2005 Freestyle/Five Hundred/Montego Workshop Manual

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Cynthia Simon
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1 Page 1 of 8 SECTION : Seating 2005 Freestyle/Five Hundred/Montego Workshop Manual DISASSEMBLY AND ASSEMBLY Procedure revision date: 07/14/2006 Seat Backrest Front Printable View (466 KB) Special Tool(s) Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool Disassembly NOTE: Passenger seat shown, driver seat similar. Item Part Number Description 1 611A08 Head restraint assembly 2 611D60 Outboard head restraint guide 3 611D62 Inboard head restraint guide 4 611D10 Side air bag module Backrest frame 6 Tie straps (3 required) 7 W S Side air bag module-to-backrest frame nut (2 required) 8 W S Backrest frame-to-backrest latch bolts (4 required) S Lumbar adjuster-to-passenger seat lumbar adjust bracket screws (2 required) 10 Passenger seat lumbar adjust bracket Backrest latch assembly (passenger) Lumbar adjust assembly 13 Lumbar adjust handle screw (passenger) A76 Lumbar adjust handle 15 Lumbar adjust handle clip (driver)

2 Page 2 of Backrest foam pad 17 14D696 Backrest heated seat element Backrest trim cover WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Side air bag modules with damaged covers must be replaced. WARNING: Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTICE: It is necessary to rezero the occupant classification sensor (OCS) system when a front passenger seat cushion is disassembled, a new trim cover is installed, or an OCS service kit is installed. A diagnostic tool is used to trigger the active command to carry out rezeroing of the OCS system. NOTE: If a side air bag deployment took place, the seat back pad, trim cover and side air bag module must be replaced. The seat back frame should be replaced if necessary. NOTE: If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to access all the seat track-to-floor pan bolts and the safety belt anchor. 2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion of Section B. 3. Remove the front seat. For additional information, refer to Seat Front in this section. 4. Remove the seat backrest. For additional information, refer to Seat Backrest Front in this section. 5. Remove the head restraint. Seats with manual lumbar 6. Remove the clip and the lumbar adjust handle. 7. Release the backrest trim cover lower J-clips. 8. WARNING: Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible. NOTICE: Use care when separating the seat back trim cover from the hook and loop strip, or the hook and loop strip can be torn from the seat back foam. Place a hand between the backrest trim cover and backrest foam pad and carefully separate the hook and loop strips, then carefully roll up the backrest trim cover in an inside out fashion to the first row of hog rings in the front. On passenger seats, pull the backrest fold-flat release strap through the trim cover bezel opening. 9. Remove the first row of hog rings.

3 Page 3 of Release the hook and loop strips and carefully roll up the backrest trim cover and remove the second row of hog rings in the front. 11. Release the J-clips at the back of the backrest trim cover. Seats with a side air bag module 12. Release the side air bag module backrest trim cover chute J-clip from around the side air bag module cover. 13. Feed the side air bag module backrest trim cover chute and J-clip retainer out through the side air bag module backrest foam pad opening.

Page 4 of 8 14. Release the hook and loop strip, and carefully roll up the backrest trim cover and remove the third row of hog rings in front. 15.

4 Page 4 of Release the hook and loop strip, and carefully roll up the backrest trim cover and remove the third row of hog rings in front. 15. Release the hook and loop strips in front, roll the backrest trim cover up and remove the hog rings at the back. 16. NOTE: The head restraint guides are not interchangeable. Release the tabs and remove the head restraint guides. 17. Remove the backrest trim cover. 18. NOTE: Vehicles with manual lumbar adjust shown. Remove the hog rings attaching the lumbar basket (if equipped) or backrest support (if equipped) and backrest foam pad to the backrest frame. 19. Remove the backrest foam pad. Seats with a side air bag module 20. NOTE: Note the routing of the side air bag module wiring for installation. Release the 3 side air bag harness pin-type retainers and remove the nuts and the side air bag module with wire harness. Passenger seat and driver seat with manual lumbar 21. Remove the tie strap.

5 Page 5 of 8 Seats with manual lumbar 22. Remove the 2 screws and separate the lumbar adjuster. 23. Release the lumbar basket at the bottom and top and remove the assembly. Passenger seat 24. Separate the backrest latch cable pin-type retainer at the lower left corner of the backrest frame. 25. Remove the 4 bolts and remove the backrest latch assembly and cable. Assembly Passenger seat 1. Position the backrest latch with cable and install the 4 bolts. Tighten to 25 Nm (18 lb-ft). 2. Attach the backrest latch cable pin-type retainer at the lower left corner. Seats with manual lumbar 3. Attach the lumbar basket to the backrest frame at the bottom and top. 4. Position the lumbar adjuster and install the 2 screws. Passenger seat and driver seat with manual lumbar 5. Wrap the 3 tie straps around the backrest latch cable and lumbar cable at the top and sides of the seat backrest frame. Seats with a side air bag module 6. WARNING: Inspect the mounting surfaces of the side air bag module and the seat back frame for any foreign objects before installing the side air bag module. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. WARNING: Before installing the side air bag module, check it for damage and foreign objects. If the air bag module is damaged, replace it. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. WARNING: If the air bag cover has separated or the air bag material has been exposed, install a new side air bag module. Do not attempt to repair the air bag module. Failure to do so may result in personal injury in the event of an air bag deployment. NOTICE: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the backrest frame. Position the side air bag module studs through the backrest frame and install the nuts. Tighten to 10 Nm (89 lb-in). 7. Route the side air bag module harness down the side of the backrest frame and install the pin-type retainers. 8. Position the backrest foam pad to the backrest frame.

6 Page 6 of 8 9. NOTE: Vehicles with manual lumbar adjust shown. Install the hog rings attaching the lumbar basket (if equipped) or backrest support (if equipped) and backrest foam pad to the backrest frame. 10. Position the backrest trim cover to the backrest foam pad and frame. 11. Position the backrest trim cover and install the hog rings. 1. Position the backrest trim cover duon tube above the lumbar support wire hooks. 2. Install the hog rings. 12. Install the third row of hog rings in front and attach the hook and loop strips. Seats with a side air bag module 13. Roll down the backrest trim cover to the side air bag module. 14. WARNING: Check the side air bag deployment chute for damage. The deployment chute must not be repaired. If there is any damage to the deployment chute, the seat back trim cover and deployment chute must be installed new as a unit. WARNING: Inspect the side air bag deployment chute and the side air bag cavity in the seat back pad for any foreign objects. If any foreign objects are found remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Feed the side air bag module backrest trim cover chute and J-clip retainer back through the side air bag module backrest foam pad opening. 15. Install the side air bag module backrest trim cover chute and J-clips around the side air bag module and backrest frame. Attach the chute J-clips.

7 Page 7 of Attach the J-clips at the back of the backrest trim cover. 17. Attach the hook and loop strips, roll the backrest trim cover down and install the second row of hog rings in the front. 18. Attach the hook and loop strips, roll the backrest trim cover down and install the first row of hog rings in the front. Passenger seat 19. Pull the backrest latch fold-flat release strap through the backrest trim cover bezel opening. 20. Attach the backrest trim cover lower J-clip. Seats with manual lumbar 21. Position the clip on the lumbar adjust handle and push it on the lumbar adjuster. 22. NOTE: The head restraint guides are not interchangeable. Install the head restraint guides. 23. Install the head restraint. 24. Install the seat backrest. For additional information, refer to Seat Backrest Front in this section. 25. Install the seat. For additional information, refer to Seat Front in this section. 26. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion of Section B. Passenger seat 27. WARNING: Do not separate components.

8 Page 8 of 8 NOTICE: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS service kit is installed. A diagnostic tool is used to trigger the active command to carry out rezeroing of the OCS system. NOTICE: Make sure the seat is completely assembled before rezeroing. NOTICE: The following precautions must be taken before rezeroing the OCS system. Make sure the OCS system components are connected and no faults are present. Make sure the OCS system is not at a temperature below 0 C (32 F) or above 45 C (113 F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0 C to 45 C (32 F to 113 F) for a minimum of 30 minutes. Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the rezeroing process. NOTE: For best results in rezeroing, the OCS system should be at or near room temperature, 10 C to 29 C (50 F to 85 F). NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. Rezero the occupant classification sensor. With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the OCS. 28. NOTE: The ignition switch must be cycled after rezeroing the OCS system. Cycle the ignition switch from ON to OFF. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool.

DISASSEMBLY AND ASSEMBLY

501-10-1 Seating 501-10-1 DISASSEMBLY AND ASSEMBLY Front Seat Cushion Special Tool(s) Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic