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Side Air Bag Module: Installation

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  1. Inspect the mounting surfaces of the side air bag module and the seat back frame mounting bracket 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.
  2. 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.
  3. 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.
CAUTION: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the backrest frame.

    All seats 

  1. Install the side air bag module and nuts onto the seat backrest frame.
    • To install, tighten to 10 N.m (89 lb-in).
    Fig 1: Locating Side Air Bag Module Nuts
    G04659752Courtesy of FORD MOTOR CO.
    2. NOTE: Seat backrest trim cover and foam are removed for clarity.
    Fig 2: Locating Side Air Bag Module Wire Routing Clips
    G04659753Courtesy of FORD MOTOR CO.
  2. Attach the side air bag module wire routing clips.
  3. Install the hog rings attaching the lumbar basket (if equipped) or backrest support (if equipped) to the foam pad and the backrest frame.
    Fig 3: Locating Hog Rings (1 Of 2)
    G04659754Courtesy of FORD MOTOR CO.
  4. Roll down the trim cover and install the third row of hog rings front and rear (backside hog rings shown).
    Fig 4: Locating Hog Rings (2 Of 2)
    G04659755Courtesy of FORD MOTOR CO.
  5. Roll down the seat trim cover to the side air bag module.
  6. 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.
    Fig 5: Locating J-Clip Retainer Back Through Side Air Bag Module Backrest Foam Pad Opening
    G04659756Courtesy of FORD MOTOR CO.
  7. Install the side air bag module backrest trim cover chute and attach the J-clip retainers.
    Fig 6: Locating Side Air Bag Module Backrest Trim Cover Chute J-Clip
    G04659757Courtesy of FORD MOTOR CO.
  8. Attach the J-clips at the back of the trim cover.
    Fig 7: Locating J-Clips
    G04659758Courtesy of FORD MOTOR CO.
  9. Attach the hook and loop strips, and roll the seat back trim cover down and install the second row of hog rings.
    Fig 8: Locating Hog Rings (1 Of 2)
    G04659759Courtesy of FORD MOTOR CO.
  10. Attach the hook and loop strips, and roll the seat back trim cover down and install the first row of hog rings.
    Fig 9: Locating Hog Rings (2 Of 2)
    G04659760Courtesy of FORD MOTOR CO.

    11. Passenger seat 

  11. Pull the backrest fold flat nylon release strap through the trim cover bezel opening.

    12. All seats 

  12. Attach the seat back lower trim cover J-clip.

    13. Seats with manual lumbar adjust 

  13. Install the manual lumbar handle.
    1. On driver seat, install the clip and manual lumbar handle.
    2. On passenger seat, install the screw and the manual lumbar handle.

    14. All seats 

  14. Attach the side air bag module wire routing clips.
    Fig 10: Locating Side Air Bag Module Wire Routing Clips
    G04659761Courtesy of FORD MOTOR CO.
  15. Connect the side air bag module electrical connector.
  16. Attach the hook and loop strip at the rear of the seat cushion.
  17. Attach the rear seat cushion trim cover J-clip.

    18. Seats with power 

  18. Install the power seat control switch to the side shield.

    19. All seats 

  19. Install the side shield and rear screw.

    20. Seats with power 

  20. Install the power seat switch knobs.

    21. Seats with manual recline 

  21. Install the recline handle.

    22. All seats 

  22. Install the front seat. For additional information, refer to SEATING .
  23. Repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time.  For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING .

    24. Passenger seat only 

    WARNING: Do not separate components.
    CAUTION:
    1. It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover 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.
    2. Make sure the seat is completely assembled before rezeroing.
    NOTE:
    1. 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).
    2. If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made.
  24. 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 eight second time period has passed after cycling the ignition switch ON before the rezeroing process.

    Rezero the occupant classification sensor.

    • With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the OCS.
    25. NOTE: The ignition switch must be cycled after rezeroing the OCS system.
  25. Cycle the ignition switch from ON to OFF.

    26. All seats 

  26. 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 six 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.

  27. Check the active restraint system for correct operation. For additional information, refer to SAFETY BELT SYSTEM .
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