damaged in any way during the rework procedure.
Appendixes
- Appendix 1 : Body Harness Templates for 2012 Model Year Vehicle
- Appendix 2 : Body Harness Templates for 2011 Model Year Vehicle
Appendix 1: Body Harness Template MY12 Driver Side
Appendix 1: Body Harness Template MY12 Passenger Side
Appendix 2: Body Harness Template MY11 Driver Side
Appendix 2: Body Harness Template MY11 Passenger Side
